Zebra P330i Card Printer. Service Manual Rev. A Draft 2 Rev. A

Transcription

1 Zebra P330i Card Printer Service Manual Rev. A Draft 2 Rev. A

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3 Foreword This manual contains service information for the Zebra P330i Card Printers manufactured by Zebra Technologies Corporation, Camarillo, California. Return Materials Authorization Before returning any equipment to Zebra Technologies Corporation for in-warranty or out-ofwarranty repair, contact Repair Administration for a Return Materials Authorization (RMA) number. Repack the equipment in the original packing material and mark the RMA number clearly on the outside. Ship the equipment, freight prepaid, to the address listed below: For USA, Latin America, and Asia / Pacific: Zebra Technologies Corporation Zebra Card Printer Solutions 1001 Flynn Road Camarillo, CA USA Phone: +1 (805) FAX: +1 (805) For Europe and Middle East: Zebra Technologies Corporation Zebra Card Printer Solutions Pittman Way, Fulwood Preston, PR2 9ZD Lancashire, U.K. Phone: FAX: Rev. A Draft 2 P330i Card Printer Service Manual i

4 Foreword Copyright Notice 2004, 2005 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 reserves the right to make changes, for the purpose of product improvement, at any time. Trademarks P330i is a trademark and Zebra is a registered trademark of Zebra Technologies Corporation. Windows and MS.DOS are registered trademarks of Microsoft Corp. All other trademarks or registered trademarks are marks of their respective holders. Product Disposal Product Disposal Information Do not dispose of this product in unsorted municipal waste. This product is recyclable, and should be recycled according to your local standards. For more information, please see our web site at: Declarations of Conformity 89/336/EEC modified by 92/31/EEC and 93/68/EEC 73/23/EEC modified by 93/68/EEC EMC Directive EN (1998) RF Emissions control EMC Directive RF Emissions and Immunity for radio EN V1.4.1 equipment EMC Directive EN55024 (2001) Immunity to Electro-Magnetic Disturbances Low voltage Directive EN (2001) Product safety 1999/5/CE R&TTE Directive EN V1.1.1 Radio Frequency Interferences For a formal certificate, please contact the Compliance Office at Zebra s Camarillo facility. ii P330i Card Printer Service Manual Rev. A Draft 2

5 Foreword EUROPE: Norway Only: This product is also designed for IT power system with phase to phase voltage 230V. Earth grounding is via the polarized, 3-wire power cord. FI: Laite on liitettävä suojamaadoitus koskettimilla varustettuun pistorasiaan SE: Apparaten skall anslutas till jordat uttag NO: Apparatet må tilkoples jordet stikkontakt Model P330i conforms to the following specification: FCC Part 15, Subpart A, Section (a) and Section (a) Class B digital device. Supplemental Information: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: Reorient or relocate the receiving antenna. Increase the separation between the equipment and the receiver. Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. Consult the dealer or an experienced radio/tv technician for help. The user may find the following booklet, prepared by the Federal Communications Commission, helpful: How to identify and resolve Radio/TV Interference Problems. This booklet is available from the U.S. Government printing Office, Washington, D.C , Stock No Use of a shielded cable is required to comply within Class B limits of Part 15 of FCC Rules. Pursuant to Part of the FCC Rules, any changes or modifications to this equipment not expressly approved by Zebra may cause, harmful interference and void the FCC authorization to operate this equipment. Industry Canada Notice This device complies with Industry Canada ICES-003 class B requirements Rev. A Draft 2 P330i Card Printer Service Manual iii

6 Foreword P330i Printer Model The Zebra Product Number tells a story: Here is a quick review of the Zebra Card Printer Series numbering and lettering system to help you. Model numbers include identifiers that specify options using the following lettering conventions: Part Number P i - _ B - - C - - D - - E - - F - - H - - _ 0 _ - - _ M _ _ _ 0 _ - - A - - C - - _ - I _ - _ - U _ - _ - _ D 0 Description Base Printer P330i Color Card Printer Smart Card Options None Contact Encoder Contact encoder & HID iclass contactless Contact encoder & MIFARE contactless Contact station HID iclass contactless MIFARE contactless Magnetic Encoder None Yes (select defaults below) Magnetic Encoder Defaults None Stripe Down, HiCo Stripe Up, HiCo Memory Expansion None Interface USB Only USB and Ethernet Power Cords U. S. and Europe U. K. and Australia Windows Drivers and User Documentation / Training CD Windows Drivers and User Documentation / Training included on one CD (Software & Documentation Package) which contains Multi-language documentation. iv P330i Card Printer Service Manual Rev. A Draft 2

7 Foreword 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 Rev. A Draft 2 P330i Card Printer Service Manual v

8 Foreword vi P330i Card Printer Service Manual Rev. A Draft 2

9 Contents Foreword i 1 General Description Printer Description Controls, Connectors, and Indicators Installation and Setup General Information Unpacking the Printer Installing the Print Driver Software and Setting Driver Options Loading a Ribbon Installing the Card Cleaning Cartridge Setting the Card Thickness Control Loading Cards Card Output Hopper Connecting the Printer to your Computer Connecting Power Printing a Test Card Packing the P330i Printer for Shipment Operation Theory of Operation Color Fundamentals Card Path Elements Card Movement During Printing CPU PCBA Description Rev. A Draft 2 Service Manual vii

10 4 Troubleshooting Power-Up Failures LCD Panel Messages Printing a Test Card Card Feed or Transport Failures Print Anomalies Troubleshooting the Ethernet Connection and Adapter Replacement Procedures Introduction Required Tools Removal Sequence Removing the Top Cover Removing the Print Engine from the Lower Cover Removing the Connector Plate Removing the Power Supply Cover Removing the Power Supply Removing the Rear Plate Removing the Cam Lever Removing the Platen Inertia Roller Removing the Printhead Pressure Spring Removing the Film/Bracket Sensor PCBA Removing the Pressure Spring Plate Removing the Cam Arm Follower Assembly Removing the Clutch Assembly Removing the Print Head / Carriage Assembly Removing the Print Head Lift Cam Replacing the Print Head Assembly Replacing the LCD PCBA and/or LCD Cable Assembly Replacing the Encoder Shroud and Exit Pressure Roller Replacing the Exit Pressure Roller Assembly Removing the Balls Retainer Plate Card Feeder Components Power / Filter Components Removing the CPU PCBA Removing the I/O Daughterboard Removing the RFID Cable Replacing the Ribbon O-Ring Drive Belt Replacing the Ribbon Pulley Assembly Removing the Ribbon Motor Pulley and the Ribbon Motor Replacing the Stepper Motor Drive Belt Removing the Stepper Motor Removing the RFID PCBA Replacing the Ribbon Color Sensor Replacing the Card Sensor Cable Assembly viii Service Manual Rev. A Draft 2

11 5.37 Removing the Print Head Cable Assembly Removing the Print Head Lift Motor Separating the Front Frame from the Center Frame Magnetic Stripe Encoder Option Smart Card Options Solenoid Assembly Preventive Maintenance Appendix A Software Appendix B Worldwide Service & Support Rev. A Draft 2 Service Manual ix

12 x Service Manual Rev. A Draft 2

13 1 General Description 1.1 Printer Description The Zebra P330i Card Printer is a photo ID card printer. It can print at 300 dpi resolution on mil ( mm) ISO CR-80 plastic cards. When equipped with a YMCK (Yellow, Magenta, Cyan, Black) ribbon, it can print full-color images. A wide range of other ribbons, including monochrome ribbons and ribbons that will additionally apply a protective transparant overprint, are also available. The P330i Printer has a USB interface as standard. In addition to the USB port, it can optionally be ordered with a 10/100T Ethernet port. If equipped with the optional Magnetic Encoder, the printer will encode a magnetic stripe on the card. Other options allow encoding of smart cards, which have embedded logic and/or memory circuitry. The following shows the main functional features found on your P330i Printer Rev. A Draft 2 P330i Card Printer Service Manual 1

14 General Description Print Head Main Cover (shown open) Print Head Carriage (shown in open position) Print Head Carriage Latch Card Feeder Cover (shown open) (Optional) Magnetic Encoding Station Card Thickness Control Card Cleaning Cartridge Panel Button Output Hopper (shown in open position) Ribbon Take-Up Spindle Ribbon Supply Spindle (Optional) Smart Card Contact Station LCD Display Panel 2 P330i Card Printer Service Manual Rev. A Draft 2

15 General Description 1.2 Controls, Connectors, and Indicators The P330i Printer has an LCD Display Panel and a Panel Button on the front and a power connector, power switch, and interface connector(s) on the rear panel. These are shown in the following figures. Panel Button LCD Display Panel 10/100base-T Connector * Ethernet Switch * Ethernet Adapter Status LED * Power Switch Network Status / Activity LED * Power Connector USB Connector Optional DB-9 Connector location for Smart Card Contact Station * These are on the optional Ethernet Adapter Rev. A Draft 2 P330i Card Printer Service Manual 3

16 General Description LCD Panel The LCD Panel can display the following messages: Message Operational INITIALIZING READY DOWNLOADING DATA PRINTING MONO MAG ENCODING CONTACT ENCODING PRINTING CYAN PRINTING YELLOW PRINTING MAGENTA PRINTING BLACK PRINTING OVERLAY DOWNLOADING FW CLEANING PRINTER Warnings CLEAN PRINTER REMOVE RIBBON THEN CLOSE HEAD EMPTY FEEDER & PRESS BUTTON LOAD CLEANING CARD IN FEEDER PRESS BUTTON TO CONTINUE FEED LONG CLEANING CARD IN EXIT CLEANING PRINTER ENCODING ERROR (printing stops) INVALID MAGNETIC DATA (encoding stops) REMOVE RIBBON Mode Scrolling Fixed Fixed Fixed Fixed Fixed Fixed Fixed Fixed Fixed Fixed Fixed Fixed Scrolling Scrolling Scrolling Scrolling Scrolling Scrolling Scrolling Blinking Scrolling Fixed Errors (Printer will not operate) OUT OF RIBBON Blinking MECHANICAL ERROR Blinking OUT OF CARDS Blinking PRINT HEAD OPEN Blinking 4 P330i Card Printer Service Manual Rev. A Draft 2

17 General Description Panel Button During normal printer operation, if the Panel Button is pressed briefly nothing happens. If the Panel Button is held down for more than three seconds, the printer will start a cleaning cycle and the LCD Panel will prompt the operator to load a cleaning card in the feeder. (If a print operation was in process when the Panel Button was pressed and held down, the print operation will be completed before the printer starts a cleaning cycle.) If the Panel Button is pressed and held down while power is turned on to the printer, the printer will print a test card. This provides a quick check of printer operation completely independently of a computer or network connection. In response to LCD Panel prompting messages, press the Panel Button to continue various operations Rev. A Draft 2 P330i Card Printer Service Manual 5

18 General Description Card Thickness Control The Card Thickness Control is used to set the P330i printer for use with cards of different thicknesses. Use of the Card Thickness Control is described in Chapter 2. Card Thickness Control 6 P330i Card Printer Service Manual Rev. A Draft 2

19 General Description (Optional) Ethernet Adapter P330i Printers equipped with the optional Ethernet Adapter have the following additional controls and indicators: (Recessed) Ethernet Reset Switch 10/100Base RJ45 Ethernet Connector Ethernet Adapter Status Indicator Network Status / Activity Indicator Ethernet Reset Switch If the Ethernet Reset Switch is pressed and held while turning the printer power on, and then released when the Ethernet Adapter Status Indicator turns green, the Ethernet Adapter will be reset to the factory default configuration parameters. While power is on, if the Ethernet Reset Switch is press and held, a configuration card showing the Ethernet Adapter s current confuguration settings will be printed. Ethernet Adapter Status Indicator The Ethernet Adapter Status Indicator is a bi-color (red - green) LED, that shows the operational status of the Ethernet Adapter. Network Status/Activity Indicator The Network Status/Activity Indicator is a bi-color (orange - green) LED, that indicates network speed, establishment of a link, and network activity. Note Detailed information on the use of these indicators is presented in Chapter 4, Troubleshooting Rev. A Draft 2 P330i Card Printer Service Manual 7

20 General Description 8 P330i Card Printer Service Manual Rev. A Draft 2

21 2 Installation and Setup 2.1 General Information This section will guide you through the installation and setup of your P330i Card Printer. This consists of the following procedures, which should be performed in the order presented. Unpacking the Printer Installing the Print Driver Software and Setting Driver Options Loading a Ribbon Installing the Card Cleaning Cartridge Setting the Card Thickness Control Loading Cards Connecting the Printer to your Computer Connecting Power Printing a Test Card to verify printer operation The procedure to be followed for Packing the Printer for Shipment is given at the end of this section. The printer should be placed in a location that allows easy access to all sides. The printer should never be operated while resting on its side or upside down Rev. A Draft 2 P330i Card Printer Service Manual 9

22 Installation and Setup Electric Shock Caution Limit AC power supplied to the P330i Printer to 110 ~ 230 volts, 60 ~ 50 Hertz. Limit excess current draw to 16 amps or less, using an associated circuit breaker or other such device. Never operate the printer in a location where operator, computer, or printer can get wet. Personal injury could result. The printer must be connected to an earthed electrical power source and properly protected against electrical surges and grounding faults; the electrical reliability of the printer is based on the reliability of the mains power source and with the earth connection. The printer s power supply is an internal unit that can only be serviced or replaced by trained and authorized personnel. 2.2 Unpacking the Printer Your P330i Card Printer ships in a carton and protective anti-static bag. Keep all packaging material in case you need to move or re-ship the printer. Step 1. Step 2. Inspect the shipping container to ensure that no damage has occurred during shipment. If any damage is apparent, file a claim with the shipper. Unlatch and remove the handles on either end of the shipping container, as shown in the figure below. UP Step 3. Step 4. (See the figure on the next page as you perform the following steps.) Lift the upper part of the shipping container off of the lower part (which will still hold the printer and its packing material). Remove the packing material around the top of the printer. 10 P330i Card Printer Service Manual Rev. A Draft 2

23 Installation and Setup Step 5. Step 6. Step 7. Lift the printer out of the carton by holding it with both hands. Please ensure that you have a clean and nearly dust free environment for proper operation and storage of the printer. Make sure the following items are included with your P330i printer: Rev. A Draft 2 P330i Card Printer Service Manual 11

24 Installation and Setup CD-ROM with Driver Wizard and User s Manual Card Cleaning Cartridge Power Cables (2) USB Cable Cleaning Kit If any items are missing, please contact your dealer. To reorder, please refer to Appendix D of this manual. Step 8. Step 9. Remove packing tape securing the printer s Main Cover and Card Feeder Cover. Your P330i Printer ships with warning tape where the Card Cleaning Cartridge will be installed, and a pad that protects the print head from possible damage in shipment. To remove the tape and pad, follow the following steps: a. Open the printer s main cover by lifting at its lower front lip. 12 P330i Card Printer Service Manual Rev. A Draft 2

25 Remove me INSTALL Installation and Setup b. Locate the Print Head protection pad and the Card Cleaning Cartridge location tape (see below). Print Head Protection Pad Card Cleaning Cartridge Location Tape c. Release the Print Head Carriage by pushing the Print Head Carriage Latch to the left, and raise the Print Head Carriage. It will remain open at about a 45 angle Rev. A Draft 2 P330i Card Printer Service Manual 13

26 Installation and Setup Print Head Carriage Latch d. Remove the print head protection pad. Keep the pad, as well as the other packing material and the shipping carton, in case the printer is shipped or moved. If the original material is lost, a replacement Shipping Kit can be ordered from Zebra; please refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer. 14 P330i Card Printer Service Manual Rev. A Draft 2

27 Installation and Setup 2.3 Installing the Print Driver Software and Setting Driver Options Printing with the P330i Printer requires the Windows Printer Driver and your card design/ issuing software or printer command level programming through the printer interface. The P330i Card Printer can be used with any Windows 2000 or Windows XP computer, using the drivers provided on CD with the printer. This section contains information on the printing of a sample card in color (using the 5-panel color ribbon YMCKO and the Windows Printer Driver). Note If updating the printer driver from a previous version, before installing the updated printer driver version, always delete the existing version from your computer Rev. A Draft 2 P330i Card Printer Service Manual 15

28 Installation and Setup Installing the P330i Print Driver To install the P330i Printer Driver automatically on all Operating Systems, use the Zebra Install Wizard. Note Ensure that you have administrative privileges to perform this installation, or contact your IT department. The Install Wizard will walk you through the appropriate installation steps. The Wizard will: Automatically launch when the driver CD is inserted. From the main menu of your documentation CD, select your desired language and then select DRIVERS from the subsequent menu. The Install Wizard will walk you through the appropriate steps. Delete previous versions of the driver and clean up any necessary Registry entries. You must select Remove from the install options to remove any previous driver versions. 2.4 Loading a Ribbon i Series Printers require the use of i Series ribbons for full color printing. The Resin Thermal Transfer and Dye Sublimination ribbons for P330i are specifically designed for your P330i Printer. Step 10. Place the printer power switch in the OFF (0) position. Step 11. If the printer s Main Cover is closed: a. Open the printer s Main Cover; lift it by the lip at the bottom front as shown in the figure below left. 16 P330i Card Printer Service Manual Rev. A Draft 2

