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Troubleshooting

Troubleshooting Motors

The best way to determine if a motor has failed versus a main control board
failure, is to swap the motor with a similar motor. If a motor has failed, then a
replacement motor should function. Conversely, if the motor’s driver has failed,
then a replacement motor will not function either.

CAUTION:

This is intended to be a limited test using Diagnostics to verify if

a motor turns or not. Do not attempt to operate the printer with motors
swapped out. Limit your test to short periods of time.

Testing General DC Motors

•

The ribbon, pick, and cam motors are all driven from the same motor driver
chip (integrated circuit). If all three motors have failed, the main control
board is faulty and needs to be replaced.

•

If a motor is drawing too much power from the motor driver IC, an LED will
be illuminated to indicate an over-current condition.

•

Once the LED has been turned on, it can be reset only by unplugging the
printer.

•

If operating a specific motor (but not the other two) results in this LED
being turned on, the likely cause is that the motor has failed.

•

If the LED turns on regardless which motor is operating, then it is more
likely that the main control board is faulty.

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Summary of Contents for CP60

Page 1: ...Datacard CP60 and CP60 Plus Card Printers Service Manual May 2007 Part No 539358 002 Rev C ...

Page 2: ...tions and options are subject to change at the sole discretion of Datacard without notice Proprietary Notice All drawings and information herein are the property of DataCard Corporation All unauthorized use and reproduction is prohibited Trademark Acknowledgments Datacard is a registered trademark and service mark of DataCard Corporation in the United States and other countries CP60 is a trademark...

Page 3: ..._______________________________________2 22 ISO IEC 7811 Parts 2 and 6 __________________________________________________2 22 AAMVA DL ID 2000 __________________________________________________________2 22 Saflok and Ving______________________________________________________________2 22 Multiple Record Format SDS _________________________________________________2 23 JIS X 6302 Type I and Type II C...

Page 4: ..._______________________________________________________4 14 Printer Driver Errors DR _______________________________________________________4 14 Input Errors IS _______________________________________________________________4 17 Duplex Module Errors DM ___________________________________________________4 17 System Errors SY ____________________________________________________________4 18 Magnetic ...

Page 5: ..._________________________________________5 37 Updating the Printer Firmware ________________________________________________5 38 Duplex Rotational Adjustment ________________________________________________5 39 Chapter 6 Removal and Replacement ___________________________________________ 6 1 General Notes______________________________________________________________________6 3 Symbols ____________...

Page 6: ...____________________6 54 Printhead Lifter ______________________________________________________________6 55 Front Card Guide ____________________________________________________________6 56 Rear Card Guide ____________________________________________________________6 57 Static Brushes ________________________________________________________________6 59 RFID Antenna________________________________...

Page 7: ...art 15 Subpart B of FCC rules designed to provide reasonable protection against radio interference in a commercial environment Operation of this equipment in a residential environment may possibly cause interference In the event of interference the user at their own expense will be required to take whatever measures are necessary to correct the problem Notice for Canada This digital apparatus does...

Page 8: ...red Know the location of equipment branch circuit interrupters or circuit breakers and how to turn them on and off in case of emergency Know the location of fire extinguishers and how to use them Use only ABC type extinguishers on electrical fires Know local procedures for first aid and emergency assistance at the customer facility Use adequate lighting at the equipment Maintain the recommended ra...

Page 9: ...o the Datacard CP60 and CP60 Plus card printers Intended Audience______________________________________________________________ 1 2 Avoiding Electrostatic Discharge _________________________________________________ 1 2 Symbol Conventions_____________________________________________________________ 1 3 ...

Page 10: ...Static grounding kit Part Number TUL006 006 containing Static grounding mat Mat grounding cable Static grounding wrist strap Wrist strap grounding cable Grounding plug Procedure 1 Wear appropriate clothing Avoid wool and synthetic fabrics 2 Remove movable carpet and rugs 3 Apply the grounding strap to a wrist Ensure that there is no clothing between the strap and skin and that the strap is snug en...

Page 11: ...age to avoid serious damage to the printer WARNING This symbol indicates a strong warning message to prevent personal injury to the technician This symbol indicates a spring hazard Safety glasses should be worn when completing the procedure This symbol indicates a reminder message or other additional information for the technician Graphic callouts with a colored background provide incidental infor...

Page 12: ...1 4 Introduction ...

Page 13: ...ic Data Principles ____________________________________________________________2 14 Encoding Format ____________________________________________________________________2 19 Magnetic Stripe Primary Data Standards _________________________________________ 2 22 ISO IEC 7811 Parts 2 and 6 __________________________________________________________2 22 AAMVA DL ID 2000 __________________________________...

Page 14: ...2 2 Theory of Operation Printer Components Functional Block Diagram ...

Page 15: ...sor This allows the printer to know the position of the printhead lifters The printhead lifters lift the printhead away from the platen roller when not printing Swingarm Open Cover arm The swingarm open sensor detects when the swingarm is open The sensor itself detects when the swingarm is closed but the signal is inverted elsewhere in the system Note The user information and Diagnostics refer to ...

Page 16: ... Magnetic Stripe Optical Encoder This encoder monitors the rotation of the idler roller in the magnetic stripe module It provides positional feedback to the module to ensure proper magnetic encoding Duplex Entry The duplex entry sensor is an optical interruption sensor that detects the presence of a card as it enters and leaves the duplex module For the clear card option this sensor is replaced wi...

Page 17: ...h a gear which also drives the main transport belt This is a 2 phase 4 wire 40 volt stepper motor Cam Motor The cam motor rotates the printhead cam which operates the printhead lifters This raises and lowers the printhead into position for printing or permitting a card to pass beneath This motor is wired bi directional and uses two channels from the motor controller so that it can be reversed Howe...

Page 18: ...ssembly rotates in unison with the large gear which keeps the drive rollers from rotating RFID Antenna The RFID antenna circuit board is a simple loop antenna that communicates with the supplies ID chip in the ribbon supply spool The bi directional communication method is similar to Non Contact Smart Cards p 2 32 using load modulation although the specific details may vary Duplex Interface Board T...

Page 19: ...CP60 and CP60 Plus Service Manual 2 7 LCD Menu Diagram ...

Page 20: ...ibbon motor being energized for a short time to detect a ribbon encoder change 5 When the printer has finished its initialization procedure and is ready to process cards the status light will turn green Default Card Production Sequence 1 After the card data has been sent to the printer it begins the card personalization process 2 The card is picked and passes through the cleaning rollers 3 After t...

Page 21: ...ing a panel the printhead is raised and the card is returned to the input sensor D The ribbon motor advances to the next panel by examining the ribbon encoder E The process is repeated for the remaining panels 7 The card is passed to the duplex module A The duplex entry sensor detects the card and determines the position within the flipper B With the magnetic clutch relaxed the drive rollers pull ...

Page 22: ... functions The table below lists the differences by printer model Printer Model Item CP60 CP60 Plus SE48 220 280 310 S character spacing L line spacing T graphics template hex character control Allow format characters in print field More than 11 dummy emboss lines Special font spacing for fonts 1 2 3 Characters not on emboss wheel permitted Graphics data control ...

Page 23: ...ransfer pigment from the print ribbon to the card the respective thermal element pixel heats up until the temperature reaches the transfer threshold At this point pigment from the print ribbon will adhere to the card The longer the element remains on the more material gets applied At temperatures below the transfer threshold no pigment is transferred to the card If the temperature of an element is...

Page 24: ... control was analog but is now digital To increase the temperature or heat on a single element it is turned On more than it is turned Off The higher the duty cycle the hotter the element becomes Because the printhead now receives full voltage from the power supply swapping the power supply for another power supply will have an impact on printing intensity The printer can easily be adjusted to comp...