29 Installation and Setup Electrostatic Discharge Caution DO NOT TOUCH the Print Head or the electronic components on the Print Head Carriage. Discharges of electro-static energy that accumulate on the human body or other surfaces can damage the Print Head or other electronic components used in the printer. Note Avoid any direct contact with the print head to prevent transfer of oils or contamination. Outside of normal operation, only the Zebra-approved cleaning materials should come in contact with the print head. b. Raise the Print Head Carriage by pressing the release latch to the left (toward the output hopper) and lifting as shown below to about a 45 angle. The Print Head Carriage will stay in that position, as shown at the right below. Ribbon Take-up Spindle Ribbon Supply Spindle Rev. A Draft 2 P330i Card Printer Service Manual 17

30 Installation and Setup Step 12. Locate the Ribbon Supply Spindle and the Ribbon Take-up Spindle (see above). Load ribbon onto the supply spindle (under the print head carriage) flange side in, and load the empty core (with tape attached) onto the take-up spindle. Make sure the ribbon comes off the top of the supply spindle and feeds to the top of the take-up spindle. Take-up Spool Flange Supply Spool Hot Surface Do not touch the print head if the printer has been in service within the last 10 minutes. It could be very hot and cause a burn. Electrostatic Discharge Caution A static discharge is possible if you touch any exposed metal parts. Use of an anti-static wrist strap or comparable anti-static protection is required. 18 P330i Card Printer Service Manual Rev. A Draft 2

31 Installation and Setup Step 13. Gently press the print head carriage down until it is fully lowered, as shown below. Very little force is neccessary to perform this step. Note During normal operation (with power connected and turned on), the ribbon would automatically synchronize when the Print Head is restored to its fully-down position. The ribbon would be identified and the corresponding parameters sent to the driver. Since power is not connected at this point in the Installation and Setup Procedure, nothing will happen when the Print Head Carriage is closed. The ribbon will synchronize when power is turned on Rev. A Draft 2 P330i Card Printer Service Manual 19

32 Installation and Setup 2.5 Installing the Card Cleaning Cartridge The Card Cleaning Cartridge cleans the cards entering the printer. The Card Cleaning Cartridge consists of a Cartridge Frame and an Adhesive Roller, which are packed together. Step 1. Remove the Cartridge Frame and the Adhesive Roller from their packaging. Insert the Adhesive Roller into the Cartridge Frame, as shown below. To avoid contamination, always hold the frame and the roller by the ends.. Step 2. Peel the protective wrapper from the Adhesive Roller. Step 3. If the printer s main cover is closed, open it. Locate the area where the Card Cleaning Cartridge will be installed (initially, this area was covered by a warning tape). Card Cleaning Cartridge Mounting Location 20 P330i Card Printer Service Manual Rev. A Draft 2

33 Installation and Setup Step 4. Locate the slot at the rear of the Card Cleaning Cartridge mounting location; see below. Card Cleaning Cartridge Positioning Slot Step 5. Hold the Card Cleaning Cartridge by the extended handle (so the large arrow on the top is pointing away from you). With the cartridge at about a 30 angle (pointing downward), insert the lip of the cartridge into the slot, until the cartridge seats against the back wall. Then press the front of the cartridge down until it seats all the way down and latches with an audible click. See below. Slot Rev. A Draft 2 P330i Card Printer Service Manual 21

34 Installation and Setup Card Cleaning Cartridge in final position Step 6. Close the printer s Main Cover. 2.6 Setting the Card Thickness Control The Card Thickness Control is set by the user to adjust the gap as cards enter the printer, to prevent double-feeds (which could cause a jam) or mis-feeds. Note Set the Card Thickness Control before loading cards. Step 1. Open the Card Feeder cover. The cover is hinged; lift it by the lip at the right front corner. Note To reduce contamination and ensure better print quality, minimize the time the Card Feeder cover is open. 22 P330i Card Printer Service Manual Rev. A Draft 2

35 Installation and Setup Step 2. The Card Thickness Control Lever is at the front of the left-side opening of the Card Feeder area. Card Thickness Control Step 3. There are four detents to set the position of the Card Thickness Control. Slide the Card Thickness Control to the position corresponding to the following: Detent Position Highest 3rd position 2nd position Lowest Card Thickness 50 mil (1.27 mm) to 60 mil (1.52 mm) 30 mil (0.76 mm) to 50 mil (1.27 mm) 20 mil (0.51 mm) to 40 mil (1.02 mm) 10 mil (0.25 mm) to 20 mil (0.51 mm) Note The overlap in settings above accomodates variations in environmental conditions (especially humidity) and cards from different manufacturers. In general, start at the lowest position and move the lever up until cards feed reliably Rev. A Draft 2 P330i Card Printer Service Manual 23

36 Installation and Setup Note 60 mil ( mm ) cards may have a significant variation (over 10%) in the actual thickness of the cards; do not use these cards unless each card has been measured to have a thickness less than 66 mil (1.676 mm). 2.7 Loading Cards This section shows how to load plastic cards into the P330i Printer. The P330i can use cards with a range of thickness from 10 mil (0.25 mm) to 60 mil (1.5 mm). Note Do not mix cards of different thicknesses! The P330i Printer can also load and print cards fed individually. Information on this is given in the next chapter. Note DO NOT bend cards or touch print surfaces as this can reduce print quality. The surface of the cards must remain clean and dust free. Always store cards in an enclosed container. Ideally, use cards as soon as possible. Note For cards with magnetic stripe, refer to Appendix A for loading instructions. The plastic cards generally come in decks of 100 cards; the Card Feeder can hold a full deck of mil cards. Cards sometimes will stick together; this can cause mis-feeding or doublefeeding. To avoid this, separate the cards before loading, as described in steps 2 through 4 below. Step 1. If the Card Feeder cover is closed, open it. The cover is hinged; lift it by the lip at the right front corner. Note To reduce contamination and ensure better print quality, minimize the time the Card Feeder cover is open. 24 P330i Card Printer Service Manual Rev. A Draft 2

37 Installation and Setup Caution Do not touch print surfaces of the cards; this can reduce print quality Step 2. Step 3. Remove all wrapping from the card deck. Holding the card deck by the sides, hold it vertically against a flat surface such as a desktop. If the deck is too thick for your hand to hold it comfortably, use about half a deck at a time. Step 4. Push the stack back and forth to an angle of about 45 from vertical, so as to separate all of the cards. Note Static charges and edge burrs from the card die-cutting process can render individual cards stuck together with significant adhesion force. These cards must be physically separated from each other before inserting into the feeder; if not separated, feeding or printing problems may occur Rev. A Draft 2 P330i Card Printer Service Manual 25

38 Installation and Setup Step 5. Restore the card stack to its original squared-off condition, and place the cards in the input hopper. Step 6. Note that there will be a gap in the card stack, with several cards lying flat and the cards above angled upward, as shown in the exaggerated drawing below. This is normal and ensures proper feeding. Note Do not try to eliminate the gap by pressing down on the card stack in the input hopper; this can cause misfeeds. 2.8 Card Output Hopper The card output hopper is normally extended to receive the printed cards. The printer may be operated with the card output hopper in its closed position; in this case the cards will not be collected in the output hopper. Step 1. Pull the card output hopper out to place it in its functional position. Note The output hopper is a very snug fit to prevent it from moving during shipping or operation; firm force is required to change its position. 26 P330i Card Printer Service Manual Rev. A Draft 2

39 Installation and Setup Step 2. Step 3. When not using the printer, slide the card output hopper back into its closed position to protect the printer from dust and protect the output hopper from damage. The output hopper can be completely removed from the printer if necessary by inserting a thin, blunt object (such as a pencil) up through the hole in the bottom of the printer enclosure and pressing (up) to release the hopper while simultaneously pulling the hopper out. To re-install the output hopper, simply slide the output hopper in until it locks in place. 2.9 Connecting the Printer to your Computer The P330i Printer includes a standard USB interface. As an option, the printer can be ordered with a 10/100base-T Ethernet Adapter (in addition to the USB interface). The Ethernet Adapter can also be ordered as an add-on option and installed in the field by a Zebra factory certified technician. Step 1. If using the USB interface, use the supplied USB cable to connect between the USB connector on the printer and a USB port on the computer, as shown below. (Note that the figure below shows the optional Ethernet Adapter directly above the USB Connector; this may not be present on your printer.) Rev. A Draft 2 P330i Card Printer Service Manual 27

40 Installation and Setup Power Switch (Optional) Ethernet Connector Power Connector USB Connector Step 2. If your printer includes the optional Ethernet Adapter as well as the standard USB connection, use either the supplied USB cable or a standard Ethernet cable to connect the printer to a corresponding port on the computer or network. Important Do not use both USB and Ethernet connections at the same time! Important Intermittent or unpredictable operation may occur from unsecured connectors. If damaged, the power cable must be replaced by an exact equivalent Connecting Power The P330i Printer includes an internal AC power supply that accepts nominal input voltage in the range from 110 to 230 volts at 50 to 60 Hertz. The power source must be grounded. Depending on specific model number, your P330i Printer will include one or two power cords; use the one that is appropriate for the AC power source connection at your location. If neither has an appropriate connector, AC power cords may be purchased locally; make sure it is a three-wire (grounded) cord. 28 P330i Card Printer Service Manual Rev. A Draft 2

41 Installation and Setup Power Switch Power Connector Step 1. Step 2. Place the Printer s power switch in the OFF ( O ) position. Depending on your local AC voltage, plug the appropriate power cord into the printer s power connector and a grounded AC power source connection. Caution If the power cord appears damaged in any way, or if the power cord will not securely plug into the Printer s power connector or the AC power source connection, STOP! Use of a damaged or incorrect power cord could cause equipment damage, result in an electrical fire, or possibly cause injury. Step 3. To turn the Printer on, set the Printer s power switch to the ON ( ) position Rev. A Draft 2 P330i Card Printer Service Manual 29

42 Installation and Setup 2.11 Printing a Test Card With ribbon and cards loaded, your P330i Printer is ready to print. To check the operation of the printer, you should print a test card. (Printing a test card does not require that the printer be connected to your computer or network, but power must be applied.) Step 1. Step 2. Step 3. Step 4. Set the printer s power switch (on the back of the printer) to the OFF ( O ) position. While pressing the Printer s front panel button (next to the LCD display panel), switch the printer ON ( ). Hold the panel button until the LCD display panel reads SELF TEST. Release the panel button, and the test card will print. This is an example of the test card: PLASTIC CARD PRINTER PRINTER: P330iM Serial N : XXXXX Firmware: XXXXXXX 300 dpi TEST CARD Head resistance: XXXX Offset: XXXX-XXXX EC:XX Printing counter: XXXXX 2.12 Packing the P330i Printer for Shipment If the P330i Printer is to be shipped, it is important to use the original packing and shipping material to prevent damage to the Printer. If the original material is lost, a replacement Shipping Kit can be ordered from Zebra; please refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer. Note The specifics of the shipment and the printer s condition may influence which of the following steps are followed; common sense should prevail. Step 1. Remove cards in the card feeder: 30 P330i Card Printer Service Manual Rev. A Draft 2

43 Installation and Setup a. While the printer still has power applied and is turned on, and is still connected to the host computer, remove cards from the card feeder. The last card may be difficult to remove. If so, use the Eject Card command available through the driver on the host computer to eject the last card that is staged in the feeder. Caution Do not physically pull the last card out of the feeder staging area. This could damage the printer and void the warranty, as well as damage the card. b. Close the Card Feeder Cover. Step 2. If the printer still has power applied and is turned on, and is still connected to the host computer, set the printer s power switch (on the back of the printer) to the OFF ( O ) position, and disconnect the interface and power cables to the printer. Step 3. Step 4. Step 5. Step 6. Step 7. Step 8. Step 9. Open the Main Cover. Open the Print Head Carriage and remove the Ribbon. (If you wish to save the ribbon for future use, you may want to put it in a plastic bag for storage.) Insert the print head protection pad, and close the Print Head Carriage. Remove the Card Cleaning Cartridge and place it in the upper foam insert. Close the Main Cover. Slide the Output Hopper in all the way against the Printer. Place the Printer in its protective plastic bag. Place the lower foam insert in the lower part of the shipping carton. Use both hands to carefully place the Printer into the recess in the lower foam insert. Place the upper foam insert onto the Printer and gently press it down so it makes a snug fit on the Printer; the top of the upper foam insert should be even with the upper edge of the lower part of the shipping carton. Step 10. Slide the upper part of the shipping carton down over the lower part. Step 11. Insert and close the handles/latches Rev. A Draft 2 P330i Card Printer Service Manual 31

44 Installation and Setup 2.13 Operation Printing with the P330i Card Printer is similar to printing with any other printer in a Windows environment. The Printer Driver Software is installed on your computer (see Chapter 2). The P330i Printer is connected to the power source and the computer (see Chapter 2). The P330i Printer is selected by either the Operating System or the appropriate application software program. Printer Properties are set (the factory default values will be appropriate for many applications). Card printing is directed by the appropriate application software program. 32 P330i Card Printer Service Manual Rev. A Draft 2

45 Installation and Setup Setting Printer Properties Printer Properties can be set either at the Operating System level or within the application software program used for printing cards. Note In the following description of setting Printer Properties, only those properties and options that are suitable for being set by the User are described. The User should not make selections or set parameters unless they are specifically described in this section Preferences settings can configure the P330i Card Printer for Landscape (wide) or Portrait (tall) printing orientation, and allow the user to verify that the desired ribbon is installed in the printer. (Monochrome ribbons are selected via the drop-down menu.) Detailed instructions on setting printer parameters is presented in Appendix XXX.. If the P330i Printer includes the optional magnetic card stripe encoder, encoding parameters and coercivity can be set. Printer cleaning can be initiated from the Tools window (printer cleaning can also be initiated at the printer; see Chapter 4). Also from the Tools window, the Test Card can be selected from several pre-loaded styles. Single Feed Options allows Disabling or Enabling Single Feed Support. If Disable Single Feed Support is selected, when the P330i Card Printer runs out of cards in the feeder, the LCD display will read OUT OF CARDS. To continue, press the panel button. If Enable Single Feed Support is selected, when the P330i Card Printer runs out of cards in the feeder it will wait until a card is inserted in the single-card slot or cards are loaded in the feeder, and then will automatically continue Rev. A Draft 2 P330i Card Printer Service Manual 33

46 Installation and Setup Printing a Sample Card Sample card designs are installed with the printer driver. Sample cards require Microsoft Word or Microsoft Paint application software. The cards are accessed via the Start menu. Select Start, select Programs, select Zebra Card Printers, and select a sample card, or follow the directions below to design a card. Follow these steps to design and print your first card: Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Launch Microsoft Word Software. Depending on your computer configuration this may be done by double-clicking an icon on your desktop, or by clicking the Windows Start icon, selecting Programs, and navigating to Microsoft Word Go to the File menu and choose Page Setup. Select the Paper Size tab, choose Card. Under orientation, select Landscape. Select the Margins tab, and set the Top, Bottom, Left, and Right margins to 0 (zero). Click OK to close the Page Setup window. The card appears on the screen. Design a card with both black and colored text and with colored pictures (see example below). us! Note For cards thinner than 20 mils (0.51 mm), the card design must be limited to (1) no more than two 30 mm x 30 mm areas of full color, (2) black information (text and barcode, for example) must cover no more than 50% of the card area, and (3) there must be at least a 5mm unprinted border along all edges. For cards thicker than 40 mils (1.02 mm), the card design must have at least a 5mm unprinted border along all edges. For cards with thickness between 20 mils (0.51 mm) and 40 mils (1.02 mm), these restrictions do not apply; full color printing is permitted edge to edge in both directions. Step 8. Once you are ready to print, go to the File menu and select Print. 34 P330i Card Printer Service Manual Rev. A Draft 2

47 Installation and Setup Step 9. If the printer was not selected as the default printer, go to the File menu, select Print Setup and choose Zebra P330i Card Printer from the printer names list. Then Close the Print Setup dialog box. Step 10. The printer will feed in a card and start printing (the data download time will vary depending on the complexity of the card design and the processing speed of your computer). Step 11. Once the printing job is complete, the card is ejected from the printer Feeding One Card at a Time A Manual Feed Slot is available below the Card Input Hopper for feeding single cards. The Card Input Hopper must be empty for single-card feeding to work properly. Step 1. Step 2. Open the Card Feeder cover. Verify that there are no cards in the feeder, then close the Card Feeder cover. Insert a single card into the slot below the Card Feeder. Do not feed more than one card at a time. 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 Rev. A Draft 2 P330i Card Printer Service Manual 35

48 Installation and Setup 36 P330i Card Printer Service Manual Rev. A Draft 2

49 3 Theory of Operation This chapter includes four major topics: Color Fundamentals Card Path Elements Card Movement During Printing CPU PCBA Description 3.1 Color Fundamentals The following offers readers a perspective on how imaging occurs in various systems, with a particular emphasis on card printers, their interaction with other system elements, and a comparison of techniques. Color refers to the hues people see. This refers to the visual spectrum. People can see the whole spectrum when they look at a rainbow or at the dispersal of white light through a prism. The extremes of this spectrum are red (the longest wavelength perceivable) and violet (the shortest wavelength perceivable). The remaining orange, yellow, green, etc., shades lie between the red and violet extremes. Ultra Violet and Infrared spectrums exist above and below the visual. A light source, such as the sun, generates the full range of color frequencies, which combine to produce white. Black results when light fails to reflect off of an object due to an absence of the object color in the source illumination or when a printed color prevents reflected light. Object colors converge toward black as source illumination decreases. Saturated colors are colors in their purest state. This means they contain no white (as in pastels) or black (contrast reduction) components. A so-called trained observer can discern about 450 fully saturated shades. When these colors are diluted by black, the number of discernable shades diminishes. However, white dilutions increase the number of colors discernible Rev. A Draft 2 P330i Card Printer Service Manual 37

50 Theory of Operation In Card Printers, images result from two types of ribbon coatings dye and resin. Dye coatings allow color gradations from a light application to a dense application using Dye Sublimation imaging. P-Series printers can apply dye in 32 steps (from zero to 31). This allows the mixing of dye colors to produce a non ribbon panel color and determines how much of the white card color shows through. Resin, however, is applied at full saturation, meaning no card or other underlying colors show through. A saturated color absorbs all non-reflected spectrum elements. In contrast, a non-saturated dye color acts as a filter that absorbs a percentage of the elements returned to a viewer and all of the non-reflected spectrum elements. In any printer imaging system, memory capacity becomes a concern. One typically reads about systems offering say 24-bit color. This refers to an RGB system that uses eight bits to describe each of the primary colors red, green, and blue. Such a system can quantify each primary color in a range of steps of from zero to 256. Twenty-four bit color yields a 16,777,216 shade pallette for each pixel in the desired image. Fifteen-bit color yields 32,768 shades and requires 15-bits for each pixel in the desired image. Thirty-two bit color adds an eight-bit transparency component to 24-bit color, which along with other non-color data, becomes an Alpha Channel component. Data compression is also a factor. Note that the memory required for images expands substantially with the number of shades. Compression attempts to reduce the memory requirements. Some compression schemes only attempt to identify repeating colors. Others, such as JPEG, can treat various amounts of change as the same repeating colors. Carried to an extreme, JPEG compression would produce a posterized result, meaning color changes would step unnaturally. This would become noticeable in blends and in photographic images. Color matching also depends on the colors available within Color Palettes. Systems typically offer palette selections that range from 256 to several million colors. Some applications also offer choices that support file size reductions. Others are file format determined. An application that creates 24-bit RGB color images needs to have a way to send data to a printer capable of say 15-bit color. An application typically creates a palette based on the colors used in its image file. For printing, a Printer Driver must map source file colors to nearby colors in the palette used by the printer. A similar process can occur during exports to some file formats. In color printing processes, particular shades of color derive by mixing quantities of the basic colors cyan, magenta, yellow, and sometimes black (usually referred to as CMY or CMYK where K designates black). When users choose some other color definition from their application e.g., hue saturation intensity (HSI) or red green blue (RGB) a conversion to CMY/CMYK must take place to support a printer. Color mixing occurs at the level of each pixel. Pixels serve as the basic elements of images. Pixels can comprise either one dot (the smallest printable element) or a small matrix of dots, depending on the methodology used to form the images. Offset printing and Dye Sublimation can produce a substantial range of colors within just one dot. Color Monitors produce their range of colors using a red, green, and blue (RGB) three-dot matrix. Scanners and digital cameras employ charge-coupled devices (CCDs) that capture and deliver RGB components. 38 P330i Card Printer Service Manual Rev. A Draft 2

51 Theory of Operation Thermal Transfer and most Ink Jet printers produce their range of colors using larger dot matrixes typically up to four-by-four or equivalent dots where each dot color can be a fundamental (CMY) or the combination of fundamentals (which adds RGB and black). Therefore, these particular devices limit their dot colors to cyan, magenta, yellow, red, green, blue, black, and the media color (usually white). Since these colors remain unmixed, color perception beyond the eight relies on a person's natural tendency to mix dot color components where associated dots appear too small for individual perception. With eight dot colors possible, a four-by-four dot pixel matrix can produce in excess of four billion combinations ((4 x 4) 8 ). However, as long as the color components remain the same, the dots in a matrix can be shuffled into any pattern without changing the color perceived. For example, a matrix containing all-white dots except for one red dot produces the same shade of pink no matter where in the matrix the red dot lies. Therefore, a matrix containing n dots can produce each color in n different ways. This makes a four-by-four matrix capable of producing more than 268 million different shades ((4 x 4) 8 /16 + white). For monochrome printing, which is the only matrix-based printing that users might want to apply to a P-Series printer, this same matrix can produce 16 different gray (or other thermal transfer ribbon shades) levels plus white ((4 x 4) 2 /16 + white). Mixing of dot colors in Offset Printing and Dye Sublimation occurs by controlling the amount of each dye or ink that gets applied to each dot. Mixing in color monitors occurs from control of RGB intensities. For CRTs (cathode ray tubes) three beams act on the respective phosphors. For Active Matrix Displays, liquid crystals emit the RGB levels. Of all the methods, Dye Sublimation produces the best quality printouts, because as is the case for all P-Series Printers, each dot can have the full range of 15-bit color (32 shades per dye color) at a full 300 dpi resolution. In fact, even with resolutions equal, Dye Sublimation still holds an advantage over offset printing. Dye Sublimation creates a dot color by applying varying densities of the CMY dyes. Offset printing creates a dot color by varying the diameter of the CMYK ink dots, which can make individual dots more observable and subject to moire pattern generation. Since without magnification no one can see individual dots at 300 dpi and since each dot results from percentages of YMC ribbon colors, Dye Sublimation offers card printer users essentially the continuous-tone quality of photographs. Moire (typically herringbone) patterns can become a factor when users generate either print files or hard copy separations for offset printing. Users creating related print files typically ask the people that do their offset printing which separation angles best reduce these patterns before risking a distorted result. Many applications offer Print Dialog options for these settings. All the non Dye Sublimation print methods work because we naturally mix dot colors that appear too small for individual perception. To see individual dot intensities or colors, view the monitor or printed page using a loupe or other such magnifier. Not all images require high dot densities. The need for high dot density decreases as the viewing distance increases. For example, a large roadside sign may require separations screened at only four lines per inch. Such a sign would appear like a mosaic of CMYK dots if viewed from too close a distance. Note that press men use lines per inch instead of dots per inch, because they image color separations through screens to generate dot-based images from continuous-tone images. However, both refer to picture resolution Rev. A Draft 2 P330i Card Printer Service Manual 39

52 Theory of Operation Pixelization, or the ability to see individual pixels, typically becomes a factor when a digital image undergoes magnification. At 300 dpi, a dot measures inches ( mm). Individual pixels in such an image remain unobserved to the naked eye. Observable pixels do not show up until a magnification reduces the resolution well below 200 dpi. Notably, monitors display images at 72 dpi. An original at 72 dpi is at a threshold. Any magnification of pixels of a 72 dpi original for a screen image occurs by repeating pixels taken from the original. Higher resolution originals can sustain greater magnifications before the need for repeats begins. In other words, an original bitmap can only be magnified so much before the need for duplicated pixels occurs and pixelation begins to become an issue. In raster systems, where line scans take data from a video memory, graphic objects comprised of lines typically undergo antialiasing. Without this, lines created at other than zero, 45, 90 degrees and their complements would have a jagged appearance. Line Generators can only put data in available dot positions in a video memory. In effect, each line-dot generated lands on the closest dot position available. A jagged appearance occurs as one axis element has intervals that stay the same while the other axis element marches along step-by-step. Antialiasing compensates for a lack of ideal dot positions by averaging the line-dot intensities with those of near-by dots. An illusion of straight lines results. Office Printers offer resolutions typically from 300 to 600 dpi. A degree of resolution reduction (down sampling) can be tolerated in order to reduce the amount of data required. When a file size needs to be kept in check by not exceeding a viewer's needs, the printed image should typically tolerate a resolution reduction to about 180 dpi. Typically, the down-sampling process occurs by averaging pixel groups, with group size a function of the desired change from one pixel density to another. Because a monitor and a printer produce color through different methods, users can expect somewhat different results. A monitor uses an additive process, meaning a particular color derives from intensity control. For example, a color moves toward the green by intensifying excitation of green CRT phosphors. Printed images, on the other hand, use a subtractive process. These images display their color through reflected light. To generate a particular printed color, the process must subtract (that is, filter out and not reflect) parts of the source illumination, which then lets other parts dominate. For example, a reduction in cyan (greater cyan filtering) would allow yellow and magenta components to become more dominate. The light reflected off of the surface of a white card passes through any colored dyes deposited on the surface of the card, both going and coming. The dyes used to form printed images serve as filters of light that would otherwise reflect off of what is typically a white print media. In printed images, complete filtration (or what serves as the maximum subtraction capability) results in black. Conversly, the absence of filtration results in the color of the print media. In monitors, maximum intensities (maximum additions) result in white, and minimum intensities produce black. Because light reflected from print media depends on ambient lighting, users may get darker images from a printer than they see on their monitor, where a brightness setting exists. 40 P330i Card Printer Service Manual Rev. A Draft 2

53 Theory of Operation Print illumination (generally from room or outdoor lighting) affects color for all printed images. When a light source emits less in certain parts of the visual spectrum, a print illuminated by such a source by necessity reflects less of the associated colors. This occurs even though the corresponding light reflecting capability remains inherent in the print. Imagine, for example, the effect of placing a color filter in front of a light source. Only the visual spectrum parts passed by this filter can reach the print. Viewers can sometimes see subtle effects of this by observing the same print under sunlight, incandescent lights, and fluorescent lights. Sunlight radiates fairly evenly over the entire visual spectrum, rising only slightly higher at the center. Incandescent lights radiate far more on the red side than on the blue side of the visual spectrum. Fluorescent lights radiate differently depending on their phosphor blends. Such classifications as Cool Light and Warm Light refer to blue-rich and red-rich enhancements, respectively. In scientific terms, the question How white is my source? is resolved by a side-by-side comparison between a source in question and a heated black body radiator. The term black body refers to a material that produces no color other than that which results from heating. Imagine such a material first appearing reddish and then gradually becoming white hot followed by bluish white as its temperature is pushed higher. These are the whites to which comparisons are made. In the Graphic Arts industry, the following standards for white exist: Region Black Body Temperature U.S K Europe 6500 K The NTSC standard for white is 6500 K. However, only a properly adjusted television or monitor can produce a standard white. When close concern for color is important in displaying prints, users should find similar ambient conditions for a color check. If a color is closely related to identifying a printed feature, users may find themselves dealing with this level of concern, with skin tones typically offering the greatest challenge. However, most applications tend to require a less critical evaluation. Usually, what looks good in one setting tends also to look good in another, despite any subtle differences in ambient lighting. Color is very much a function of the device either sensing or producing the color. A computer monitor that uses a CRT, for example, can produce very bright images, typically brighter than those produced by a television set. A television set typically can produce a broader range of colors than can a CRT monitor. Television manufactures emphasize color range over brightness; monitor manufacturers emphasize brightness over color range. While the forgoing compromises generally hold true, each device manufacturer, in fact, takes a different perspective when deciding which formulations to use in the red, green, and blue CRT phosphors. Moreover, devices with a brightness control allow a wide range of image intensities. Active Matrix Displays generate images from a back-lighted grid that activates red, green, and blue LCD pixel elements. For paper, and other print media, gloss affects brightness, and Black Body Temperature affects hue Rev. A Draft 2 P330i Card Printer Service Manual 41

54 Theory of Operation More issues arise with the addition of a color scanner to a system. These devices also differ between manufacturers. WYSIWYG (what you see is what you get) from scanned picture to monitor to printer gets complicated because of different device color ranges (Gamuts) and by the different color systems used. A printed color outside the range of a scanner cannot make it to a monitor; only a nearby color can. Users that attempt to use a computer application to edit the image received from a scanner may add colors beyond the range of their printer. Notably, some applications issue gamut warnings. Both monitors and scanners use the RGB system, while color printers use the CMY/CMYK system. Additive systems produce a better range of colors using RGB, while subtractive systems do better with CMY/CMYK. An important concern then becomes "how does a device handle color data beyond its range?" If a device just substituted the best color available, objects filled with blends, starting from inside the gamut and ending at some point beyond the gamut, would lose their desired appearance. For example, an object blending from say an orange to a red beyond its red range would abruptly stop blending at the point the device could no longer produce a deeper red. The remaining blend would then continue with the same color. Some devices avoid this effect by compressing (via re-mapping) the gamut. While compression can maintain the desired effect, similar to JPEG data, too much compression produces posterized images. Even in nature, different conditions produce different colors. Painters of seascapes point out how the ocean reflects the color of the sky. The bright, sunny day colors differ from the cloudy day colors. Women have more color sensitivity than men. Different colors provoke different emotional responses, which do not necessarily remain the same from one country to the next. All-in-all, there is much to consider, but most decisions rely on subjectivity before they become final. 42 P330i Card Printer Service Manual Rev. A Draft 2

55 Theory of Operation Printing Color imaging requires three passes of Card media underneath the Print Head. Card media shuttles back and forth across the print head during this process. The ribbon feeds between the image head and the card media and during printing advances from its supply to its take-up reels in step with an advancing Card. Heat, when generated at an image head element, transfers ribbon dye in a measured quantity onto the print media. In color printing, the ribbon advances from one color panel to the next between each imaging pass. A card either exits a Printer following the last pass or transitions to the Card Flip in preparation for printing on the opposite side. Monochrome printing for black resin images requires an additional pass, as does the application of a clear overlay varnish. Printers employ an image head with a single row of 672 print head elements, 300 to the inch (11.8 per millimeter). Notably, the capability for card coverage exceeds the needs of a standard card size by inches (2.9mm), or about 34 dots. This excess supports both programmable centering and full bleed imaging. Each element can generate 32 different heat levels for color and a single heat level for resin monochrome Rev. A Draft 2 P330i Card Printer Service Manual 43

56 Theory of Operation 3.2 Card Path Elements The figure below shows the rollers that transport Cards as they make their way through the P330i printer. The rollers keep the card on a horizontal path, reducing the chance of a card edge catching on anything. Cleaning Roller Card Path Transport and Platen Rollers Card Feed Roller The figure below shows the sensors that track card and ribbon position and movement. Head Open Sensor Ribbon Sync. Sensor Smart Card Sensor (if equipped) Single Card Feed Sensor (on enclosure) Magnetic Encoder Sensor (if equipped) Ribbon Color Sensor Cam Sensor (PCBA) Card Entry Sensor Feeder Sensor 44 P330i Card Printer Service Manual Rev. A Draft 2

57 Theory of Operation 3.3 Card Movement During Printing The P330i printer moves a card through a specific sequence of movements as it encodes and prints the card. (Optional) Magnetic Stripe Encoding Station Cleaning Cartridge Card Exit Card Input Hopper Output Hopper Print Head (Optional) Smart Card Encoding Station Single Card Feed Slot The card is fed from the bottom of the stack in the Card Input Hopper, or in through the Single Card Feed Slot. The card moved along in contact with the exposed sticky area of the Cleaning Cartridge; this cleans dust or dirt particles from the (upper) card surface. If the printer includes an optional Smart Card Encoder (either contact-style or contactless), the smart card is encoded. If encoding fails, the card is moved directly to the card exit, without printing. This is done to avoid wasting time and ribbon panels on a defective card. If the printer includes an optional Magnetic Stripe Encoder, the card is moved past the print head to the magnetic encoder, and the stripe is encoded. Note that the card goes past the print station without being printed at this time. After magnetic encoding, the card is moved back to just before the print head. As with smart-card encoding, if magnetic encoding fails, the card is moved directly to the card exit, without printing Rev. A Draft 2 P330i Card Printer Service Manual 45

58 Theory of Operation The leading edge of the card is moved under the Print Head, and the print head is lowered. When the printer was turned on, the ribbon was automatically synchronized, bringing the leading edge of the yellow ribbon panel under the print head. Lowering the print head reduces space between the print head, the ribbon, and the card, reducing spread of the printed spot and giving sharper images. As the card and ribbon move along, each element of the print head is energized to one of 32 levels (from completely off to maximum heat), which melts a corresponding amount of yellow dye onto that particular spot on the card. If using a resin ribbon (used when printing a bar code on a card), the head elements are energized to either on or off. The on level actually transfers the spot of resin under the print head 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 unprinted areas. After this yellow pass is completed, the print head is raised, the card is moved back, and printing continues with the Magenta ribbon panel, then the Cyan panel, then the Black ( K ) panel if present, then an Overlay panel. When using a monochrome ribbon, the card makes a single pass under the print head. When printing is completed, the card is moved (past the magnetic encoder, if present) to the Card Exit, where it falls into the Output Hopper. 46 P330i Card Printer Service Manual Rev. A Draft 2