Page 25: ...perature than it would if only 300 pixels were turned on This would result in a lighter image if more pixels are needed and a darker image if only a few pixels are needed The Strobe setting is a time factor that compensates for this reduction in power by increasing the on time for each pixel based on how many pixels are required for the printed column The strobe setting value is a baseline number ...

Page 26: ...ipe Magnetism All magnets including the Earth have a North Pole and a South Pole These poles always appear in North South pairs and there will never be one without the other A magnetic field is comprised of Magnetic Lines of Force or Magnetic Flux which travel from North to South between the poles Even though magnetic flux is invisible the effects of these lines can be seen as they interact with p...

Page 27: ...a magnetic field moves past a wire a current3 will be generated induced in the wire Note that in the case of magnetic stripe cards a static non changing magnetic field is physically moving past the conductor This would be analogous to flying over the mountains in an airplane The hills and valleys make the distance between the airplane and the ground increase and decrease but the landscape itself d...

Page 28: ...ate the magnetic field When electrical current passes through the head coil a small but concentrated magnetic field is generated across the open ends of the core The magnetic stripe on the card is magnetized with the opposite magnetic polarity from the head This is shown in the image below To change the polarity of the magnetic stripe under the magnetic head the polarity of the current in the head...

Page 29: ...a flux line no current will be induced Because the flux density is greatest at the poles of a magnet the current will also be greatest as the magnetic pole passes below the head This is illustrated in the drawing below If the magnetic stripe were comprised of a single North to South magnet no current would be induced in the magnetic head for the majority of the length of the card When two North Po...

Page 30: ...re recorded for the whole length of the stripe The binary data is written between each of the clock pulses These two signals are merged together into a serial data stream and sent to the magnetic head as an alternating current of varying frequency In the example below the binary data to be written to the card is 011001 When this is merged with alternating clock pulses the result is 1011111010111 T...

Page 31: ...h Each piece of information written to the magnetic stripe is a binary coded character These characters numeric or alphanumeric are represented by a binary number known as a binary word Typically these binary words are between 4 and 8 bits in length The number of bits per word is determined by how many possible characters there are in a character set The common alphanumeric character set requires ...

Page 32: ...followed This basic layout is shown below Leading Clock Pulses Start Sentinel Specific Data End Sentinel Longitudinal Redundancy Check Trailing Clock Pulses Leading Trailing Clock Pulses The actual information written to a magnetic stripe cannot extend fully to the edges of the stripe The main reason for this is because the card reader needs to synchronize its timing to the speed at which the card...

Page 33: ...f with the same number of bits as the specific data characters Each bit in the LRC binary word except its own parity bit represents a single parity check for all of the preceding bits in the same position This can best be explained by examining the binary data in the tabular form shown below Each character s parity bit makes the horizontal sum of bits an odd number The LRC makes the vertical sum o...

Page 34: ... ABA and TTS This acronym should not be used to describe a 3 track card because it describes the content not the technique It is more accurate to describe these tracks as ISO 1 2 or 3 Full Name Abbreviated Name Former Designation ISO IEC 7811 part 2 or 6 Track 1 ISO 1 IATA ISO IEC 7811 part 2 or 6 Track 2 ISO 2 ABA ISO IEC 7811 part 2 or 6 Track 3 ISO 3 TTS Note that this standard permits the use ...

Page 35: ... times This is to ensure that the beginning and end of the record has been detected Number of Nulls Between duplicate data records there can exist empty non recorded space This separates the records to ensure that two adjacent records are not misread as one record JIS X 6302 Type I and Type II Cards JIS X 6302 is the Japanese standard for magnetic striped cards and identifies two distinct card for...

Page 36: ...etic stripe on a card follows the specifications outlined in the two drawings below The first graphic is for a two or three track card ISO IEC and JIS Type I Note that under the ISO and JIS standards even if only one of the three tracks is used the minimum track size follows this specification ...

Page 37: ... Manual 2 25 Data Track Locations The positions where data can be recorded on a 3 track stripe are described in the graphic below This applies to all three of the aforementioned standards but does not apply to a JIS Type II card ...

Page 38: ...arizes the data specifications for the primary standards ISO IEC 7811 JIS Type I JIS Type II Parameter Track 1 Track 2 Track 3 Single Track Bit Density 210 75 210 210 Total Length 79 40 107 72 Record Length 76 37 104 69 Data Type 7 bit A N 5 bit N 5 bit N 7 bit A N Start Sentinel DEL End Sentinel DEL Field Separator Word Parity ODD EVEN LRC Parity EVEN EVEN N Numeric character set A N Alphanumeric...

Page 39: ... 0 0 0 1 1 0 1 0 0 0 1 1 1 0 1 0 0 1 1 1 1 0 0 0 1 0 0 0 0 1 1 0 1 0 0 0 1 2 1 0 1 0 0 1 0 3 0 0 1 0 0 1 1 4 1 0 1 0 1 0 0 5 0 0 1 0 1 0 1 6 0 0 1 0 1 1 0 7 1 0 1 0 1 1 1 8 1 0 1 1 0 0 0 9 0 0 1 1 0 0 1 H 0 0 1 1 0 1 0 H 1 0 1 1 0 1 1 H 0 0 1 1 1 0 0 H 1 0 1 1 1 0 1 H 1 0 1 1 1 1 0 E 0 0 1 1 1 1 1 Binary Note Char Parity 25 24 23 22 21 20 H 0 1 0 0 0 0 0 A 1 1 0 0 0 0 1 B 1 1 0 0 0 1 0 C 0 1 0 0 0...

Page 40: ... 1 0 1 0 1 6 1 0 1 1 0 7 0 0 1 1 1 8 0 1 0 0 0 9 1 1 0 0 1 H 1 1 0 1 0 S 0 1 0 1 1 H 1 1 1 0 0 F 0 1 1 0 1 H 0 1 1 1 0 E 1 1 1 1 1 Code Description H These characters are used to control the hardware and cannot be part of the data content These may or may not be used by different device manufacturers S E F Reserved characters for Start Sentinel End Sentinel and Field Separator ...

Page 41: ...sent this unique identifier as part of the answer to reset which is discussed below Even if the card protocol permits it this identifier should not be altered There are two basic types of smart cards Contact Smart Cards and Non Contact Smart Cards or a combination of both types as shown in the graphic below Contact smart cards connect to the external interface via a set of eight electrical contact...

Page 42: ...mmunication When the card is inserted into a reader it needs to be initialized and communication protocols defined Note that steps 1 through 6 all occur while the card is forced to remain in a reset state no activity 1 The card reader senses that the card is in position under the contacts In most cases this is a mechanical switch that detects the presence of a card any type of card 2 The Reset lin...

Page 43: ...tains The format of the communication Permissible baud rates Parameters of the circuitry in the card Required programming voltage on Vpp The make and model of the card Other information the manufacturer chooses 9 With communication parameters known the interface can begin to communicate with the card 10 Serial communication across the I O line commences 11 If necessary the voltage on Vpp is altere...

Page 44: ...cy cards are frequently referred to as Wiegand cards and generally only provide a unique ID when energized The FeliCa card format was developed by the Sony Corp and is similar to the standard Type A card except it uses 212 kb s data rate instead of the standardized 106 kb s data rate There are also some variations on the modulation protocol The Mifare card is fairly common because it is based on a...

Page 45: ...ed with a higher frequency the carrier The higher frequency is more easily transmitted and received Combining two signals together is called modulation There are many different types of signal modulation but they all boil down to three basic parameters altering the amplitude frequency and or phase of the carrier signal You are probably familiar with the terms Amplitude Modulation and Frequency Mod...