59 Theory of Operation 3.4 CPU PCBA Description Most of the circuitry in the P330i is on the CPU PCBA. Since the CPU PCBA is not a serviceable unit, circuit analysis to the component level is pointless; but a basic understanding of the CPU PCBA helps to better understand the P330i printer. The figure below shows the connectors on the P330i CPU PCBA. J11 (Ribbon RFID) J7 (Smart Card) J1 (Mag Encoder Head) J8 (Auxiliary RS-232; factory use only) J2 (Mates with Ethernet Extension Board) J6 (USB Port) J10 (LCD Panel) J13 (Motors and Sensors - Connects to I/O Daughterboard) J12 (+24 VDC Input from Power Supply) J4 (Not Used) J3 (Out of Cards Sensor) J9 (Print Head, Head Lock, Head Temp. Sensor) Rev. A Draft 2 P330i Card Printer Service Manual 47

60 Theory of Operation Below is a block diagram of the functional circuits on the P330i CPU PCBA; the block diagram also shows how signals are passed to and from the CPU PCBA to the rest of the printer. P330i CPU PCBA Ethernet Port (Ethernet Option Components) Ethernet Printserver Board Ethernet Extension Board Ethernet Connection Circuitry Memory for CPU Motor Drivers A/D Circuitry for Optical Sensors I/O Daughterboard Ribbon and Card Transport Motors Optical Sensors RFID Tag in Ribbon Core USB Port USB Circuitry CPU Sensor Calibration Circuitry Printhead Circuitry Printhead RFID Transponder Ribbon RFID Circuitry Clock LCD Display and Panel Button Circuitry LCD Display Panel Panel Button (Mag Encoder Option Components) AC Voltage Power Supply 24 VDC Power Control Magnetic Encoder Circuitry Magnetic Encoder (Smart Card Option Components) Smart Card Encoder Circuitry Contact or Contactless Smart Card Encoder 48 P330i Card Printer Service Manual Rev. A Draft 2

61 4 Troubleshooting 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. The Test Software described in Appendix A includes selections to exercise most printer functions. Beyond this, Zebra Card Printer Solutions offers Technical Support and factory repair as options Rev. A Draft 2 P330i Card Printer Service Manual 49

62 Troubleshooting 4.1 Power-Up Failures Some problems are evident as soon as power is applied to the printer. The following table will help in diagnosing these problems. Symptom Possible Cause Corrective Action When power is turned on, nothing at all happens (no sound, LCD panel stays dark). 1. No power to printer. 1. Check AC power source, verify power cord is plugged into printer, try a different power cord. When power is turned on, sounds are heard inside printer and ribbon advances, but LCD Panel stays dark. 2. Defective EMI filtering components. 3. Check Fuse in Power Supply. 4. Defective Power Supply. 1. Cable from CPU PCBA to LCD Panel unplugged at either end. 2. Defective LCD Panel. 2. Check EMI filtering components. 3. If Fuse in Power Supply is blown, replace it. If replacement fuse blows, replace Power Supply. 4. Replace Power Supply. 1. Verify cable from CPU PCBA to LCD Panel securely plugged in at both ends. 2. Replace LCD Panel. When power is turned on, sounds are heard inside printer, LCD Panel lights up and INITIALIZING message scrolls, but LCD Panel message does not change to a steady READY message within about 30 seconds. 3. Defective CPU PCBA. 3. Replace CPU PCBA. 1. Defective CPU PCBA. 1. Replace CPU PCBA. 4.2 LCD Panel Messages The LCD Panel on the front of the printer continuously displays messages as to what operation the printer is performing as well as certain fault messages. The following table lists possible causes and solutions to the fault messages. 50 P330i Card Printer Service Manual Rev. A Draft 2

63 Troubleshooting Problem / Description The LCD Panel displays OUT OF CARDS message. The LCD Panel displays OUT OF RIBBON message. The LCD Panel displays PRINT HEAD OPEN message. The LCD Panel displays MECHANICAL ERROR message. The LCD Panel displays ENCODING ERROR message. The LCD Panel displays CLEAN PRINTER message. Cause / Solution 1. Check for cards in the card feeder. If no cards present, load cards. 2. Check that Card Thickness Control lever is properly adjusted (see Loading Cards in Chapter 2). 3. Press the Panel Button for 1 second. The printing job will restart. 1. Check ribbon. Replace if defective or entirely used. Ribbon will automatically synchronize and printing will restart with a new card. 1. Check that Print Head Carriage is closed and latched. If not, close and latch it. 1. Check that you are using the correct card type (see Technical Specifications). 2. Check that Card Thickness Control lever is properly adjusted (see Loading Cards in Chapter 2). 3. If two cards are fed into the printer at the same time: Open cover and remove Card Cleaning Cartridge, empty the Card Feeder, and pull the jammed cards out. Replace the Card Cleaning Cartridge. Separate the cards as shown in Loading Cards in Chapter 2, and replace. 4. Check that ribbon is loaded correctly. 1. Check that you are using the correct magnetic card type (for low or high coercivity encoding). 2. Verify command syntax. 3. Contact Zebra technical support. 1. Clean the printer (see Chapter 4) Rev. A Draft 2 P330i Card Printer Service Manual 51

64 Troubleshooting 4.3 Printing a Test Card Printing a Test Card is an efficient way to determine if there is a card transport problem or a printing problem. Print a Test Card (See Section 2.11) Test Card Emerges from Printer? No Check Problems Associated With Card Transport. See Section 4.4. Yes P75i Test Card OK? No Check Problems Associated With Print Anomalies. See Section 4.5. Yes No Problem With Basic Printing. 52 P330i Card Printer Service Manual Rev. A Draft 2

65 Troubleshooting 4.4 Card Feed or Transport Failures Troubleshooting of card feed or transport failures generally involves seeing where the failure occurs or what type of failure it is. That determination leads to checking certain assemblies or components. Symptom Possible Cause Corrective Actions Cards don t feed at all. 1. Card Thickness Control is 1. Set Card Thickness Control improperly adjusted. correctly (see section 2.6). Multiple card jam. Partial Card Feed. Card stalls near Cleaning Cartridge. 2. Defective Feeder Sensor. 3. Dirty or torn/missing Card Feeder Belt. 4. Defective Card Feed Roller. 5. Broken Card Feed Drive Belt. 6. Defective Card Feed Motor. 1. Card Thickness Control is improperly adjusted. 2. Cards are sticking together. 1. Card Thickness Control is improperly adjusted. 1. Dirty or defective Clean Drive Roller. 2. Defective 63T x 4mm Stepper Motor Belt. 3. Defective Stepper Motor. 2. Replace Feeder Sensor. 3. Clean or replace Card Feeder Belt. 4. Replace Card Feed Roller. 5. Replace Card Feed Drive Belt. 6. Replace Card Feed Motor. 1. Set Card Thickness Control correctly (see section 2.6). 2. Be sure to separate the cards when loading them into the Card Feeder, as described in section Set Card Thickness Control correctly (see section 2.6). 1. Clean or replace Clean Drive Roller. 2. Replace 63T x 4mm Stepper Motor Belt. 3. Replace Stepper Motor Rev. A Draft 2 P330i Card Printer Service Manual 53

66 Troubleshooting Symptom Possible Cause Corrective Actions Card stalls at Platen (i.e., under the Print Head). 1. Dirty or defective Print Head Platen Roller. 1. Clean or replace Print Head Platen Roller. Card doesn t exit printer 2. Defective 56T x 1/8 Timing Belt. 1. Defective 104T x 1/8 Timing Belt. 2. Dirty or defective Exit Pressure Roller. 3. Dirty or defective Exit Card Drive Roller. 2. Replace 56T x 1/8 Timing Belt. 1. Replace 104T x 1/8 Timing Belt. 2. Clean Exit Pressure Roller or replace Exit Pressure Roller Assembly. 3. Clean or replace Exit Card Drive Roller. 4.5 Print Anomalies A careful examination of the cards that are printed will lead to efficient troubleshooting of printing problems. Keep in mind that cleanliness and the card stock are two factors that strongly affect print quality. Note For optimum print quality, always keep the Main Cover and the Card Feeder Cover of the printer closed, 54 P330i Card Printer Service Manual Rev. A Draft 2

67 Troubleshooting Symptom Possible Cause Corrective Action No Image. 1. Ribbon is not an i-series 1. Always use i-series Ribbons Ribbon. in the P330i printer. Faint Image. Artifacts. Horizontal Lines. Multiple Evenly-Spaced Horizontal Lines. Wavy horizontal lines (these will be especially noticeable in solid blocks of color). 2. Ribbon incorrectly installed. 3. Cards may not meet specifications. 4. Print Head elements may be scratched or burnt. 5. Print Head not being positioned correctly. 1. Dirty Print Head. 2. Low Print Head Voltage. 1. Particles on Feed or Transport Rollers. 1. Dirty or damaged Print Head element. 1. Print Head Registers on CPU PCBA 1. Printhead Assembly out of alignment. 2. Check that ribbon is installed correctly (see section 2.4). 3. Use a different supply of cards. 4. Replace Print Head. 5. Replace CPU PCBA. Replace Print Head Up/Down Motor. Check Print Head Position Sensors, replace if defective. 1. Clean Print Head. 2. Replace CPU PCBA. 1. Clean the Print Head (see Chapter 4). If horizontal lines are still present, replace the Printhead Assembly. 1. Replace CPU PCBA. 1. Align Printhead Assembly (see Printhead Replacement Procedure). Replace Printhead Assembly. Vertical Lines. Sticking Ribbon. Washout. 1. Peel Bar on Print Head Assembly out of adjustment. 1. Peel Bar on Print Head Assembly out of adjustment. 1. Adjust Peel Bar or replace Print Head Assembly. 1. Adjust Peel Bar or replace Print Head Assembly. Sheared Ribbon 1. X-Offset value incorrect. 1. Adjust X-Offset value Rev. A Draft 2 P330i Card Printer Service Manual 55

68 Troubleshooting Symptom Possible Cause Corrective Action Image Off-Center 1. Excessive border at trailing edge of card. 2. Excessive border at leading edge of card. 3. Excessive border at card edge nearer front of printer. 4. Excessive border at card edge nearer back of printer. CYMK Not Aligned. Abrupt Color Change. Small spots appear on the printed card with a non-printed area or a different color. 1. X-Offset value too low. 2. X-Offset value too high. 3. Y-Offset value too low. 4. Y-Offset value too high. 1. Contamination on the card surface. 2. Dust inside the printer and/or dirty Cleaning Cartridge. 1. Increase X-Offset value. 2. Decrease X-Offset value. 3. Increase Y-Offset value. 4. Decrease Y-Offset value. 1. Check that cards are stored in a dust free environment. 2. Clean the printer (see Chapter 4). 3. Replace Cleaning Cartridge (see Chapter 4). There are non-printing horizontal lines (white) on the card surfaces. 1. Ribbon not correctly positioned. 3. Print Head is dirty. 4. Print Head elements are damaged (e.g., scratched or burnt). 1. Ensure that the ribbon is properly rolled onto the ribbon spindles and that there are no wrinkles in the ribbon. 2. Replace ribbon. 3. Clean the Print Head 4. Replace Print Head Assembly. 56 P330i Card Printer Service Manual Rev. A Draft 2

69 Troubleshooting Symptom Possible Cause Corrective Action Printing shows very pale, very dark, or inconsistent results 1. Defective ribbon. 2. Cards may not meet specifications. 1. Change ribbon and print again. 2. Use a different supply of cards. Printing shows blurry printed image. 3. Contrast and/or Intensity may be set to incorrect values. 4. Head Settings are too low / high. 5. Dust or embedded contamination on elements of the Print Head. 1. Ribbon cartridge may not be correctly positioned. 2. Ribbon may not be synchronized on the correct color panel position. 3. Cards may not meet specifications. 3. Adjust Contrast and/or Intensity values in software. 4. Adjust Head Settings higher / lower. 5. Clean the Print Head (see Chapter 4). If contamination cannot be removed, replace the Printhead Assembly. 1. Check that the ribbon is properly rolled onto the spindles.. Replace ribbon and print again. 2. Open the Print Head Carriage, then close it. This will cause the ribbon to re-synchronize. 3. Use a different supply of cards. Only one panel of a color ribbon prints. Text prints ok but graphics have image distortion, blotches of color, color dots or grid. 4. Dust or embedded contamination inside the printer and/or dirty Cleaning Cartridge. 1. Using the wrong type of ribbon. 4. Clean the Printer. Replace the Cleaning Cartridge. 1. Use only i Series ribbons for full color printing. 1. Graphics incompatibility. 1. Use different format for graphics. Use higher-resolution graphics Rev. A Draft 2 P330i Card Printer Service Manual 57

70 Troubleshooting 4.6 Troubleshooting the Ethernet Connection and Adapter Resetting to Factory Defaults To reset the Ethernet Adapter configuration parameters to the factory defaults, press the Ethernet Switch and hold it in while turning the printer power on. Keep the Panel Button pressed until the Status Indicator light turns green, then release the Ethernet Switch. To print a configuration card, press and hold the Ethernet Switch until a card starts to print. Ethernet Reset Button Ethernet Adapter Status Indicator Network Status / Activity Indicator 58 P330i Card Printer Service Manual Rev. A Draft 2

71 Troubleshooting Ethernet Adapter Status Indicator A bi-color Status Indicator displays the operational status of the Ethernet Adapter. The following conditions might occur: During normal operation, the LED is solid green for more than 30 seconds. This indicates all the hardware is functioning properly and the Ethernet Adapter has detected the presence of the network. It does not mean the Ethernet Adapter has an IP address or is attached to a printer queue. If the LED is rapidly flashing green (9 times/sec), the Ethernet Adapter has not detected the presence of a network cable. To solve the problem: Verify that the network cable is appropriate for the network and has an RJ-45 connector. Turn the printer power off (O). Remove the network cable from the Ethernet Adapter. Plug the network cable back in until you hear a positive click. Check the other end of the cable in the same manner. Turn the printer power on; if the Ethernet Adapter still does not detect a cable, continue. Connect the Ethernet Adapter to a known good network connection. If the Ethernet Adapter is still unable to detect the network cable, contact Technical Support for assistance. Important Cables with a rating higher than CAT-6 have not been tested. If the LED is slowly flashing green (1 time/sec), the Ethernet Adapter is trying to print a job. If the job does not print, check the following: Verify that the printer has media and ribbon. If the printer is showing any errors, it is unlikely that the Ethernet Adapter can send data to the printer. The LED continues to blink until the printer malfunction is resolved or until the printer is turned off (O). Flashing red indicates the Power On Self Test (POST) is in progress. If the LED is solid red for more than 30 seconds, the Ethernet Adapter has failed the POST. A failed POST can be caused by any of the following: The printer attached to the Ethernet Adapter device is malfunctioning. Turn the printer power off, wait 10 seconds, then turn the printer back on ( ). If the Ethernet Adapter still fails the POST, the Ethernet Adapter has a hardware problem that can be fixed only by replacing or returning the unit. Contact Technical Support for repair or replacement information. If the LED is alternately flashing red and green for longer than 2 minutes, the Ethernet Adapter is in firmware-download mode. This means it is waiting for new firmware data to be sent before it continues normal functioning. Perform the following: Rev. A Draft 2 P330i Card Printer Service Manual 59

72 Troubleshooting If the Ethernet Adapter was purposely put into firmware-download mode, finish the download with the proper update utility. Contact the Zebra web site at to download this utility. Contact Technical Support for help recovering this unit. 60 P330i Card Printer Service Manual Rev. A Draft 2

73 Troubleshooting Network Status/Activity Indicator A bi-color Status/Activity LED indicates network speed, established link, and network activity. If the LED is off, no link was established. If the LED is solid green, a 100Base link is established. If the LED is flashing green, a 100Base link is established and network activity has been detected. If the LED is solid orange, a 10Base link is established. If the LED is flashing orange, a 10Base link was established and network activity has been detected. Network activity detected by this LED does not mean the activity is data for the print server. The activity is all activity on the network as seen by the Ethernet Adapter Rev. A Draft 2 P330i Card Printer Service Manual 61

74 Troubleshooting 62 P330i Card Printer Service Manual Rev. A Draft 2

75 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. Electric Shock Caution Before performing any of the procedures in this chapter, set the printer power to OFF (O) and disconnect the power cord. still 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 printers with different configuration or options than your particular printer. They may also show additional parts removed in addition to removals for the process being described. Please disregard these differences; the information pertaining to the replacement process being described will still apply to your printer Rev. A Draft 2 P330i Card Printer Service Manual 63

76 5.2 Required Tools This section lists the tools required for the replacement procedures described in this chapter. 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. blah Flat-Blade Screwdrivers, from 1/16 inch (2 mm) to 1/4 inch (6.5 mm) 2. Numbers 0, 1, and 2 Phillips Screwdrivers 3. Torx T10 and T15 drivers 4. Small Gear Puller (strongly recommended) 5. Small Crescent Wrench or locking pliers 6. Fine-Point, Offset Fine-Point, and Needle-Nose pliers 7. Small Diagonal Cutters or other cutter for cutting cable ties mm and 2.0 mm hex keys mm hex driver (this can also be used for securing push nuts) 10. Small and Medium Spring Hook Tools 11. Soldering Iron with fine pointed tip Note Unless specifically stated, all screws noted in this document use the Torx T10 driver. 64 P330i Card Printer Service Manual Rev. A Draft 2