Page 46: ...ns close to the carrier frequency but the drawing is exaggerated for clarity Amplitude Shift Keying This is a digital variant on the AM modulation It comes in two common forms 100 and 10 Note 10 modulation ASK10 means the carrier is modulated by only 10 100 modulation means that the carrier signal is fully modulated Both of these variants are shown to the right Load Modulation The card switches th...

Page 47: ...at it is more immune to noise and errors because there is a strong difference in amplitude at bit transitions The drawback to this is that the card doesn t receive power during the low cycle of the modulation The card doesn t turn off during these times but the effect is that less overall average power is being transmitted to the card ASK10 provides more power to the card because the modulated sig...

Page 48: ...the current in the primary winding is inversely proportional to the load on the secondary winding As a result if the load is varying with time the circuitry on the primary side of the transformer can detect the change in current draw When the card engages and disengages switches resistance in its own antenna the reader detects this change by examining the current draw within its antenna Type A Car...

Page 49: ...arrier frequency of 847 kHz using amplitude modulation but shifts the phase of the subcarrier by 180 degrees inverted at each data transition In other words the carrier is always modulated with the subcarrier but during data transitions the subcarrier signal is altered inverted The subcarrier is permitted to invert only at its own transition points which is why the frequencies are even multiples o...

Page 50: ...2 38 Theory of Operation ...

Page 51: ... Routine Maintenance Procedure _________________________________________________ 3 3 Clean the Interior of the Printer ________________________________________________________3 3 Mechanical Inspection________________________________________________________________3 5 Run the Cleaning Card _______________________________________________________________3 8 Visual Inspection for Card Quality_________...

Page 52: ... card 552141 001 Cleaning sleeve 549288 002 Molykote DX grease 807421 001 Cleaners used on the printer s exterior should not contain any abrasives oils fragrances antibacterial agents solvents or isopropanol Do not use soft scrubbing cleansers products with petroleum or products with mineral pine or lemon oil CAUTION Use only canned compressed air on this printer Do not use facility air as it will...

Page 53: ...lectrical device Clean the Interior of the Printer 1 Unplug the printer 2 Remove the printer enclosures 3 Remove the chassis from the base enclosure 4 Using canned compressed air Blow out any debris near the sensors Blow out any dust from the control board and other surfaces of the base Blow out any dust and debris from the underside of the chassis Make sure to include the cam sensor 5 If the grea...

Page 54: ...a cloth dampened with water to clean the sensor reflector on the printhead cartridge 7 Using an isopropanol cleaning pen clean the thermal printhead by rubbing the isopropanol tip over the printing portion of the printhead Sp35707s ...

Page 55: ... damage 3 Check springs to verify they are in position and not damaged 4 Inspect the transport system Inspect the timing belt for wear and missing teeth Inspect the three or four idler pulleys and make sure they are securely seated Inspect the drive pulleys for wear and broken teeth Inspect the platen roller gear and pulley for wear and broken teeth 5 Inspect the ribbon drive gear for wear and bro...

Page 56: ... cassette has a plastic encoder wheel inspect it for scratches and missing lines Check the spindles for proper movement and that the clutches are providing a slight drag 7 Inspect the print cam gear and motor gear on the underside of the printer for wear and broken teeth 8 Inspect the cam lobes for wear or grooves ...

Page 57: ... CP60 Plus Service Manual 3 7 9 Reassemble the printer 10 Wipe the exterior of the printer with a cloth dampened with a non abrasive general purpose cleaning solution Let the printer dry before connecting power ...

Page 58: ...ess the lower cleaning roller by removing the cleaner rocker assembly Access the front drive roller by removing the front roller rocker arm Access the magnetic stripe encoder roller by removing the magnetic encoder roller rocker assembly 5 Put a new cleaning sleeve on the cleaning spindle and replace the roller Visual Inspection for Card Quality 1 Print an internal test card by pressing and holdin...

Page 59: ...he Ribbon RFID Antenna_______________________________________________4 8 Performance Problems___________________________________________________________ 4 9 Printer Initialization Errors_______________________________________________________________4 9 Card Jams at Card Input_____________________________________________________________4 10 Card Stalls at Output Stacker ____________________________...

Page 60: ... diagnostic software For brevity details about the diagnostic software are not discussed unless required For further information about Diagnostics refer to chapter 5 of this manual CAUTION Unless instructed otherwise always unplug the printer before connecting or disconnecting any electrical device from any circuit board Non Clearing Repetitive Messages If the printer encounters an error that will...

Page 61: ...unctioning is with a volt meter Use the test points in the figure below to test the sensor 3 Unplug the printer and swap the sensor with another sensor You cannot swap the ribbon motion sensor with any other sensor It is not compatible with any other sensor Because this is a test of the sensor the original sensor does not need to be removed Simply unplug the original sensor from the control board ...

Page 62: ...test to short periods of time Testing General DC Motors The ribbon pick and cam motors are all driven from the same motor driver chip integrated circuit If all three motors have failed the main control board is faulty and needs to be replaced If a motor is drawing too much power from the motor driver IC an LED will be illuminated to indicate an over current condition Once the LED has been turned o...

Page 63: ...erate both motors from Diagnostics Testing the Cam Motor Use care with this procedure Even though the motors are different their controlling circuitry is similar The connectors are not compatible but can be interchanged for testing purposes only 1 Unplug the DC motor harness ribbon and pick motors 2 Connect the cam motor to one side of the DC motor connector as shown below Note that you will recei...

Page 64: ... only reliable way of verifying if the motor is non functional is to replace the motor with another identical motor Troubleshooting Other Devices Testing the Smart Card Solenoid The driving circuitry for the smart card solenoid is located on the smart card daughter board A power transistor on the daughter board amplifies the signal going to the solenoid If the solenoid is not receiving a signal th...

Page 65: ...he flipper should rotate in only one direction If it can be rotated in both directions the spring is damaged and needs to be replaced 2 With the printer powered off remove the duplex clutch cable from the interface board and connect it to the cam motor connector Note that you will receive a repetitive error see page 4 2 when the printer is powered up 3 In Diagnostics set the motor test duration to...

Page 66: ... is non functional the most likely cause is the cable between the interface board and the main control board The interface board contains driver circuitry for the duplex clutch and the duplex motor If either of these devices aren t working yet the device itself is not the cause the interface board is likely at fault Diagnosing the Ribbon RFID Antenna The circuit board for the RFID antenna is very ...

Page 67: ...t fully seated obscured by part of the chassis The printer initializes but reports a broken print ribbon Verify that a cartridge is installed Check the encoder wheel for damage Make sure the ribbon motion sensor is connected and functioning The printer initializes and the ribbon is advanced but the printer reports that the index mark could not be found Remove the ribbon and close the cover Check t...

Page 68: ...to be properly positioned but the error is still reported Clean the card input sensor Check the position of the card input sensor and make sure it is firmly seated Check the operation of the card input sensor using the sensor screen in Printer Diagnostics If the sensor is always blocked it is either disconnected or not fully seated obscured by part of the chassis If the sensor never blocks either ...

Page 69: ...f using a monochrome ribbon make sure an CP Series print ribbon is installed Other ribbons are not designed for the increase in printhead heat Inspect the card for improper print ribbon panel placement Printing with the wrong panel can cause the ribbon to adhere to the card Decrease the printing brightness setting Inspect the card guide and rocker assembly springs for placement and damage Card sto...

Page 70: ...ake up spool gear for damage or broken teeth Check the ribbon cartridge clutch Check that the ribbon is attached to the take up ribbon core Check to see that the ribbon is not sticking to the card The ribbon frequently breaks Check the Card Registration Offset Adjust the image trimming farther from the edge of the card Make sure an CP Series ribbon is installed Make sure the printing intensity is ...

Page 71: ...o handle routine errors The solutions presented are for repetitive errors For example a simple card jam can occur periodically without a specific cause However a repetitive card jam would indicate a problem with the printer In the tables below the name of the error handling procedure call is included under the symptom of the error This procedure name is never displayed but it is included here to p...

Page 72: ...nction out of the proper sequence Contact the print application developer AP 00811 The application sent a value that is not consistent with current settings Contact the print application developer AP 00812 The application sent a value that is not supported by the Datacard printer API Contact the print application developer AP 00813 A printer error occurred while picking a card Inspect the card pic...

Page 73: ...on The print processor has an error opening or reading the temporary files Make sure the TEMP environment variable is set correctly User should have sufficient rights to write to this folder Delete the job and resend it from the application If the spooler crashes restart Windows DR 00908 The printer driver cannot get enough PC memory Click Help for more information There is not enough memory to pr...

Page 74: ...ly applications needed to print cards b Wait until the captured image is displayed on the PC before printing the card to prevent competition for PC resources Interactive mode jobs including smart card jobs and read magnetic stripe jobs are not supported for networked printers Do not send interactive mode jobs to a network printer DR 00919 The current printer was disconnected or powered off Card jo...

Page 75: ...dule Errors DM Error Code Symptom Comments DM 00760 The duplex mechanism did not reach the correct position ERR_FLP_POSITION One or more sensor transitions was not detected Check the flipper for obstructions Check if the clutch is functioning Check if the sensor is functioning Check the duplex motor DM 00762 The card is stuck in the duplex module ERR_FLP_CARD_JAM The duplex entry sensor did not cl...

Page 76: ...E A logo loaded into flash memory is too large SY 01314 Warning EEPROM flash write error Do not power off the printer RETRY the update file ERR_SYS_FLASH_WRITE Main control board problem NOTE Do not power off the printer Try to reinstall the printer firmware or download an updated firmware update utility SY 01317 Memory error ERR_SYS_MEM The printer could not save the data being sent SY 01325 The ...

Page 77: ...gnostics Check the magnetic stripe head Check the magnetic stripe optical encoder Check the magnetic stripe daughter board MS 01407 MS 01408 MS 01409 LRC error reading data on track 1 2 or 3 MS_T1_LRC_ERR MS_T2_LRC_ERR MS_T3_LRC_ERR The longitudinal redundancy check failed If this occurs frequently Run a cleaning card Try different card stock Check the printer s coercivity setting to make sure it ...

Page 78: ...the encoder roller is free to turn Inspect the card track for obstructions Check card stock for powder dirt or oil on cards and then run a cleaning cycle Check the transport belt and pulleys for operation If the card is not over the sensor check the following Make sure the sensor reflector is in position on the magnetic stripe rocker Check the magnetic stripe sensor using the sensor Diagnostics MS...

Page 79: ...tion If the read back direction is forward then it may also be possible that the card input sensor never cleared Check the operation of the card input and magnetic stripe sensors Check the front and magnetic stripe rockers for proper spring pressure and roller movement Check the transport for proper operation or obstructions MS 01421 A card was lost when attempting to read or write magnetic stripe...

Page 80: ...not accepted by the magnetic stripe module MS_CONFIG_ERR Check the magnetic stripe configuration settings using Diagnostics For a custom application incorrect values may have been sent MS 01428 Status request passed through by the printer driver was not accepted by the magnetic stripe module MS_STATUS_ERR Illegal command Try again Verify application is sending the correct data Verify printer drive...

Page 81: ...r MS_OPS_WRITE_ERR Check the magnetic stripe configuration settings using Diagnostics Try the operation again Power cycle the printer If the error continues replace the main control board MS 01434 Magnetic stripe module settings EEPROM write error MS_FAC_WRITE_ERR Check the magnetic stripe configuration settings using Diagnostics Try the operation again Power cycle the printer If the error continu...

Page 82: ... PR 01715 The cover was opened during printing ERR_PRN_HEAD_OPEN If the cover was not opened check the sensor for a loose connection PR 01716 The cover is open ERR_PRN_HEAD_OPEN_WARNING This will be reported if the sensor is disconnected Use Diagnostics to see if the sensor toggles when blocked PR 01717 Printing is suspended while the printhead returns to operating temperature ERR_PRN_HEAD_TEMP_WA...

Page 83: ...lipping YMC K T power Check the swingarm assembly it may not be secure or is defective PR 01726 Out of print ribbon Replace the print ribbon with the same type and click OK when ready ERR_PRN_RIBBON_OUT If the ribbon is not empty Check the ribbon index sensor for proper operation Verify that the ribbon ID tag was not swapped with another ribbon PR 01730 Unable to read the printhead temperature Pow...

Page 84: ...lled or detected Make sure the card creation application does not request smart card programming ERR_IC_NOT_INSTALLED Verify that the smart card option is enabled using Diagnostics Check the smart card assembly Possible failed components are the sensor the cable and the smart card control board Power cycle the printer ...

Page 85: ...__________________________________5 12 Transport Speed__________________________________________________________________5 13 YMC K T F Strobe Duty ________________________________________________________5 13 YMC K T and F Power and Base Power ___________________________________________5 14 Duplex Infeed Offset _____________________________________________________________5 14 Duplex Home Offset____...

Page 86: ...figuration __________________________________________5 33 Start Sentinel Position_________________________________________________________________5 35 Card Registration Offset Adjustment __________________________________________________5 36 Ribbon Offset Adjustment ____________________________________________________________5 37 Updating the Printer Firmware ______________________________________...

Page 87: ...e The difference between 25 C and 30 C is 5 C Helpful Hint There may be times when you wish to perform a task while observing sensor changes in another diagnostic window It is permissible to open multiple instances of Diagnostics to view separate dialog boxes not normally viewable with a single instance To do this double click on the Diagnostics icon and then double click on the icon again Two ins...

Page 88: ...installation 4 You will see a prompt for changing the destination directory It is recommended that you not change this setting Click Next 5 You will then be asked to which program group the icon should be added Make no changes and click Next 6 The program performs the installation and informs you when it is completed Click on Finish ...

Page 89: ...r will disable some of the settings within Diagnostics No password will be required for this option B At the prompt enter the service technician password 926918 Do not share this password with the end user of the printer It permits access to settings that should not be altered by untrained personnel Parts of the Diagnostics Window The main Diagnostic window shows the near real time status of the p...

Page 90: ...iting Diagnostics but if you do not wish to select Exit without reset Printer Test Card Use this option to print the default test card for the printer The gray test card is available to the Advanced User only The rewrite card is available only when the printer is configured for rewrite cards In rewrite mode the white and grey cards are not available Printer Values This option is for changing the o...

Page 91: ...ts for the Printer Magnetic Stripe Test Card This option provides access to printing test cards for the magnetic stripe module Only Advanced Users can read cards Magnetic Stripe Configuration This option for configuring the magnetic stripe module is available only to the Advanced User It is for configuring Start Sentinels etc as described in Configuring the Magnetic Stripe Magnetic Stripe Diagnost...

Page 92: ...om the list in the Change Values box 3 Type your change in the New Value data box and click on Apply The new value is temporarily stored in the printer s RAM memory but it is not permanently stored in EPROM memory yet If you turn off or reset the printer the value is removed from RAM and the original power on default value is loaded 4 Use the Test card option or a card creation program to print a ...