77 5.3 Removal Sequence This figure shows the recommended removal sequence. For example, to remove the CPU PCBA, you would remove the Top Cover (procedure given in section 5.4 on pg 66), remove the Print Engine from the Lower Cover (section 5.5 on pg 69), remove the Connector Plate (section 5.6 on pg 70), and then remove the CPU PCBA (section 5.26 on pg 144). Start Here Complete P330i Printer 5.25 Power and Filter Components (pg 143) Card Sensor Cable Assy (pg 129) 5.20 LCD PCBA (pg 113) 5.20 LCD Cable Assy (pg I/O Daughterboard (pg 147) 5.26 CPU PCBA (pg 144) 5.32 Stepper Motor Drive Belt (pg 158) 5.33 Stepper Motor (pg 159) Remove Print Head Assembly if not already removed (96) 5.37 Print Head Cable Assy (includes Sensor & Fan) (pg Top Cover (pg 66) 5.5 Remove Print Engine from Lower Cover (pg 69) 5.6 Connector Plate (pg 70) 5.7 Power Supply Cover (pg 73) 5.8 Power Supply (pg 75) 5.9 Rear Plate (save bearings and wavy washers) (pg 77) 5.10 Cam Lever (pg 80) 5.11 Platen Inertia Roller (pg 81) 5.12 Printhead Pressure Spring (pg 82) 5.13 Film/Bracket Sensor PCBA (pg 83) 5.14 Pressure Spring Plate (pg 84) 5.15 Cam Arm Follower Assy (pg 85) 5.16 Clutch Assembly (pg 86) 5.17 Print Head / Carriage Assembly (pg 90) 5.18 Print Head Lift Cam (pg 94) 5.21 Encoder Shroud & Exit Pressure Roller (pg 115) 5.22 Exit Pressure Roller Assy (pg 118) 5.28 RFID Cable (pg 149) 5.34 RFID PCBA (pg 162) 5.19 Print Head Assembly (pg 96) 5.23 Balls Retainer Plate, Springs, Balls (pg 127) 5.29 Ribbon O-Ring Drive Belt (pg 151) 5.30 Ribbon Pulley Assy, Ribbon Take-Up Spindle (pg 153) Remove I/O Daughterboard if not already removed (pg 147) 5.36 Card Sensor Cable Assy (pg 168) 5.35 Ribbon Color Sensor (pg 164) 5.39 Replace Parts that Require Separating the Front Frame from the Center Frame (pg 183) Card Feeder Drive Belt, Card Feeder Motor (pg 131) 5.31 Ribbon Motor Pulley, Ribbon Motor (pg 156) 5.38 Print Head Lift Motor (pg 182) Card Feeder Assy, ESD Brush, Card Feeder Belt, Card Feeder Rollers (pg 136) 5.40 Magnetic Stripe Encoder Option (pg 188) 5.41 Smart Card Options (pg 190) Rev. A Draft 2 P330i Card Printer Service Manual 65

78 5.4 Removing the Top Cover Step 1. Step 2. Step 3. Step 4. Turn the printer power off, and disconnect the power cord. If an interface cable (USB or ethernet) is plugged into the printer, disconnect it. Remove any plastic cards from the Card Input Hopper. Turn the printer over, and rest it upside-down on a work surface. Press a screwdriver or similar tool into the Hopper Release Hole and slide the Card Output Hopper out of the printer. Remove five screws securing the top cover from underneath. Four of them are at the Card Input Hopper end of the printer, as shown below. Hopper Release Hole Top Cover Attachment Screws Step 5. The fifth Top Cover attachment screw is located above the card output opening (this is why the Card Output Hopper was removed). See below. 66 P330i Card Printer Service Manual Rev. A Draft 2

79 Top Cover Attachment Screw Step 6. Turn the printer over, so it is right-side up. Remove two screws into the upper part of the back of the printer. Remove These Screws Step 7. Remove one remaining screw attaching the top cover Rev. A Draft 2 P330i Card Printer Service Manual 67

80 Remove This Screw Step 8. Carefully remove the top cover. Be careful to avoid damaging the cable to the LCD Panel PCBA or the wires to the card sensor. Top Cover 68 P330i Card Printer Service Manual Rev. A Draft 2

81 5.5 Removing the Print Engine from the Lower Cover Step 1. Remove two screws from the back of the lower cover to release the print engine. Remove These 2 Screws Step 2. Remove the print engine from the lower cover Rev. A Draft 2 P330i Card Printer Service Manual 69

82 5.6 Removing the Connector Plate Step 1. Remove the two Phillips-head screws shown in the figure below. Remove These 2 Phillips-head Screws Step 2. Disconnect the ground lug as shown below. Ground Lug 70 P330i Card Printer Service Manual Rev. A Draft 2

83 Step 3. Remove the screws attaching the print engine to the Connector Plate as shown in the two pictures below. Remove This Screw Remove This Screw Rev. A Draft 2 P330i Card Printer Service Manual 71

84 Step 4. Swing the Connector Plate away from the Print Engine as shown below. If your printer includes the Contact Station Smart Card Option, disconnect wires to the Smart Solenoid PCBA as you swing the Connector Plate. Smart Solenoid PCBA (Part of Contact Station Smart Card Option) Connector Plate Step 5. Then detach the wires at the Power Switch that go to the Power Supply, freeing the Connector Plate from the Print Engine. 72 P330i Card Printer Service Manual Rev. A Draft 2

85 5.7 Removing the Power Supply Cover Power Supply Cover Step 1. Remove four screws holding the Power Supply Cover in place, as shown in the next two pictures, and remove the Power Supply. Remove These Two Screws Rev. A Draft 2 P330i Card Printer Service Manual 73

86 Remove These Two Torx T-10 Screws, then Remove the Power Supply Cover. 74 P330i Card Printer Service Manual Rev. A Draft 2

87 5.8 Removing the Power Supply Step 1. Unplug the two connectors shown in the picture below. The mating part of each connector has a tab/latch that must be moved out of the way to allow removal of the connector; this is easier with the use of a small flat-blade screwdriver. Power Supply Unplug These Connectors Step 2. Remove four Torx T-10 screws shown in the picture below, and remove the Power Supply Rev. A Draft 2 P330i Card Printer Service Manual 75

88 76 P330i Card Printer Service Manual Rev. A Draft 2

89 5.9 Removing the Rear Plate The Rear Plate is removed to provide access to the I/O Daughterboard and many other mechanical and electrical components of the printer. Note In the pictures that follow, the Power Supply has been removed from the Rear Plate. The Rear Plate can be removed without removing the Power Supply, but it is suggested that you remove the Power Supply Cover so the wires to the Power Supply can be disconnected. Step 1. This step only applies for printers that include a Magnetic Stripe Encoder. Using a small flat-blade screwdriver, pry open the Cable Clip that secures the Magnetic Encoder cable. (These wires are present only if your printer has a Magnetic Stripe Encoder Option.) 2. Then unplug this connector from the CPU PCBA. 1. Use small flat-blade screwdriver to pry the Cable Clip open, being VERY careful to not crush any of the wires Rev. A Draft 2 P330i Card Printer Service Manual 77

90 Remove these 3 screws, and lift the Rear Plate back from the Print Engine. As you remove the Rear Plate, pass this cable through the rectangular cutout. Important When you remove the Rear Plate, take careful note of the Wavy Washers and Bearings as shown in the picture below. They are held in place by the Rear Plate; when the Rear Plate is removed they can fall off their shafts. It is suggested that you remove them and store them until the Rear Plate is to be replaced. When you replace them, make sure each Bearing s flange side is inward and that the Wavy Washer is centered and seated on the Bearing s body. 78 P330i Card Printer Service Manual Rev. A Draft 2

91 Rev. A Draft 2 P330i Card Printer Service Manual 79

92 5.10 Removing the Cam Lever Upper Cam Print Head Lift Cam Cam Lever Platen Inertia Roller Step 1. Remove the Cam Lever The upper (smaller) hole in the Cam Lever fits over a peg in the Upper Cam; the lower (larger) hole fits over the raised cam of the Printhead Lift Cam. (The Cam Lever is not attached at either end; it is held in place by the Rear Plate.) 80 P330i Card Printer Service Manual Rev. A Draft 2

93 5.11 Removing the Platen Inertia Roller Platen Inertia Roller Step 1. The Platen Inertia Roller is secured to the Step Motor shaft with a small setscrew. Since access to the setscrew is limited, turn the Platen Inertia Roller so the setscrew is accessible, and use an L-shaped 2-mm hex key to loosen the setscrew; then slide the Platen Inertia Roller off the shaft. Shaft That Held Platen Inertia Roller Rev. A Draft 2 P330i Card Printer Service Manual 81

94 5.12 Removing the Printhead Pressure Spring Step 1. With a heavy Spring Hook or similar tool, free the Printhead Pressure Spring from the Pressure Spring Plate, as shown below. The Printhead Pressure Spring is under a lot of tension, it will snap off the Pressure Spring Plate when freed. Printhead Pressure Spring Spring Hook Tool Pressure Spring Plate Step 2. Then remove the Printhead Pressure Spring from the Cam Arm Follower Assembly. Cam Arm Follower Assembly 82 P330i Card Printer Service Manual Rev. A Draft 2

95 5.13 Removing the Film/Bracket Sensor PCBA Step 1. Open the Aluminum Cable Tie to free the Film/Bracket Sensor PCBA s cable. Film/Bracket Sensor PCBA Aluminum Cable Tie Step 2. Step 3. Follow the Film/Bracket Sensor PCBA s cable to where it plugs into the I/O Daughterboard. Unplug it. Then work it out from behind the RFID Cable Assembly. Remove the screw securing the Film/Bracket Sensor PCBA to the Print Engine Center Frame, and remove the Film/Bracket Sensor PCBA. RFID Cable Assembly Screw that Secures the Film/ Bracket Sensor PCBA Film/Bracket Sensor PCBA s Cable Rev. A Draft 2 P330i Card Printer Service Manual 83

96 5.14 Removing the Pressure Spring Plate Step 1. After removing the Film/Bracket Sensor PCBA, remove the screw securing the Pressure Spring Plate to the Print Engine Center Frame, and remove the Pressure Spring Plate Pressure Spring Plate Mounting Screw 84 P330i Card Printer Service Manual Rev. A Draft 2

97 5.15 Removing the Cam Arm Follower Assembly Step 1. Remove the two Torx T15 screws that hold the Cam Arm Follower Assembly in place, as shown below. The upper one screws into the threaded end of the Print Head U-Support Assembly; it can be removed easily. Torx T15 Screws Cam Arm Follower Assembly Step 2. The lower T15 screw goes into the threaded end of the Printhead Bracket Shaft; to remove this one it will be necessary to prevent the Printhead Bracket Shaft from turning. The best way to do this is to hold the shaft in place with a medium flat-head screwdriver from the front of the Print Engine, as shown in the next picture. Printhead Bracket Shaft Rev. A Draft 2 P330i Card Printer Service Manual 85

98 5.16 Removing the Clutch Assembly Important Do not attempt to take the Clutch Assembly apart! If the Clutch Assembly is damaged, it is replaced as a unit. Clutch Assembly 86 P330i Card Printer Service Manual Rev. A Draft 2

99 Step 1. Hold the Ribbon Supply Spindle, and use a Number 1 Phillips screwdriver to remove the screw securing the Ribbon Supply Spindle to the Clutch Assembly Shaft, as shown in the next picture. If necessary to prevent the shaft from turning, use a small crescent wrench on the flat of the Clutch Assembly Shaft to prevent the shaft from turning, as shown in the second picture. Remove Phillips- Head Screw Prevent the Clutch Assembly Shaft from turning Rev. A Draft 2 P330i Card Printer Service Manual 87

100 Step 2. Remove the Ribbon Supply Spindle from the Clutch Assembly Shaft by pulling and turning the spindle. Step 3. Now pull the Clutch Assembly straight out from the rear of the Print Engine. If the Clutch Assembly is to be re-installed, be careful to avoid bending the Flag Disk. Flag Disk 88 P330i Card Printer Service Manual Rev. A Draft 2

101 When replacing or re-installing the Clutch Assembly, make sure the hole in the tab on the Clutch Assembly fits over the raised pin through the RFID PCBA, as shown below. Clutch Assembly Tab Raised Pin Through RFID PCBA Rev. A Draft 2 P330i Card Printer Service Manual 89

102 5.17 Removing the Print Head / Carriage Assembly Step 1. Note that when the Clutch Assembly is removed, the entire Print Head / Carriage Assembly can be removed from the Print Engine (the shaft which had held the Clutch Assembly will be sticking through the Center Frame, and the Printhead Bracket Assembly will rest against the Front Frame, as shown in the next two pictures). Shaft which had held the Clutch Assembly Printhead Bracket/Fan Cable Assembly 90 P330i Card Printer Service Manual Rev. A Draft 2

103 Hole that the Printhead Bracket Shaft normally passes through Step 2. As you remove the Print Head / Bracket Assembly, gently pull the Print Head Cable Assembly through the opening in the Center Frame. Print Head Cable Assembly (Normally Plugs into CPU PCBA) Rev. A Draft 2 P330i Card Printer Service Manual 91

104 Caution Don t touch the Print Head Elements, shown in the picture below. 92 P330i Card Printer Service Manual Rev. A Draft 2

105 Print Head Elements Rev. A Draft 2 P330i Card Printer Service Manual 93

106 5.18 Removing the Print Head Lift Cam Step 1. Rotate the Print Head Lift Cam clockwise until the Setscrew lines up with the cut out in the Center Frame, as shown in the second picture below. The best way to rotate the Cam is to place both index fingers on the inner surface (toward the front of the printer) and both thumbs on the outer surface (nearest you). Do not try to rotate the Cam in a counter-clockwise direction; this could damage the Print Head Lift Motor. Setscrew Rotate Clockwise Only Cut Out in Center Frame Print Head Lift Cam 94 P330i Card Printer Service Manual Rev. A Draft 2

107 Setscrew Step 2. Use a Number 0 Phillips Screwdriver to loosen the Print Head Lift Cam Setscrew. Then pull the Print Head Lift Cam off the Motor shaft. Important When re-installing the Print Head Lift Cam, do not over-tighten the Setscrew; it should only be snug against the shaft Rev. A Draft 2 P330i Card Printer Service Manual 95

108 5.19 Replacing the Print Head Assembly Electrostatic Discharge Caution The Print Head is extremely susceptible to Electrostatic Discharge (ESD) damage. Do not touch the bottom surface of the Print Head. 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 Print Head Assembly. The Print Head 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 Print Head Assembly Replacement Procedure Step 1. Step 2. Turn the printer power off, and disconnect the power cord. Open the printer s main (translucent blue) cover. Then remove the cover by pressing inward and twisting at the pivot points. Step 3. Press the Print Head Carriage Latch to the left, and open (raise) the Print Head Carriage. 96 P330i Card Printer Service Manual Rev. A Draft 2

109 Step 4. Remove the ribbon by pulling both the supply and take-up spools straight out. Step 5. Using the Torx T10 driver, remove the retaining screw on the front side of the Print Head Carriage Rev. A Draft 2 P330i Card Printer Service Manual 97

110 Step 6. While removing the retaining screw, the Print Head Adjustment Screw may slip out of the notch in the front of the Print Head Carriage. Whether it has slipped or not, use a medium flat-blade screwdriver to remove the Print Head Adjustment Screw and its associated washer and spring. Print Head Adjustment Screw Washer Spring Step 7. Looking at the Print Head Carriage from the rear of the printer, note that the Print Head Assembly Shaft has a notch just inside the slotted end. That notch will be riding in a reduced-size cutout in the Print Head Carriage Frame, as shown below. Cutout in the Print Head Carriage Frame End of Print Head Assembly Shaft 98 P330i Card Printer Service Manual Rev. A Draft 2

111 Step 8. Gently rock the Print Head Assembly back and forth (the Print Head Assembly Shaft will be the pivot) until the end of the Print Head Assembly Shaft lines up with the circular opening in the Print Head Carriage Frame. End of Print Head Assembly Shaft Step 9. Slide the Print Head Assembly Shaft out of the Print Head Carriage. It can be slid out toward the front or the rear of the printer; you may need to press on the end of the Shaft, and it may be a snug fit. Print Head Assembly Shaft Rev. A Draft 2 P330i Card Printer Service Manual 99

112 Step 10. Disconnect the Ground Lug Spade Connector, as shown in the picture below (this is more easily done by using needle-nose pliers). Gently use a small flat-blade screwdriver to pry the Print Head Cable Connector up and unplug it. Print Head Cable Connector Ground Lug Spade Connector Step 11. Rock the Print Head back and forth while gently separating the sides of the Print Head Carriage until the Print Head can be slid free from the Print Head Carriage. 100 P330i Card Printer Service Manual Rev. A Draft 2