Page 93: ...s View current values Select to display the values that are currently loaded in the printer s non permanent memory View power on values Select to display the values that are currently loaded in the printer s permanent power on memory Save current values to file Writes all parameters and values currently saved in memory to a text file View factory values Select to display the values that were perma...

Page 94: ...ther loaded from a file using Load Script or created by modifying printer values To perform a single step and run the selected line of the script click on Run Step The line will be run and the next line highlighted To test the entire script click on Run Script To delete the highlighted line of a script click on Delete value This option may not be available for loaded scripts After making printer v...

Page 95: ...stomer s PC This is available only to the advanced user If the main control board is replaced follow the Saving and Restoring a Printer Configuration procedure on page 5 33 Card Registration Offset This parameter determines how far the card travels after being detected by the card input sensor for the leading edge of the card to arrive at the printhead This setting can also be changed in the print...

Page 96: ...nter how far to advance the print ribbon after the index mark is detected by the ribbon index sensor This value is applied only to the first panel following an index mark This parameter should not be modified from the factory default setting If it does become necessary to change it refer to the Ribbon Offset Adjustment on page 5 37 Range 0 to 10 000 in thousandths of an inch Value Too Large Printi...

Page 97: ...ge 150 to 3000 YMC K T F Strobe Duty These parameters are used to maintain a consistent print intensity between full columns and partial columns YMC Yellow Magenta Cyan K Black T Topcoat F Fluorescent These parameters should not be changed However if one parameter is altered all three should be altered accordingly Range 0 to 255 Increase Value Columns with fewer pixels print darker Decrease Value ...

Page 98: ...o tune the printing results to suit the needs of the user YMC Yellow Magenta Cyan K Black T Topcoat F Fluorescent Range 100 to 100 Value Too Low Colors will be dull and washed out K panel printing may have dropouts Value Too High Frequent ribbon breaks and bar code growth Duplex Infeed Offset This parameter controls how far a card will travel after it leaves the duplex entry sensor If this value i...

Page 99: ... Handoff Offset This parameter controls where the duplex flipper stops when in the vertical handoff position Range 70 to 130 Value Home Offset plus 77 Adjust the Duplex Home Offset and then set this value to be 77 units larger Smart Card Registration Offset This parameter controls the distance a contactless smart card travels to reach the programming station Because of the nature of the contactles...

Page 100: ...f the card Undesirable white space on the leading edge of the card Reduce the leading edge image clipping Also check the Card Registration Offset Adjustment p 5 36 to make sure that is not the cause Undesirable white space on the trailing edge of the card Reduce the trailing edge image clipping Verify that the card design is not too short to extend to the end of the card Symptom Solution Frequent ...

Page 101: ...ions currently saved in the printer Apply Click this button to store the change in the printer s non permanent RAM memory The changes will be discarded when the printer is reset unless you click on Save Save This saves the changes to the printer s EPROM memory You will be prompted for a password Enter 42360 Status Display Area This area displays the status of the current operation Prioritize messa...

Page 102: ...s displayed in the window at the left Name Description Printer error log Select this option and click Query to display the error history for the printer in the display window Print Ribbon information Select this option and click Query to display the type of ribbon detected by the printer in the display window Laminate information This option is not available for the CP60 and CP60 Plus printers ...

Page 103: ...Motor Printhead Cam Motor Card Pick Motor remove cards from the hopper first Printhead Fan Motor the fan cycles on and off 2 Enter a duration in seconds or number of cycles for the fan in the box below the test type selection 3 Click Start to begin the test Stop ends the test before it times out 4 Click Reset Printer as it is a good practice to reset the printer before returning to card production...

Page 104: ... of the printer Magnetic Stripe Module Test This test picks a card and continuously cycles it back and forth between the magnetic stripe sensor and the input sensor Printhead Cam Test The printhead cam continually cycles between elevated and retracted until you click Stop 2 Enter the number of cycles to perform in the Cycle duration box 3 Click Start to begin the test Stop ends the test before it ...

Page 105: ...lly or as a procedure of successive routines Buttons that are appropriate for the printer model are selectable the others are grayed out To run a single routine click on its name button To create a procedure check the appropriate boxes of routines to indicate the steps and then click on Run checked steps It is very important that you use the Reset printer button every time you have completed a tes...

Page 106: ...Read only mode Select Read only mode to read back data from a previously encoded card This is available only with the Advanced User login Track 1 Track 2 and Track 3 Enter encoding data into the three track data boxes These boxes will also contain read back information Use sample data Select Use sample data to fill in the track data boxes automatically some formats do not have sample data Checking...

Page 107: ... how far the card travels to ensure that trailing clock pulses are encoded for the entire length of the card Retries This setting indicates how many times the card is re read in the event of a read back error Note that during a retry the card is read in both the forward and reverse direction regardless of the mode set in read back mode Read back mode This setting determines the direction the card ...

Page 108: ...edia and result in periodic errors Encoding a HICO card with a LOCO setting may result in non encoded cards which will result in more frequent read back errors Custom track formats The options on the right side of the screen open a separate dialog box for customizing the magnetic stripe formatting Refer to Configuring Custom Track Formats on page 5 25 ...

Page 109: ...formation about magnetic data formats is located in the Theory of Operation chapter of this manual Procedure 1 Start with an existing data standard by selecting IATA ABA TTS etc at the top of the dialog box and clicking Load presets or by clicking on Load current to start with the settings now used in the printer 2 Modify the settings as required using the boxes at the left 3 Click on Apply to sen...

Page 110: ...to perform and click on the Run Checked Steps button If you want to use a test that picks a card and passes it through the magnetic stripe area multiple times enter the number of times in the Number of cycles box and click Start Click on Start in the Mag stripe encoder test to cause the transport motor to turn for about half a second and report the number of encoder interrupts in the display box ...

Page 111: ...position is set to front When back is selected the card needs to be loaded with the contacts facing down and the duplex module only on selected model printers flips the card over Graphics and Mag stripe options Select the personalization options that should be used when making a smart card test card Text will be printed on the card for all options except None and Mag stripe back Number of copies S...

Page 112: ...he Smart Card menu select Test Card When the test card window first opens the Diagnostics software will poll the computer to identify all smart card readers This will take a few seconds 4 From the Reader type list select the card reader that Diagnostics should use 5 Select Smart card front from the smart card choices If you select Smart card back the card must be loaded with the contacts on the bo...

Page 113: ...network administrator for the proper settings The MAC Address is a unique identifier for the physical printer The first 6 digits of the MAC address are assigned to Datacard and cannot be changed The remaining 6 digits are assigned to each individual printer The MAC Address shown on the LCD display should match the address printed on the chassis Adjustment Procedure 1 Simultaneously press the Up an...

Page 114: ...IP Address and a Static IP Address use the Up or Down arrow to select the protocol and press the Enter Key To apply the changes press the Enter key again If DHCP is selected the printer will reboot when Apply Restart is selected If DHCP is selected the IP Addresses submenu will no longer be visible If Static IP is selected you will automatically be brought into the IP Addresses submenu before the ...

Page 115: ...he address to change and press the Enter key B Use the Up or Down arrow to change the value in each field and press the Enter key to move the cursor to the next field 6 To change the MAC Address The MAC Address should match the sticker on the printer chassis A Use the Up or Down arrows to scroll to the MAC Address Menu and press the Enter key When the Change Value option appears press the Enter ke...

Page 116: ...the value use the Up or Down arrows to change the hexadecimal value in each field and press the Enter key to move to the next field C After the value has been changed press the Enter key to apply the settings and reboot the printer ...

Page 117: ...e serial number listed in the script file corresponds to the serial number printed on the side of the printer s transport Use your own laptop or PC to complete this procedure Do not perform this procedure on the customer s PC When the printer is first connected without a serial number it will create a duplicate instance of the driver with a Null serial number Even if the Null instance is deleted s...

Page 118: ...ne is not deleted the script will halt on error and you will have to step through the remaining lines of the script manually 2 Resave the file 3 Connect the printer to the computer and start Diagnostics 4 From the Printer menu select Values 5 Click on the Load Script button and select the configuration file Before running the script verify that the appropriate edits have been made to the file A Cl...

Page 119: ...c Stripe menu and select Configuration 3 Click Calibrate MS Head The system will pick the card pass the card through the magnetic stripe 10 times and then eject the card Note that this card will be blank all zeros and will not display data if read in a card reader However it can be developed with magnetic developing solution The values 292 290 and 292 will always be displayed after the calibration...

Page 120: ... of the card to the black outline printed on the card B If the distance is greater than 0 100 inch decrease the offset C If the distance is less than 0 100 inch increase the offset Note that the trailing edge of the test card may have a smaller distance than the leading edge This is unrelated to this adjustment that is do not attempt to center the image 4 If no changes were made to the registratio...

Page 121: ...her white or gray the gray card is shown below 2 After printing remove the print ribbon and examine the yellow panel some ribbon types will not have an index mark as shown in the graphic below A Locate the first printed circle in the panel The image will be faint but should be visible if the ribbon is held up to the light This circle is where the red circle is printed on the card B If the circle i...

Page 122: ... following are true If Datacard has provided you with a flash update file that is specifically engineered for a customer If Datacard has provided you with a flash update file that is newer than the firmware utility in the printer driver Update the firmware using Diagnostics if an fls file is used After selecting the fls file the rest of the procedure is automated Using Diagnostics Procedure 1 Star...

Page 123: ...ues window 4 Examine the physical position of the duplex calibration pointer The proper location of the pointer is at the letter E on the duplex chassis If the pointer is right of the E add the number of units to the current setting each letter represents 2 units because every other letter is shown If the pointer is left of the E subtract the number of units from the current setting 5 Verify the s...

Page 124: ...5 40 Adjustments ...

Page 125: ...y ____________________________________________________________ 6 13 Printhead Fan _______________________________________________________________________6 14 Printhead Spring _____________________________________________________________________6 15 Sensors ________________________________________________________________________ 6 16 Card Input Sensor Without Clear Card ____________________________...

Page 126: ..._______________________________________6 59 RFID Antenna________________________________________________________________________6 60 Duplex Module_________________________________________________________________ 6 61 Duplex Entry Sensor __________________________________________________________________6 63 Duplex Home Sensor Without Clear Card ____________________________________________6 65 Duple...

Page 127: ...charge sensitive components ESD procedures should be used This symbol indicates a spring hazard Safety glasses should be worn when completing the procedure Graphic callouts with a colored background provide incidental information about the graphic itself Graphic leaders with a colored background indicate a direction of movement or similar information Required Tools T10 Torx driver Slotted screwdri...

Page 128: ...6 4 Removal and Replacement Front Wire Routing ...

Page 129: ...CP60 and CP60 Plus Service Manual 6 5 Duplex and Printhead Wire Routing ...

Page 130: ...6 6 Removal and Replacement Functional Block Diagram ...

Page 131: ...er Removal Procedure 1 Place your fingertips under the back of the cover and pull back to release the retaining tab 2 Push the cover toward the swingarm latch and then rotate it upward to release the forward retaining tab 3 Pull the cover back and lift it off the swingarm ...

Page 132: ...enclosure Work back and forth as necessary until all six locking tabs are free Note that there are alignment tabs inside the enclosure Do not pull out too far or these will break 6 With the swing arm closed but not latched lift the enclosure off the base If the swingarm is open the rear of the enclosure will not clear the swingarm Once this is clear you can open the swingarm There is a small proje...

Page 133: ...Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure p 6 8 4 Press in on the transport chassis locking tabs and lift up on the back of the transport assembly 5 If the printer is equipped with an LCD display in the hopper disconnect the cable from the main control board ...

Page 134: ...6 10 Removal and Replacement 6 Simultaneously pull back on the transport chassis and forward on the card hopper Remove the hopper from the chassis ...

Page 135: ...n the lower card hopper Removal Procedure 1 Unplug the printer 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure p 6 8 4 Press in on the transport chassis locking tabs and lift up on the back of the transport assembly 5 Disconnect the LCD cable connector from the main control board ...

Page 136: ... from the hopper A Reach in from the back of the hopper and press down on the retaining tab B Lift the LCD away from the retaining tab C Tilt the LCD inward over the top of the retaining tab Note When pressing against the front of the LCD display try to avoid pushing directly on the face of the liquid crystal 8 Remove the cable from between the hopper walls ...

Page 137: ...l If the swingarm needs to be fully removed from the printer it will be necessary to remove the printhead cable A Remove the Transport Assembly from the base p 6 29 B Disconnect the printhead power and data cable connectors from the main control board C Disconnect the printhead fan connector from the main control board D Pull the cables back through the cable guides in the transport chassis 5 Unhi...

Page 138: ...nplug the printer 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure including the swingarm cover p 6 8 4 Unplug the fan from the main control board 5 To remove the thick fan press in on the two retaining tabs and lift the fan out from the top of the swingarm right hand image below Do not attempt to remove the thick fan using the thin fan procedure The retaining tab will...

Page 139: ...inter 2 Remove the ribbon cartridge and cleaning roller 3 Press in on the printhead release lever and remove the printhead 4 Pull up firmly on the printhead spring to unhook it from the retaining pin on the swingarm latch 5 Remove the other end of the spring from the printhead release lever ...

Page 140: ... any further is it okay to pull the sensor out with the wires 6 Unplug the connector from the main control board Replacement Notes When pushing the sensor back into position use a blunt tool and push only on the top tab bottom tab or the center of the body Do not push against the wire entry points or crush the wires Make sure the sensor is fully seated The tip of the sensor should be flush with th...

Page 141: ... the main control board Replacement Notes When pushing the sensor back into position use a blunt tool and push only on the center of the body Do not push against the wire entry points or crush the wires Make sure the sensor is fully seated The tip of the sensor should be flush with the edge of the chassis Refer to the Front Wire Routing and Functional Block Diagram for replacement details Use Diag...

Page 142: ...hassis Do not push against the tip of the sensor arm It may break Only when the sensor cannot be pushed out any further is it okay to pull the sensor out with the wires 5 Unplug the connector from the main control board Replacement Notes Make sure the sensor is fully seated The edge of the sensor arm should be against the edge of the chassis Refer to the Front Wire Routing and Functional Block Dia...

Page 143: ...o free the sensor from the retaining pin B Continue to pull the sensor out of the chassis by grasping the sides of the circuit board 5 Disconnect the sensor cable connector from the sensor s circuit board Replacement Notes When replacing the sensor do not push against the cable connector the solder leads will bend Push against the corners of the circuit board Use the sensor display in Diagnostics ...

Page 144: ...Ribbon Guide p 6 42 5 Unplug the sensor from the main control board 6 Pull the sensor off the mounting post on the ribbon guide Pry underneath with a screwdriver if necessary Replacement Notes Route the cable through the ribbon guide as shown below Refer to the Front Wire Routing and Functional Block Diagram for replacement details Use the sensor display in Diagnostics to verify the sensor changes...