113 Step 12. Remove the replacement Print Head Assembly from its protective packaging. Caution When handling the Print Head Assembly, be careful to avoid touching the active surface of the Print Head. The Print Head is extremely susceptible to damage from static discharge. Also, oil from your fingers can cause poor print quality and/or shorter Print Head life. Active Surface of Print Head Step 13. Slide the Print Head Assembly Shaft through the holes in the Print Head Assembly Frame as shown. Slotted and Notched End of Print Head Assembly Shaft Goes Through This Hole Rev. A Draft 2 P330i Card Printer Service Manual 101

114 Step 14. The Print Head Assembly Shaft should stick through both sides of the Print Head Assembly Frame. Step 15. Turn the Print Head Assembly Shaft so the threaded hole in the center is accessible through the center cutout in the Print Head Assembly Frame. Start the Print Head Adjustment Screw (with its associated Spring and Washer in place) into the threaded hole in the center of the Print Head Assembly Shaft. Run it in two or three turns; it must stay engaged in the Shaft during the steps that follow. 102 P330i Card Printer Service Manual Rev. A Draft 2

115 Step 16. Position the Print Head Assembly as shown below. Gently separate the sides of the Print Head Carriage while rocking the Print Head Assembly back and forth and slide it into approximate position within the Print Head Carriage. See the following pictures. You want the Print Head Assembly Shaft to (first) engage the circular cutout in the back side of the Print Head Carriage, and then (at the same time) engage the large cutout in the front of the Print Head Carriage. Keep the Print Head Assembly Screw Below the Notch in the Print Head Carriage as You Rock the Print Head Assembly Into Place Rev. A Draft 2 P330i Card Printer Service Manual 103

116 Print Head Assembly is in Proper Position when the End of the Shaft Sticks Through the Circular Cutout Step 17. When the Print Head Assembly Shaft is in position at the circular cutout (above), press the Shaft toward the back of the printer (i.e., so it sticks out about 1/16 inch or 2mm); this will make it easier to rock the front end of the shaft into position, as shown below. Then press the Shaft (forward) so it is approximately centered within the Print Head Carriage. End of Print Head Assembly Shaft Sticks Through this Large Cutout 104 P330i Card Printer Service Manual Rev. A Draft 2

117 Step 18. Plug in the Print Head Cable Connector, and use a small flat-blade screwdriver to press the connector evenly and firmly into place. Connect the Ground Lug Spade Connector (this is more easily done by using needle-nose pliers). Step 19. See the following pictures. With your fingertips or a small flat-blade screwdriver, slightly compress the Print Head Adjustment Screw Spring and slide the Washer down; now pivot the Print Head Adjustment Screw upward so it is within the notch in the front of the Print Head Carriage (and the Washer and Spring are inside the Carriage, as shown in the second picture Rev. A Draft 2 P330i Card Printer Service Manual 105

118 Step 20. With a medium flat-blade screwdriver, turn the Print Head Adjustment Screw clockwise. (Don t let the screw head slip out of the notch in the Print Head Carriage.) Note that as the Screw is turned, the Print Head Assembly pivots about the Print Head Assembly Shaft. 106 P330i Card Printer Service Manual Rev. A Draft 2

119 As the Print Head Adjustment Screw is driven clockwise, the Print Head Assembly Shaft Moves Into the Narrower Part of the Cutout Print Head Shaft in Position, roughly centered laterally and within the middle curved slot Rev. A Draft 2 P330i Card Printer Service Manual 107

120 Step 21. Drive the Print Head Adjustment Screw in (clockwise) until the single raised bump on the Print Head just makes contact with the front end of the curved slot in the Print Head Carriage. Single Raised Bump at Front of Curved Slot Step 22. Turn the screw out (counter-clockwise) exactly four and one-half turns. The (upper) single raised bump will be somewhere within the arc of the curved slot. (The Print Head will rotate on its shaft and the two lower raised bumps; ignore their positions as long as they are within their respective curved slots.) Single Raised Bump Somewhere Within Curved Slot 108 P330i Card Printer Service Manual Rev. A Draft 2

121 Step 23. Insert and tighten the Torx head retaining screw. Step 24. Re-install the ribbon; lower the Print Head Carriage until it clicks into place; reinstall the printer cover. Connect the power cord, and turn the printer power on Rev. A Draft 2 P330i Card Printer Service Manual 109

122 Enter the Print Head Resistance Before proceeding to the Final Adjustment, the resistance value of the replacement must be entered, since the resistance will affect the physical adjustment. Step 1. From the Windows Start button or from the Printers or Printers and FAXes Control Panel, select the P330i printer. Right click to bring up Properties, select Device Settings, and select Tools / Properties. This will bring up the Tools window, as shown below. Step 2. As shown above, in the Command to send to printer area, enter!r followed by a space followed by the resistance value of the replacement print head. (The resistance value will be shown on the replacement print head.) Then click the Execute button, then close the Tools window. 110 P330i Card Printer Service Manual Rev. A Draft 2

123 Print Head Final Adjustment Print Head final adjustment involves printing a card, inspecting it, and if necessary adjusting the Print Head Adjustment Screw. This sequence is repeated until the card print quality is acceptable. Step 1. From the Windows Start button or from the Printers or Printers and FAXes Control Panel, select the P330i printer. Right click to bring up Properties, select Device Settings, and select Tools / Properties. This will bring up the Tools window, as shown below. Step 2. If your printer has a color ribbon, enter IM in the Command to send to printer area, then click the Execute button. A card like the following one will be printed. Step 3. If your printer has a monochrome ribbon, enter IMB in the Command to send to printer area, then click the Execute button. A gray (ideally) or moire-pattern card like the following one will be printed Rev. A Draft 2 P330i Card Printer Service Manual 111

124 Step 4. If the card print quality is acceptable, no additional adjustment is necessary. If the card print quality is not acceptable, loosen the Torx head retaining screw and turn the Print Head Adjustment Screw one-quarter turn clockwise or counterclockwise. Print another card. a. If the print quality is better, turn the Print Head Adjustment Screw one-eighth turn in the same direction. b. If the print quality is worse, turn the Print Head Adjustment Screw one-half turn in the other direction. Step 5. Continue making smaller adjustments in either direction until the print quality is optimized. Then tighten the Torx head retaining screw. 112 P330i Card Printer Service Manual Rev. A Draft 2

125 5.20 Replacing the LCD PCBA and/or LCD Cable Assembly Note To replace the LCD PCBA, detach the Top Cover and proceed as follows. If the LCD Cable Assembly is to be replaced, the Print Engine must be removed from the Lower Cover. Step 1. Unplug the LCD Cable Assembly from the LCD PCBA. It may help to use a small flat-blade screwdriver to gently pry the cable connector out of the PCBA connector; if you do this be very careful to avoid damaging either connector or bending any pins. Unplug LCD Cable Assembly Step 2. If replacing the LCD Cable Assembly, unplug it from J10 on the CPU PCBA. LCD Cable Assembly Plugs into J10 on CPU PCBA Rev. A Draft 2 P330i Card Printer Service Manual 113

126 Step 3. While lifting on the right-hand end of the LCD PCBA, use a small flat-blade screwdriver to gently pry the support clip to the right as shown below. Use just enough force to free the PCBA; too much force could damage or break the support clip. Support Clip Step 4. When installing the LCB PCBA, place it in position on the Top Cover and press to snap it into place. 114 P330i Card Printer Service Manual Rev. A Draft 2

127 5.21 Replacing the Encoder Shroud and Exit Pressure Roller Note This procedure covers replacing the Exit Pressure Roller only, not the complete Exit Pressure Roller Assembly (which also includes the Pivot Shaft and Spring). For instructions on replacing the complete Exit Pressure Roller Assembly, see the next procedure. The instructions given in this procedure also apply in general terms to the other Pressure Rollers. Step 1. Remove the protective Encoder Shroud that protects the Magnetic Encoder Sensor and Head (if present). (Note that the Shroud is present whether or not there is a Magnetic Encoder.) Press the two removal tabs toward the rear of the printer, and lift the shroud by the lift tab. Lift Tab Protective Shroud Removal Tabs Rev. A Draft 2 P330i Card Printer Service Manual 115

128 Step 2. With the shroud removed, note the position of the Exit Pressure Roller. Exit Pressure Roller Assembly Spring Exit Pressure Roller Exit Pressure Roller Assembly Pivot Shaft Step 3. Lift the legs of the Exit Pressure Roller so they disengage from the Pivot Shaft. 116 P330i Card Printer Service Manual Rev. A Draft 2

129 Step 4. Push the Exit Pressure Roller outward, then pull it the rest of the way out from under the Pressure Spring. Pressure Spring Step 5. When the Exit Pressure Roller has been removed, the Pressure Spring on the Pivot Shaft will look like the picture below Rev. A Draft 2 P330i Card Printer Service Manual 117

130 5.22 Replacing the Exit Pressure Roller Assembly Note This procedure covers replacing the complete Exit Pressure Roller Assembly (which also includes the Pivot Shaft and Spring). For instructions on just replacing the Exit Pressure Roller, see the previous procedure. The instructions given in this procedure also apply in general terms to the other Pressure Roller Assemblies. Important Do not even attempt this procedure if you do not have a thin spring hook tool like the one shown below (shown next to a Pressure Roller for size reference). Note This procedure can also be perfomed with the Exit Pressure Roller already removed, as described in the previous procedure. The pictures and steps are so similar that differences will be readily apparent. 118 P330i Card Printer Service Manual Rev. A Draft 2

131 Step 1. Note the location of the components of the Exit Pressure Roller Assembly shown in the following pictures. Exit Pressure Roller Assembly Spring Exit Pressure Roller Exit Pressure Roller Assembly Pivot Shaft Exit Pressure Roller Step 2. (See Next Picture) Pivot Shaft Remove the screw that covers and secures the end of the Pivot Shaft, shown in the picture below Rev. A Draft 2 P330i Card Printer Service Manual 119

132 Screw Head Securing End of Pivot Shaft Step 3. In the next picture, you can see the end of the Pivot Shaft after the securing screw has been removed. End of Pivot Shaft 120 P330i Card Printer Service Manual Rev. A Draft 2

133 Step 4. With fine-point pliers, grab the Pivot Shaft between the legs of the Pressure Roller and slide it out of the Front Frame. It will be a snug fit; it may help to simultaneously rotate the Pivot Shaft and slide it out. (If the Pressure Roller has already been removed, grab the Pivot Shaft anywhere along its length and slide it out.) Caution As the Pivot Shaft is freed from the bearing in the Front Frame, keep in mind that the Exit Pressure Roller Spring is under tension. Step 5. If you will be replacing the Exit Pressure Roller Assembly, be sure to keep the three parts as shown in the picture below. Pivot Shaft Pressure Roller Spring Rev. A Draft 2 P330i Card Printer Service Manual 121

134 Step 6. Feed the Pivot Shaft through the hole in the Front Frame. Step 7. As you feed the Pivot Shaft inward, place the Spring on the Shaft as shown below. The two ends and the large central portion all come from the bottom of the Spring, and the two legs of the Spring must be facing as shown. 122 P330i Card Printer Service Manual Rev. A Draft 2

135 Step 8. Continue feeding the Pivot Shaft until it is engaged in its bearing on the Center Frame. Step 9. With fine-nose pliers, bring the leg of the Spring over the Pivot Shaft as shown in the next two pictures. This may be somewhat easier if you slide the Spring away from the Center Frame about 1/8 inch (4 mm) Rev. A Draft 2 P330i Card Printer Service Manual 123

136 Step 10. Reach in under the Pivot Shaft with the spring hook tool and grab the end of the spring. Then let go with the pliers. Step 11. Pull the end of the Spring under the Pivot Shaft (again, this may be easier if you slide the spring away from the Center Frame). Continue pulling the end of the Spring around the Pivot Shaft until the Spring s leg can rest in the detent of the ridge as shown below. There is a small hole in the side of the frame next to the detent; the very end of the Spring s Leg should be pressed into that hole. Detent of Ridge 124 P330i Card Printer Service Manual Rev. A Draft 2

137 Step 12. Then follow the same steps with the end of the Spring closer to the Front Frame, as shown in the following series of pictures Rev. A Draft 2 P330i Card Printer Service Manual 125

138 Lift End of Spring onto Flat Area Step 13. Then replace the Exit Pressure Roller as described in the previous procedure. 126 P330i Card Printer Service Manual Rev. A Draft 2

139 5.23 Removing the Balls Retainer Plate The Balls Retainer Plate is located below the Ribbon Supply Spindle. It covers the access hole for the pivot shaft of a pressure roller assembly. It also holds a pair of springs in place, which in turn provide spring pressure to a pair of Delrin Balls that precisely position the card within the card path. Important When the Balls Retainer Plate is removed, be careful to not lose the springs and/ or balls that it holds in place. Step 1. The Balls Retainer Plate is held in place below the ribbon supply spindle by a flathead Phillips screw. Using a Number 0 Phillips screwdriver, remove the screw and remove the Balls Retainer Plate. Balls Retainer Plate Rev. A Draft 2 P330i Card Printer Service Manual 127

140 Step 2. The next picture shows the Balls Retainer Plate removed. Pivot Shaft Access Springs (Delrin Balls not visible) Step 3. The following picture is a magnified view of the springs and Delrin Balls. Actual size of the Balls is 5 mm (about 1/5 inch). 128 P330i Card Printer Service Manual Rev. A Draft 2

141 5.24 Card Feeder Components This section describes replacing various components of and associated with the Card Feeder. Some of these procedures involve detaching and disassembling the Card Feeder Assembly, others do not Replacing the Card Sensor Cable Assembly The Card Sensor Cable Assembly can be replaced with or without disassembling the Card Feeder Assembly; it can even be replaced without detaching the Card Feeder Assembly from the Print Engine. Step 1. Step 2. The Card Sensor Cable Assembly in turn plugs into a Cable Assembly that goes to the I/O Daughterboard. Unplug the connector. The Card Sensor Cable Assembly snaps into a recess in the side of the Card Feeder Assembly frame, as shown in the picture below. (Card Feeder Assembly shown detached from the Print Engine) Card Sensor Cable Assembly Unplug this connector from the Cable Assembly that goes to the I/O Daughterboard Rev. A Draft 2 P330i Card Printer Service Manual 129

142 Step 3. To remove the Card Sensor Cable Assembly, hold the four wires close to the sensor and push up while lifting away from the Card Feeder frame, as shown in the next picture. 130 P330i Card Printer Service Manual Rev. A Draft 2

143 Replacing the Card Feeder Drive Belt and/or Card Feeder Motor The Card Feeder Drive Belt and/or Card Feeder Motor can be replaced with or without disassembling the Card Feeder Assembly; either or both can even be replaced without detaching the Card Feeder Assembly from the Print Engine; the procedure for detaching the Card Feeder Assembly is given in paragraph (The pictures in this section show the Card Feeder Assembly disassembled.) (Card Feeder Assembly shown detached from the Print Engine) Card Feeder Drive Belt Step 1. In the following picture, note the location of the push nut on the Roller Shaft Rev. A Draft 2 P330i Card Printer Service Manual 131

144 Push Nut Step 2. With a small flat-blade screwdriver, gently pry the pushnut off the shaft. Step 3. This will allow you to slip the Timing Belt off the Pulleys. 132 P330i Card Printer Service Manual Rev. A Draft 2

145 After removing the Card Feeder Drive Belt, the Card Feeder Motor can be replaced. Step 4. There is a very small E-Ring that secures the Feeder Pulley to the Motor shaft (see below). With a small flat-blade screwdriver, push this E-Ring around the shaft until the center of the E-Ring is at the flat of the shaft (this will give maximum access to the E-Ring). Then, with a very small flat-blade screwdriver, free the E-Ring from the groove of the Motor shaft Rev. A Draft 2 P330i Card Printer Service Manual 133

146 Step 5. With the E-Ring removed, lift the Feeder Pulley and two spacer washers from the Card Feeder Motor shaft. 134 P330i Card Printer Service Manual Rev. A Draft 2

147 Step 6. Then remove three screws as shown below to free the Card Feeder Motor. (If the Card Feeder Assembly has not been disassembled, remove the Card Feeder Motor by reaching up through the open bottom of the Card Feeder Assembly Rev. A Draft 2 P330i Card Printer Service Manual 135

148 Detaching and Disassembling the Card Feeder Assembly Step 1. The Card Feeder Assembly is attached to the Print Engine by two screws, as shown in the picture below. Remove This Screw on Front Remove This Screw on Back Step 2. Unplug the spade lug on the green ground wire at the location shown in the next picture. Detach Green Wire at the Spade Lug on This End 136 P330i Card Printer Service Manual Rev. A Draft 2

149 Step 3. Slide a medium flat-blade screwdriver into the gap below the left side of the ESD Brush as shown in the picture below. Then turn the screwdriver clockwise to push the left side of the ESD brush upward, as shown in the next picture Rev. A Draft 2 P330i Card Printer Service Manual 137

150 Step 4. Lift the left end of the ESD Brush just enough to clear the protective lip of the frame. Protective Lip Caution Handle the ESD Brush carefully to avoid bending or otherwise damaging it. Step 5. Gently bring the left end of the ESD Brush in front of the protective lip, so it is approximately in its original horizontal orientation. 138 P330i Card Printer Service Manual Rev. A Draft 2