Page 145: ...ove the sensor A Place a screwdriver into the removal access slot and push the sensor out B Only when the sensor is partially removed loose is it acceptable to push against the sensor arm or pull with the wires C Disconnect the sensor cable connector from the main control board Replacement Notes Make sure the sensor is fully seated The edge of the sensor arm should be against the edge of the chass...

Page 146: ...er it will have no affect on the printer or error messages from the driver The sensor can be utilized only after a programmer has done custom development to incorporate it Removal Procedure 1 Unplug the printer 2 Remove the Main Enclosure p 6 8 3 Unplug the Hopper Empty sensor from the J40 connector labeled Spare The plug is located below the CAM Motor 4 Pull the wire free from the printer 5 Uncli...

Page 147: ...not already disconnected from the main control board unplug it 6 Using the T10 Torx driver remove the two screws that hold the transport motor During replacement tighten the screws to 8 in lbs Caution Do not force the motor against the platen roller Doing so causes print artifacts Follow up Procedure Refer to the Functional Block Diagram for replacement details Use the motor tests in Diagnostics t...

Page 148: ...ing roller 3 Remove the Main Enclosure p 6 8 4 Unplug the wires from the motor 5 To access the motor mounting screws it is necessary to remove the Card Hopper p 6 9 A Unsnap the rear transport feet from the base B Slide the transport chassis back and simultaneously pull forward on the card hopper Remove the card hopper ...

Page 149: ...port chassis 2 While positioning the pick motor rotate the pick roller until the shaft flat lines up with the flat on the roller 3 Tighten the mounting screws to 8 in lbs 4 Reconnect the wires to the motor The motor will turn backward if the wires are reversed 5 Continue reassembling the printer 6 Run the Pick and Eject Card Test in Diagnostics to verify that the motor is functioning properly ...

Page 150: ... the motor gear until the mounting screws are accessible through the slots 6 Loosen the two mounting screws and lift the motor out of the chassis Unless necessary don t remove the screws as they can be difficult to replace Follow up Procedure Tighten the mounting screws to 8 in lbs Refer to the Functional Block Diagram for replacement details Run the Printhead Cam Test in Diagnostics to verify tha...

Page 151: ...on cartridge and cleaning roller 3 Remove the Main Enclosure p 6 8 4 Unhinge the swingarm by pulling back on the hinge tab 5 Using pliers pull the gear off the motor shaft During replacement make sure to line up the shaft flats 6 Remove the two screws that secure the motor to the transport chassis and remove the motor ...

Page 152: ...e wires as shown below Make sure the wires are not routed under the motor Refer to the Front Wire Routing and Functional Block Diagram for replacement details Run the ribbon motor test in Diagnostics to verify the motor is functioning Print several test cards to verify the motor operates under a load ...

Page 153: ...re to access a component you may want to consider disconnecting only those cables necessary to turn the transport on its side This reduces the number of connectors needed to be re connected on the control board Removal Procedure 1 Unplug the printer 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure p 6 8 4 Press in on the transport chassis locking tabs and lift up on th...

Page 154: ...s and forward on the card hopper The hopper can be left attached or removed B When the tabs on the chassis are clear of the openings lift the chassis and control board out of the base 6 If present pull back on the duplex assembly and lift it off the transport chassis 7 Disconnect all cable connectors from the main control board ...

Page 155: ...printer up at an angle and continue to make connections A Smart card contact ribbon cable B Smart card solenoid C Printhead data D Printhead cam sensor 3 Set the printer on top of the control board and make the last connections A Transport motor B Printhead fan C Pick Ribbon motors D Cam motor E Ribbon index sensor F Ribbon motion G Card input sensor H Swingarm up sensor I LCD display 4 With the c...

Page 156: ...rinter Values 1 With the printer powered and connected to a computer start Diagnostics and log in as an Advanced User 2 From the Printer menu select Values 3 Click on the Save as button Name the file with a unique name using the printer serial number and current date for example F50123 01 31 04 txt 4 Exit from Diagnostics but leave the printer running ...

Page 157: ...Procedure 1 Unplug the printer 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure p 6 8 4 Remove the Transport Assembly from the base p 6 29 5 Disconnect all cables from the control board 6 Lift the board out of the base 7 If the printer is equipped with the magnetic stripe option remove the Magnetic Stripe Circuit Board p 6 75 from the main control board 8 If the printe...

Page 158: ...assemble the printer Restore the Printer Values 1 Using Notepad open the original configuration script you saved in step 3 on page 6 32 2 Locate the entry Ribbon Type xx and delete the whole line 3 Resave the file 4 Plug the printer in turn it on and open the Diagnostic software 5 From the Printer menu select Configuration Script 6 Click on the Load Configuration Script button and select the confi...

Page 159: ...press the Enter key to access the menu 3 Update the settings The image below shows the MAC Address screen as an example A Press the Up or Down arrow to locate each setting and press the Enter key one or more times to access the Change Value screen B To change the value press the Up or Down arrow to increment or decrement the existing value in each field C Press the Enter key to move the cursor to ...

Page 160: ...move the Main Enclosure p 6 8 4 Release the belt tension and remove the transport belt Replacement Notes Follow the belt routing shown below If the printer is not equipped with the duplex option the drive pulley and idler pulley shown at the left will not be present Print a couple of test cards to verify that the printer is functioning properly ...

Page 161: ... 1 Unplug the printer 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure p 6 8 4 Release the belt tension and remove the transport belt 5 Lift the release tab and slide the tensioner down as far as it will go and remove the spring 6 Pull the idler pulley off the tensioner ...

Page 162: ...y pulling them off their studs 5 Remove the drive pulleys from their shafts by squeezing the end of the shaft and slipping the pulley off The pulley s flange is permanently adhered to the pulley Do not try to remove the flange Replacement Notes After slipping the pulley onto the shaft rotate it until the square key slips into the square keyway Print several test cards to ensure there are no transp...

Page 163: ...replace the springs as well Removal Procedure 1 Unplug the printer 2 Remove the ribbon cartridge and cleaning roller 3 Push the rocker mount one direction and the rocker arm the other direction and pull up and out Be careful not to lose the springs Rocker Arm Assembly Rocker Arm Mount Spring 2x Sp35726s Front of Printer ...

Page 164: ...lug the printer 2 Remove the ribbon cartridge and cleaning roller 3 Push the rocker assembly one direction and the rocker mounting tab in the opposite direction and pull up on the rocker Be careful not to lose the springs Replacement Note Make sure the springs are seated in the pockets of the transport chassis and on the alignment pins of the rocker assembly ...

Page 165: ...ipe Rocker Assembly refer to page 6 80 When replacing the rocker assembly it is a good idea to replace the springs as well Removal Procedure 1 Unplug the printer 2 Remove the ribbon cartridge 3 Push the rocker assembly one direction and the rocker mounting tab in the opposite direction and pull up on the rocker Be careful not to lose the springs ...

Page 166: ...s sidewalls A Simultaneously grasp the left and right sides of the ribbon guide with both hands B Flex the transport chassis sidewalls outward with the sides of your fists This releases the small locking nibs on the ends of the ribbon guide see inset photo below C Slowly lift the ribbon guide straight up 3 If necessary remove the index sensor from the ribbon guide by lifting it off the mounting po...

Page 167: ...ent Notes Route the cable through the ribbon guide as shown below Refer to the Front Wire Routing and Functional Block Diagram for replacement details Use the sensor display in Diagnostics to verify the sensor changes state as the ribbon is advanced ...

Page 168: ...ning roller 3 Remove the Main Enclosure p 6 8 4 To access the pick motor mounting screws remove the card hopper A Press in on the transport chassis locking tabs and lift up on the back of the transport assembly B Slide the transport chassis back and simultaneously pull forward on the card hopper Remove the card hopper ...