151 Step 6. Gently push the ESD Brush to the right, so the elongated hole at the right end can disengage from the post on the frame, and remove the ESD Brush. Important If the ESD Brush appears damaged in any way, replace it. Step 7. Remove four screws inside the counterbores as shown in the picture below Rev. A Draft 2 P330i Card Printer Service Manual 139

152 Step 8. Use a small flat-blade screwdriver to gently pry the two parts of the Card Feeder Assembly frame apart. (It will probably be necessary to go around the entire seam several times to gradually separate the parts.) Step 9. With the Card Feeder Assembly Frame apart, the Card Feeder belt can be removed off its rollers (turning the rollers back and forth will make this somewhat easier). (Note that the picture also shows the Card Feeder Motor in place.) After the Card Feeder Belt is removed, the Card Feeder Rollers can be removed if desired. (If the Roller over the Card Feeder Motor is to be removed, remove the gear from its shaft.) Card Feeder Belt Card Feeder Rollers 140 P330i Card Printer Service Manual Rev. A Draft 2

153 Step 10. Reassembling the Card Feeder Assembly is shown in the following series of pictures. First, hold the two sides of the Frame together as shown, and place the Feeder Gate Lever in position. Note that the Feeder Gate Lever must be placed so the hole in the arm fits over the raised pin on the frame. Feeder Gate Lever Hole in Feeder Gate Lever fits over Raised Pin on Feeder Frame Step 11. Place the Ruber Gate over the raised pins on the frame as shown in the next picture. Rubber Gate Fits Over Raised Pins Rev. A Draft 2 P330i Card Printer Service Manual 141

154 Step 12. Place the Feeder Gate Plate in approximate position. Make sure the slot in the Feeder Gate Plate engages the raised pin on the Feeder Gate Lever, then press the Feeder Gate Plate inward on each side to snap it into the groove on each side of the frame. Feeder Gate Plate Make Sure Slot in Feeder Gate Plate Engages Pin on Feeder Gate Lever, then Snap Feeder Gate Plate into place. Step 13. Replace the screws into the counterbores that were removed in step 7. Step 14. Reinstall the ESD Brush, or install a new one. 142 P330i Card Printer Service Manual Rev. A Draft 2

155 5.25 Power / Filter Components Step 1. The Power / Filter Components are mounted on the Connector Plate, and are shown in the picture below. The two unused lugs on the left side of the Power Switch connect to the Power Supply. AC Power Connector Power Switch EMI Ferrite Cable Assembly EMI Filter Rev. A Draft 2 P330i Card Printer Service Manual 143

156 5.26 Removing the CPU PCBA The CPU PCBA can be removed whether you remove the Connector Plate (as described in section 5.4) or not. If you do not remove the Connector Plate, be careful to avoid damaging components on the Connector Plate or wires to/from it. Step 1. The CPU PCBA rests on slides below the Rear Plate, as shown below. Note that the CPU PCBA is not secured by any mounting hardware; it is simply held in place by the wires to/from it (and, when the Print Engine is in place on the Lower Cover, by the Lower Cover itself). CPU PCBA Step 2. Slide the CPU PCBA straight out, carefully unplugging connectors as you slide the board out, as shown in the next three pictures. 144 P330i Card Printer Service Manual Rev. A Draft 2

157 To Card Feeder Sensor This Cable goes to the LCD Screen Use a Small Flat-blade Screwdriver to Remove the Restraining Clip on this connector RFID Cable Rev. A Draft 2 P330i Card Printer Service Manual 145

158 Step 3. The next figure shows for reference the primary functions of the various connectors on the CPU PCBA. J11 (Ribbon RFID) J7 (Smart Card) J1 (Mag Encoder Head) J8 (Auxiliary RS-232; factory use only) J2 (Mates with Ethernet Extension Board) J6 (USB Port) J10 (LCD Panel) J13 (Motors and Sensors - Connects to I/O Daughterboard) J12 (+24 VDC Input from Power Supply) J4 (Not Used) J3 (Out of Cards Sensor) J9 (Print Head, Head Lock, Head Temp. Sensor) Step 4. When sliding the CPU PCBA back into position, make sure it is between the guides on either side. Re-attach connectors as you slide the board in. Slide CPU PCBA Between Guides On Either Side 146 P330i Card Printer Service Manual Rev. A Draft 2

159 5.27 Removing the I/O Daughterboard Step 1. When the Rear Plate is removed (see section 5.7), the I/O Daughterboard is visible. It is directly above the CPU PCBA, but it is hidden (and held in position) by the very bottom of the Rear Plate. I/O Daughterboard CPU PCBA (Shown with Ethernet Adapter) (Rear Plate Removed) I/O Daughterboard Rev. A Draft 2 P330i Card Printer Service Manual 147

160 Step 2. Unplug as many of the connectors to the I/O Daughterboard as you can reach before starting to slide it out; unplug other connectors as they become accessible. Step 3. The following figure shows the connectors on the I/O Daughterboard. Color Sensor 1 J07 J04 Color Sensor 2 J09 J02 DC Motor J06 DC Motor J08 Stepper Motor J01 J03 J05 Synchro Film Sensor Position Bracket Sensor DC Motor Synchro Card Sensor (To J13 on CPU PCBA) 148 P330i Card Printer Service Manual Rev. A Draft 2

161 5.28 Removing the RFID Cable The RFID Cable connects the RFID PCBA to the CPU PCBA. RFID PCBA RFID Cable CPU PCBA Rev. A Draft 2 P330i Card Printer Service Manual 149

162 Step 1. Use a small flat-blade screwdriver to remove the restraining clip on the connector at each end of the RFID Cable. Open the Aluminum Cable Ties that hold the RFID Cable in place on the Center Frame. Remove the RFID Cable. Retaining Clip (on connector at each end of RFID Cable) Aluminum Cable Ties 150 P330i Card Printer Service Manual Rev. A Draft 2

163 5.29 Replacing the Ribbon O-Ring Drive Belt Ribbon O-Ring Drive Belt Step 1. Step 2. Remove the Ribbon O-Ring Drive Belt by slipping it off the Ribbon Motor Pulley and the Ribbon Pulley. To install the Ribbon O-Ring Drive Belt, seat it in the groove of the Ribbon Pulley, pass it around both sides of the Upper Cam, and roll it into the groove of the Ribbon Motor Pulley Rev. A Draft 2 P330i Card Printer Service Manual 151

164 Important Make sure that the Ribbon O-Ring Drive Belt passes on the inside of the shield, as shown in the picture below. Ribbon Pulley Upper Cam Ribbon Motor Pulley Shield CORRECT -- Ribbon O-Ring Drive Belt Inside Shield INCORRECT -- Ribbon O-Ring Drive Belt Outside Shield 152 P330i Card Printer Service Manual Rev. A Draft 2

165 5.30 Replacing the Ribbon Pulley Assembly Step 1. The Ribbon Pulley Assembly Shaft is secured by a screw in the middle of the Ribbon Take-Up Spindle. Ribbon Pulley Assembly Rev. A Draft 2 P330i Card Printer Service Manual 153

166 Step 2. While holding the Ribbon Take-Up Spindle, use a No. 1 Phillips screwdriver to remove the screw attaching the Ribbon Take-Up Spindle to the Ribbon Pulley Assembly Shaft, and slide the Spindle off the shaft (it may be a snug fit). 154 P330i Card Printer Service Manual Rev. A Draft 2

167 Step 3. Slide the Ribbon Pulley Assembly (which includes the shaft) out of the bearing in the center frame Rev. A Draft 2 P330i Card Printer Service Manual 155

168 5.31 Removing the Ribbon Motor Pulley and the Ribbon Motor Step 1. The Ribbon Motor Pulley is secured to the Ribbon Motor Shaft with a setscrew. Use a 1.5 mm hex key to loosen the setscrew, and remove the Ribbon Motor Pulley. Ribbon Motor Pulley Ribbon Motor Shaft 156 P330i Card Printer Service Manual Rev. A Draft 2

169 Step 2. Cut the Cable Tie holding the bundle of Cables at the I/O Daughterboard Cut This Cable Tie These wires go to the Ribbon Motor Step 3. Unplug the Connector for the Ribbon Motor from the I/O Daughterboard. Step 4. The Ribbon Motor is held in position by three Torx T10 screws. Remove them. Ribbon Motor Mounting Screws Rev. A Draft 2 P330i Card Printer Service Manual 157

170 Step 5. Now reach up into the lower cavity between the Center Frame and the Front Frame and remove the Ribbon Motor Replacing the Stepper Motor Drive Belt The Stepper Motor Drive Belt should be very snug so it will not slip off the Stepper Motor Drive Pulley during printer operation. Also, if the belt is too loose, vertical lines may appear on cards printed. A limited amount of tensioning adjustment can be made as follows. Step 1. Step 2. Step 3. Step 4. Loosen the three 5.5 mm hex nuts securing the Stepper Motor to its Mounting Plate. Reach up into the space between the Front Frame and the Center Frame, and move the Stepper Motor (the holes in the Center Frame are slightly enlarged, permitting some movement). Tighten the three 5.5 mm hex nuts. When pressing with a finger against the mid-point of the Stepper Motor Drive Belt, there should be less than 1/8 inch (3 mm) deflection. 158 P330i Card Printer Service Manual Rev. A Draft 2

171 Stepper Motor Drive Belt Stepper Motor Mounting Plate Stepper Motor Drive Pulley 5.33 Removing the Stepper Motor Step 1. Remove the Stepper Motor Drive Belt Rev. A Draft 2 P330i Card Printer Service Manual 159

172 Stepper Motor Drive Belt Step 2. Step 3. Remove the Stepper Motor Pulley. (If the old Stepper Motor will be re-installed and there is no apparent damage to the Stepper Motor Pulley, the Stepper Motor Pulley does not need to be removed.) Remove the three 5.5 mm hex nuts securing the Stepper Motor to its Mounting Plate. 5.5 mm Hex Nuts Stepper Motor Mounting Plate Step 4. Reach up into the space between the Front Frame and the Center Frame, and remove the Stepper Motor. 160 P330i Card Printer Service Manual Rev. A Draft 2

173 Rev. A Draft 2 P330i Card Printer Service Manual 161

174 5.34 Removing the RFID PCBA Step 1. If the RFID Cable is still plugged into the RFID PCBA, use a small flat-blade screwdriver or fine-point plierst remove the retaining clip on the RFID Cable connector, as shown in the picture below. Unplug the RFID Cable. Note that this pin on the Center Frame passes through a hole on the RFID PCBA. Retaining Clip RFID Cable Step 2. With a Number 1 Philips screwdriver, remove two screws as shown in the next picture. RFID PCBA Mounting Screws 162 P330i Card Printer Service Manual Rev. A Draft 2

175 Step 3. Remove the RFID PCBA Rev. A Draft 2 P330i Card Printer Service Manual 163

176 5.35 Replacing the Ribbon Color Sensor The Ribbon Color Sensor is located under the Ribbon Supply Spindle, as shown below. Note that the Ribbon Color Sensor cannot be removed until items have been removed from the Center Frame through the RFID PCBA. Ribbon Color Sensor 164 P330i Card Printer Service Manual Rev. A Draft 2

177 Step 1. See the two pictures below. With a small flat-blade screwdriver, gently pry up toward the front of the Ribbon Color Sensor until it pops free of the Print Engine Rev. A Draft 2 P330i Card Printer Service Manual 165

178 Step 2. The wires from the Ribbon Color Sensor are held in place on the Center Frame by two aluminum Cable Ties, as shown in the next picture. The wires are also routed through two guides, and secured in the guides by glue. Guides with glue holding the wires in place Aluminum Cable Ties Step 3. Step 4. Open the Cable Ties. Scrape the glue off the surface of the guides, being careful to avoid nicking or crimping the wires. Free the wires from the guides. Unplug the wires from the Ribbon Color Sensor from the I/O Daughterboard. The connectors are behind the Ribbon Lift Cam. Ribbon Lift Cam 166 P330i Card Printer Service Manual Rev. A Draft 2

179 Step 5. Step 6. Unplug the wires from the Ribbon Color Sensor from the I/O Daughterboard. The connectors are behind the Ribbon Lift Cam. The Ribbon Color Sensor can now be removed by passing its wires through the rectangular cutout in the Center Frame Rev. A Draft 2 P330i Card Printer Service Manual 167

180 5.36 Replacing the Card Sensor Cable Assembly Important The Torx T10 driver used in this procedure must have a blade at least 4 inches (100 mm) long to reach through the access hole to the Card Sensor Mounting Screw. Step 1. The Card Sensor is located just inside the support for the Print Head Carriage, as shown in the picture below. The picture also shows the location of the Mounting Screw; the Mounting Screw location is also shown in the following picture.. Card Sensor Card Sensor Mounting Screw Step 2. Looking up from under the Print Engine, note the routing of the wires in the Card Sensor Cable Assembly. When replacing or re-installing the Card Sensor, the wires must be routed the same way. If it has not already been done, unplug the Card Sensor Cable Assembly from the I/O Daughterboard. The picture also shows the location of the Card Sensor Mounting Screw. 1. Red and Green Wires come out on this side, and stay below the White and Black Wires. 3. All Four Wires then pass under this post. Card Sensor Mounting Screw 2. White and Black Wires come out on this side, then bend over the Card Sensor and route over the Red and Green Wires. 168 P330i Card Printer Service Manual Rev. A Draft 2

181 Step 3. See the following picture. If necessary, turn the Print Head Lift Cam and deflect the belt as shown to clear the Card Sensor Mounting Screw Access Hole. With a longbladed Torx T10 driver, go straight through the Access Hole until the Torx head engages the head of the Mounting Screw. Remove the Mounting Screw (the Card Sensor will remain in place). Card Sensor Mounting Screw Access Hole Print Head Lift Cam Step 4. The following picture (from underneath) shows the Torx T10 driver bit in the Card Sensor Mounting Screw. Card Sensor Mounting Screw Rev. A Draft 2 P330i Card Printer Service Manual 169

182 Step 5. Using a Number 0 Phillips screwdriver, remove the Balls Retainer Plate and the springs and Delrin Balls it holds in place (more detailed information is given in section 5.21). Be careful to not lose the springs and/or balls. Balls Retainer Plate Step 6. The next picture shows the Balls Retainer Plate, springs, and balls removed. The Card Sensor Cable Assembly is barely visible. Card Sensor Cable Assembly 170 P330i Card Printer Service Manual Rev. A Draft 2

183 Step 7. Using a small flat-blade screwdriver, gently pry the Card Sensor toward the back of the Print Engine, as shown in the next picture. Be very careful to avoid crimping or breaking any of the wires. Pushing the wires upward (from underneath) will make prying the Card Sensor easier. Use Small Flat-Blade Screwdriver Here To Pry the Card Sensor This Way. Step 8. The following picture shows the Card Sensor pried toward the back of the Print Engine Rev. A Draft 2 P330i Card Printer Service Manual 171

184 Step 9. Use a small flat-blade screwdriver to gently pry the Card Sensor upward, while rocking it back and forth until the Card Sensor clears the card path, as shown in the next picture. Rock the Card Sensor back and forth while gently lifting / prying it upward. Step 10. Lift the Card Sensor free of the Print Engine. Be careful to avoid damaging any of the wires. Continue lifting until the connector clears the hole in the card path. 172 P330i Card Printer Service Manual Rev. A Draft 2

185 5.37 Removing the Print Head Cable Assembly The Print Head Cable Assembly includes the Print Head Fan and the Ribbon Sync Sensor. Caution During this procedure, be careful to avoid touching the Print Head Elements. Step 1. If you have not already done so, remove the Print Head Assembly from the Printhead Bracket Assembly (steps are given in detail in section 5.19, but are repeated here in simplified form for convenience). a. With a medium flat-blade screwdriver, remove the Print Head Adjustment Screw (and its washer and spring) Rev. A Draft 2 P330i Card Printer Service Manual 173

186 b. With a Torx T10 driver, remove the retaining screw on the front side of the Print Head Carriage. (You may need to use a flat-blade screwdriver on the other end of the Print Head Assembly Shaft to remove the retaining screw.) c. Remove the Print Head Assembly Shaft. 174 P330i Card Printer Service Manual Rev. A Draft 2

187 d. Unplug the Print Head Cable (you may need to use a small flat-blade screwdriver to pry the plug apart from the connector). Disconnect the Ground Lug Spade Connector. Ground Lug Spade Connector Print Head Cable Connector Rev. A Draft 2 P330i Card Printer Service Manual 175

188 e. Rock the Print Head Assembly back and forth while gently separating the sides of the Print Head Carriage until the Print Head Assembly can be slid free of the Print Head Carriage. Step 2. Cut the Cable Tie and remove the screw that holds the Ribbon Sync Sensor in place, as shown in the picture below. Cable Tie Screw Attaching Ribbon Sync Sensor 176 P330i Card Printer Service Manual Rev. A Draft 2

189 Step 3. Push the Print Head Cable Connector, the Ground Lug, and the Ribbon Sync Sensor out of the way so you can see the four latches (two on each side) that hold the Print Head Fan in place, as shown in the next two pictures. Fan Motor Attachment Latches Rev. A Draft 2 P330i Card Printer Service Manual 177

190 Step 4. Through the cutouts in the Print Head Bracket, note the four Fan Motor mounting holes (even though they are not used to mount the Fan Motor). Fan Motor Mounting Holes Step 5. While in turn pressing the four Fan Motor Attachment Latches away from the Fan Motor, use a Number 2 Phillips Screwdriver (the blade is too big to go through the Fan Motor Mounting Holes) to press against the Fan Motor Mounting Holes). You may need to go around the four latches and holes more than once, but eventually the Fan Motor will be freed by all four Latches. 178 P330i Card Printer Service Manual Rev. A Draft 2

191 Step 6. Then the Fan Motor can be pulled clear of the Attachment Latches. Step 7. Remove two screws, shown in the next picture, that attach the Print Head Pivot Bracket to the Print Head Carriage. Remove These Screws Rev. A Draft 2 P330i Card Printer Service Manual 179

192 Step 8. Press and hold the Print Head Carriage Latch; twist and gently pull the Print Head Pivot Bracket until it separates from the Print Head Carriage. 2. Separate Head Pivot Bracket from the Print Head Carriage 1. Press and Hold Print Head Carriage Latch Step 9. Work the Print Head Cable Assembly through the cut-outs in the Print Head Carriage. Bend the cable so the connector is roughly parallel to the cable to get it through the cut-outs. 180 P330i Card Printer Service Manual Rev. A Draft 2

193 Rev. A Draft 2 P330i Card Printer Service Manual 181

194 5.38 Removing the Print Head Lift Motor Step 1. The I/O Daughterboard and the Print Head Lift Cam must be removed to access the Print Head Lift Motor Mounting Screws. With a Number 0 Phillips screwdriver, remove three Mounting Screws as shown in the picture below. Print Head Lift Motor Mounting Screws Step 2. Reach up into the space between the Front Frame and the Center Frame, and remove the Print Head Lift Motor. 182 P330i Card Printer Service Manual Rev. A Draft 2

195 5.39 Separating the Front Frame from the Center Frame There are only a limited number of parts that would require separating the Front Frame from the Center Frame. These are: The Clean Drive Roller The Card Drive Roller The Platen Drive Roller The Exit Drive Roller The three Transport Rollers past the Platen The Card Pressure Plate attached to the Front Frame The Magnetic Encoder Station Roller attached to the Front Frame (Roller is present whether the printer includes the Magnetic Stripe Encoder Option or not) Separating the Front Frame from the Center Frame constitutes a significant dismantling of the printer! The suggested procedure follows; procedures that are described in greater detail have references to the appropriate sectiion. Step 1. Remove the Top Cover (5.2) Step 2. Remove the LCD PCBA (5.18) Step 3. Remove the Print Engine from the Lower Cover (5.3) Step 4. Remove the Card Feeder Assembly (5.22.3) Step 5. Remove the Connector Plate (5.4) Step 6. Remove the CPU PCBA (5.24) Step 7. Remove the Power Supply Cover (5.5) Step 8. Remove the Power Supply (5.6) Step 9. Remove the Rear Plate (5.7) Step 10. Remove the Cam Lever (5.8) Step 11. Remove the Platen Inertia Roller (5.9) Step 12. Remove the I/O Daughterboard (5.25) Step 13. Remove the Printhead Pressure Spring (5.10) Step 14. Remove the Film/Bracket Sensor PCBA (5.11) Step 15. Remove the Pressure Spring Plate (5.12) Rev. A Draft 2 P330i Card Printer Service Manual 183

196 Step 16. Remove the Cam Arm Follower Assembly (5.13) Step 17. Remove the Clutch Assembly (5.14) Step 18. Remove the Print Head / Carriage Assembly (5.15) Step 19. Remove the Ribbon Color Sensor (5.32) Step 20. Remove the Smart Card Contact PCBA, if present Step 21. Remove the Card Sensor Cable Assembly (5.33) Step 22. Remove the Encoder Shroud and Exit Pressure Roller (5.19); remove all other Pressure Rollers using the same procedure. Step 23. Remove the Balls Retainer Plate, Springs, and Balls (5.21) Step 24. Remove Exit Pressure Roller Assembly (5.20); remove all other Pressure Roller Assemblies using the same procedure. Step 25. Remove the Stepper Motor Drive Belt (5.30.1) Step 26. Remove the ESD Brush at the Card Exit. Use a soldering iron to melt the flattened plastic posts and gently pry off the push nuts. When replacing, use the soldering iron to flatten the plastic posts to secure the push nuts. Step 27. Remove the items shown in the next two pictures in the order shown. Do not remove the Pulleys and Push Nut specified in the second picture. 184 P330i Card Printer Service Manual Rev. A Draft 2

197 5. Timing Belt 4. Front Pulley 3. Timing Belt 7. Pulley 6. Push Nut, then Rear Pulley 1. Stepper Motor Drive Belt 2. Pulley (Do NOT remove Front Pulley, Push Nut, and Rear Pulley) 8. Timing Belt 9. Pulley 10. Push Nut 12. Pulley 11. Timing Belt 13. Position Front Frame/Center Frame with Center Frame Flat on work surface, then remove 7 Torx T10 Screws at bottom of these bores and lift the Front Frame straight up off the Center Frame Rev. A Draft 2 P330i Card Printer Service Manual 185

198 Step 28. Lift the Front Frame straight up off the Center Frame, and note the orientation of the Rollers shown in the next picture. The Rollers simply slip into their bearings in the Center Frame; they are held in place by corresponding bearings in the Front Frame when the Front Frame is attached. Exit Drive Roller Platen Drive Roller Card Drive Roller Clean Drive Roller Step 29. The Card Pressure Plate is held in position (inside the Front Frame) by two springs, which provice slight pressure inward to the card in the card path. The Card Bias Guide limits the travel of the Card Pressure Plate Magnetic Encoder Station Roller Card Bias Guide Card Pressure Plate 186 P330i Card Printer Service Manual Rev. A Draft 2

199 Step 30. To remove the Card Pressure Plate, detach the Springs, then remove the Card Bias Plate (it is held by 3 Torx T10 screws). Magnetic Encoder Station Roller Card Bias Guide Card Pressure Plate Springs Step 31. To remove the Magnetic Encoder Station Roller, remove (in order) the outer Pulley, Push Nut, and inner Pulley shown in the picture below. Then slide the Magnetic Encoder Station Roller on its shaft through the bearing in the Front Frame. 1. Outer Pulley 2. Push Nut 3. Inner Pulley Rev. A Draft 2 P330i Card Printer Service Manual 187

200 5.40 Magnetic Stripe Encoder Option The Magnetic Stripe Encoder Option consists of a Magnetic Encoder Sensor and Magnetic Encoding Head. These can be located below the card path ( regular ) or above the card path ( reverse encoding ). The instructions presented here are general enough that they can be applied to either. Step 1. Remove the protective shroud that protects the Magnetic Encoder Sensor and Head. Press the two removal tabs toward the rear of the printer, and lift the shroud by the lift tab. Lift Tab Protective Shroud Removal Tabs 188 P330i Card Printer Service Manual Rev. A Draft 2

201 Step 2. When the shroud is removed, the Magnetic Encoder Sensor and Magnetic Encoding Head are visible, as shown below. Regular: Reverse: Magnetic Encoding Head Magnetic Encoder Sensor Step 3. The Magnetic Encoding Head and the Magnetic Encoder Sensor are attached with Torx T10 screws. Step 4. If the Rear Plate has not been removed, remove it (see section 5.7). Step 5. The wires for either type of Encoding Head and Encoder Sensor pass through a rectangular cut-out in the Center Frame Rev. A Draft 2 P330i Card Printer Service Manual 189

202 5.41 Smart Card Options There are four different Smart Card Options available for the P330i. These can be summarized as follows: Contact Smart Card options use a Solenoid below the Card Path and a Contact PCBA above the Card Path. The Solenoid presses the card upward so the Contact PCBA s pins make electrical contact with the appropriate pads on the smart card. For the Contact Station version, wires from the Contact PCBA connect to a Smart Solenoid PCBA which mounts on the Connector Plate and includes a db9 connector for an external serial interface. For the GEM PLUS version, wires from the Contact PCBA (which includes logic for the GEM PLUS version) connect to the CPU PCBA. Additional logic circuitry on the CPU PCBA allows passing Smart Card signals via the USB connector, along with the normal functions of the USB interface. Contactless Smart Card options use either of two short-range radio technologies ( HID or MiFARE ) to communicate with the smart card. One component is a combination antenna and PCBA for the specific technology; this is mounted below the Card Path. There is also an Auxiliary PCBA, which is mounted on the bottom of the Center Frame, which provides an interface between the Antenna/PCBA and the CPU PCBA. Removal of most of these items is readily apparent Solenoid Assembly If your printer includes a Contact Smart Card Option, it will include a Solenoid Assembly, which will be apparent by the two mounting screws shown in the following picture. Solenoid Assembly Mounting Screws 190 P330i Card Printer Service Manual Rev. A Draft 2

203 Step 1. Step 2. With a Number 0 Phillips screwdriver, remove the two Solenoid Assembly Mounting Screws. Reach up into the space between the Front Frame and the Center Frame, and remove the Solenoid Assembly. Solenoid Assembly Mounting Holes Solenoid Assembly Rev. A Draft 2 P330i Card Printer Service Manual 191

204 192 P330i Card Printer Service Manual Rev. A Draft 2

205 6 Preventive Maintenance Introduction The Model P330i Printer is designed for operation with minimal maintenance. If the printer is cleaned on a regular basis, as described in this section, it should provide trouble-free operation. There are no periodic measurements, adjustments, or other preventive maintenance procedures required in normal usage. Cleaning the Printer Caution PROTECT YOUR FACTORY WARRANTY! The recommended cleaning procedures must be performed to maintain your factory warranty. Other than the recommended cleaning procedures described in this manual, allow only Zebra authorized technicians to service the P330i Printer. Clean your P330i Printer using Pre-Saturated Cleaning Cards provided. The regular use of these cards will clean and maintain important parts of your printer that cannot be reached, including the Print Head, Transport Rollers, and optional Magnetic Encoder Station Rev. A Draft 2 P330i Card Printer Service Manual 193

206 Preventive Maintenance Cleaning the Printer When to Clean the Printer Clean the printer when either of the following occurs: When the LCD Panel displays the message CLEAN PRINTER. Approximately every 1000 cards when using 5-panel color ribbon, or every 5000 cards when using a monochrome ribbon. How to Clean the Printer Note This cleaning procedure uses two cleaning cards. One cleaning card is the size of a regular plastic card, and is referred to as the cleaning card. The other is elongated, with a wider section at one end; it is referred to as the long cleaning card. Step 1. Step 2. Step 3. Step 4. Step 5. Step 6. Step 7. Leave the Printer power on, or turn it on if it was off. Initiate the cleaning process by either of the following methods: At the printer, press and hold the panel button for several seconds, until the LCD Panel displays the message REMOVE RIBBON THEN CLOSE HEAD. From the computer, enter the P330i Printer Tools software, and click on the CLEAN button. The LCD Panel will display the message REMOVE RIBBON THEN CLOSE HEAD. Open the Main Cover, release the Print Head Carriage, and remove the ribbon. Then close the Print Head Carriage. (For details, see Chapter 2.) The LCD Panel will display the message EMPTY FEEDER & PRESS BUTTON. Open the Card Feeder Cover and remove cards from the Card Feeder. The last card is difficult to remove; leave it in place. Press the Panel Button on the front of the printer. The card remaining in the feeder will be ejected. The LCD Panel will then display the message LOAD CLEANING CARD IN FEEDER. Place a pre-saturated Cleaning Card into the Card Feeder. The Cleaning Card will automatically feed into the printer and the cleaning process will start (there is a several second delay after the Cleaning Card feeds before the cleaning movement starts). While the cleaning process is underway, the LCD Panel will display the message CLEANING PRINTER. At the conclusion of this part of the cleaning process, the Cleaning Card will be ejected, and the LCD Panel will display the message PRESS BUTTON TO CONTINUE. After the user presses the panel button, the LCD Panel will display the message FEED LONG CLEANING CARD IN EXIT. Insert the long end of the long cleaning card into the card exit (directly above the Output Hopper). If the user inserts a regular cleaning card into the card exit, the LCD Panel will display the message INVALID CARD, PRESS BUTTON until the user presses the panel button and inserts the long cleaning card into the card exit. 194 P330i Card Printer Service Manual Rev. A Draft 2

207 Preventive Maintenance Cleaning the Print Head Note If the user does nothing at this point (i.e., does not insert the long cleaning card), after a timeout the LCD Panel display will change to CLEAN PRINTER. The printer will be able to print, but the LCD Panel will continue to display CLEAN PRINTER. This limited cleaning does not do a thorough cleaning, but may be performed if no long cleaning cards are available. To restore the display to READY, you will need to perform a complete cleaning process, using both short and long cleaning cards, from step 2 above through step 9 below. Step 8. Step 9. The long cleaning card will automatically feed into the printer and the printing process will continue. The LCD Panel will again display the message CLEANING PRINTER. When the cleaning process is completed, the long cleaning card will be ejected and the LCD Panel will display the message READY, indicating that the printer is ready to resume normal printing operations. Step 10. Discard both cleaning cards after a single use. Cleaning the Print Head Note Do not use previously used cleaning cards. A cleaning using the Cleaning Cards usually suffices. However, a separate Print Head cleaning can remove more stubborn deposits when print anomalies persist. To avoid deposits, only use foam-tipped swabs. Step 1. Step 2. Step 3. Step 4. Place the printer power switch in the OFF ( O ) position. Open the Main Cover, release the Print Head Carriage, and remove the ribbon. Leave the Print Head Carriage in its raised position. (For details, see Chapter 2.) Clean Print Head by moving an alcohol-moistened swab tip side-to-side across the Print Head elements. Only use moderate force. To re-order swabs, please refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer. The swabs can also be used in a similar manner to clean the optional magnetic encoding head Rev. A Draft 2 P330i Card Printer Service Manual 195

208 Preventive Maintenance Card Cleaning Cartridge Caution Never use a sharp object or any abrasive to scrape deposits from the print head. Permanent damage to the print head will result. Hot Surface Do not touch the print head if the printer has been in service in the last 10 minutes. It could be very hot and cause a burn. Card Cleaning Cartridge Your P330i Printer includes a Card Cleaning Cartridge. This item cleans the cards entering the printer through the card feeder. To ensure print quality, the cleaning roller requires periodic replacement. New cleaning rollers are included with each ribbon or may be purchased separately. (To reorder, please refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer.) Installation of the Card Cleaning Cartridge is described in Chapter 2 and is not repeated in detail here. When to Replace the Cleaning Roller Note Before replacing the Card Cleaning Cartridge or its cleaning roller, clean the Printer using the Cleaning Cards as described earlier in this chapter. Replace the Cleaning Roller each time you install a new ribbon. How To Replace the Cleaning Roller Step 1. Open the main cover and locate the Card Cleaning Cartridge. 196 P330i Card Printer Service Manual Rev. A Draft 2

209 Preventive Maintenance Card Cleaning Cartridge Card Cleaning Cartridge Step 2. Gently remove the Card Cleaning Cartridge. Lift the handle end, and then pull it away from the printer. Step 3. Remove the cleaning roller from the Card Cleaning Cartridge and discard Rev. A Draft 2 P330i Card Printer Service Manual 197

210 Preventive Maintenance Card Cleaning Cartridge Step 4. Install new cleaning roller into the Card Cleaning Cartridge. To avoid contamination, always hold the cleaning roller by the ends. (For replacement cleaning rollers, please refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer.) Step 5. Peel protective wrapper from the cleaning roller by gently pulling on the tape. Note DO NOT touch the adhesive roller surface that contacts the cards. 198 P330i Card Printer Service Manual Rev. A Draft 2

211 Preventive Maintenance Card Cleaning Cartridge Step 6. Replace the Card Cleaning Cartridge into the printer: Card Cleaning Cartridge in final position Step 7. Close the printer main cover Rev. A Draft 2 P330i Card Printer Service Manual 199

212 Preventive Maintenance Card Cleaning Cartridge 200 P330i Card Printer Service Manual Rev. A Draft 2

213 APPENDIX A Software Introduction This section lists software commands to initiate, check, or adjust various system functions, parameters, and variables. Detailed information on the use of these commands are given in the EPCL Programmer s Guide, Zebra document , which can be downloaded from the Zebra Card Printer Solutions website at Entering Software Commands Step 1. From the Windows Start menu or from the Windows Control Panel, navigate to Printer Properties. This will bring up a display like the one below Rev. A Draft 2 P330i Card Printer Service Manual 201

214 Software Entering Software Commands Step 2. Click on the Device Settings tab, then select Tools, then click on the Properties block that will appear, as shown below. Step 3. This brings up the Tools display. Type the desired command in the Command to send to printer window, and click the Execute button. Type the command here then click the Execute button. 202 P330i Card Printer Service Manual Rev. A Draft 2