Page 169: ...ment Procedure 1 Place the pick roller in the transport chassis 2 While positioning the pick motor rotate the pick roller until the shaft flat lines up with the flat on the roller 3 Tighten the mounting screws to 8 in lbs 4 Continue reassembling the printer 5 Run the Pick and Eject Card Test in Diagnostics to verify that the motor is functioning properly ...

Page 170: ...aning roller 3 Remove the Main Enclosure and card hopper p 6 8 4 Remove the Transport Timing Belt p 6 36 5 Remove the cleaning rocker assembly 6 Remove the pulley from the shaft by squeezing the end of the shaft and slipping the pulley off The pulley s flange is permanently adhered to the pulley Do not try to remove the flange ...

Page 171: ...CP60 and CP60 Plus Service Manual 6 47 7 Remove the drive roller A Lift the pulley end of the shaft up B Slide the shaft out the side C Lift the opposite end of the shaft and remove the roller ...

Page 172: ...4 Lift the Ribbon Guide p 6 42 out and set it aside 5 Remove the Front Rocker Assembly p 6 40 6 Remove the Front Card Guide p 6 56 7 Release the belt tension and remove the transport belt 8 Remove the pulley from the shaft by squeezing the end of the shaft and slipping the pulley off The pulley s flange is permanently adhered to the pulley Do not try to remove the flange ...

Page 173: ... Manual 6 49 9 Lift the pulley end of the shaft slide it out until the roller touches the sidewall and lift the other end out of the chassis Follow up Procedure Print several test cards to ensure there are no transport problems ...

Page 174: ... the configuration of the printer remove either the Rear Rocker Assembly p 6 41 or the Magnetic Stripe Rocker Assembly p 6 80 5 If present partially remove the smart card contact carrier A Insert a screwdriver between the carrier and the left mounting tab B Twist the blade to pry the carrier out of the mounting tab C It is not necessary to fully remove the carrier ...

Page 175: ...educe the chance of the spring flying loose when the guide is removed B Pull up on the card guide 7 Remove the Transport Timing Belt p 6 36 8 Remove the pulley from the shaft by squeezing the end of the shaft and slipping the pulley off The pulley s flange is permanently adhered to the pulley Do not try to remove the flange ...

Page 176: ...lide the shaft out the side It is necessary to deform the roller slightly as it will not fully clear the opening in the bottom of the transport chassis C Lift the opposite end of the shaft and remove the roller Follow up Procedure Print several test cards to ensure there are no transport problems ...

Page 177: ...e knob on the platen roller and lift the roller up and out through the side wall of the transport chassis Replacement Notes If reusing the roller clean the rubber with isopropanol and wipe off the original grease from the shaft Make sure the washer is between the platen roller and the transport chassis Put a thin film of Molykote DX grease Part No 807421 001 on the shaft at the locations shown Pri...

Page 178: ...4 Remove the Transport Assembly from the base p 6 29 5 Rotate the cam until the cam flag is clear of the sensor 6 Using a screwdriver pry the flag side of the cam out of the transport chassis 7 Gently lift the cam out of the chassis taking care not to bind the gears Follow up Procedure Run the Printhead Cam Test in Diagnostics to verify that the motor is functional ...

Page 179: ...osure p 6 8 4 Depending on the configuration of the printer remove either the Rear Rocker Assembly p 6 41 or the Magnetic Stripe Rocker Assembly p 6 80 5 Remove the Platen Roller p 6 53 6 Grasp the rear lever of the lifter and pull up and out of the chassis Follow up Procedure Run the Printhead Cam Test in Diagnostics to verify that the lifters are operating properly ...

Page 180: ...e ribbon cartridge and cleaning roller 3 Remove the Ribbon Guide p 6 42 4 Remove the Front Rocker Assembly p 6 40 5 Remove the front card guide A Remove the bias spring from the card guide This will reduce the chance for the spring flying loose when the guide is removed B Pull up on the card guide ...

Page 181: ...e configuration of the printer remove either the Rear Rocker Assembly p 6 41 or the Magnetic Stripe Rocker Assembly p 6 80 4 If present partially remove the smart card contact carrier A Insert a screwdriver between the carrier and the left mounting tab B Twist the blade to pry the carrier out of the mounting tab C It is not necessary to fully remove the carrier ...

Page 182: ...Removal and Replacement 5 Remove the rear card guide A Remove the bias spring from the card guide This will reduce the chance of the spring flying loose when the guide is removed B Pull up on the card guide ...

Page 183: ...osure p 6 8 4 Remove the Card Hopper p 6 9 5 Remove the Pick Roller p 6 44 6 Peel the static brushes off the chassis surface Replacement Notes Before putting new static brushes on the transport use isopropanol to clean off the old adhesive residue from the chassis Run the Pick and Eject Card Test in Diagnostics to verify that the pick motor is functioning properly ...

Page 184: ...e connector from the bottom of the antenna board 5 With the tip of your finger or a screwdriver pull back slightly on the bottom of the circuit board and lift the board out of the slots Follow up Procedure Make sure the cable is routed through the opening in the chassis side wall Place a ribbon cartridge in the printer and verify that the printer is able to identify the type of ribbon ...

Page 185: ...requisite procedure for many other procedures Removal Procedure 1 Unplug the printer 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure p 6 8 4 Press in on the transport chassis locking tabs and lift up on the back of the transport assembly ...

Page 186: ...6 62 Removal and Replacement 5 Disconnect the interface cable from the duplex interface board 6 Pull back on the duplex assembly and lift it off the transport chassis ...

Page 187: ...nplug the printer 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure p 6 8 4 Disconnect the duplex interface cable from the interface board 5 Remove the Duplex Module p 6 61 from the printer 6 Disconnect the entry sensor connector from the interface board ...

Page 188: ...ry Rocker from the module p 6 68 8 Push the sensor out of the duplex chassis Replacement Notes When pushing the sensor into the duplex chassis do not push against the wires or crush them Print a test card to verify that the duplex is functioning properly ...

Page 189: ...d cleaning roller 3 Remove the Main Enclosure p 6 8 4 Disconnect the sensor connector from the duplex interface board 5 Carefully push the sensor out of the duplex chassis Replacement Notes When pushing the sensor into the duplex chassis do not push against the wires or crush them Print a test card to verify that the duplex is functioning properly ...

Page 190: ...4 Disconnect the sensor connector from the duplex interface board 5 Carefully push the sensor out of the sensor bracket in the duplex chassis Replacement Notes When pushing the sensor into the duplex chassis do not push against the wires or crush them Use Diagnostics to verify that the sensor is working properly Print a test card to verify that the duplex is functioning properly Sensor ...

Page 191: ...he ribbon cartridge and cleaning roller 3 Remove the Main Enclosure p 6 8 4 Disconnect all connectors from the duplex interface board 5 Lift the edge of the board slightly and slide it off the retaining pins Remove the board Follow up Procedure Print several test cards to ensure the duplex is operating properly ...

Page 192: ...d and remove the Duplex Module p 6 61 from the printer 5 Lift one side of the entry rocker off its pivot pin As soon as possible grasp the pressure spring and remove it before it gets loose 6 Repeat the step for the other side and remove the rocker Replacement Note It is easiest to replace the rocker first and add the springs afterward A Insert the spring over the guide pin B Compress the spring a...

Page 193: ...move the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure p 6 8 4 Disconnect the duplex interface cable from the interface board 5 Remove the Duplex Module p 6 61 from the printer 6 Disconnect the motor connector from the interface board 7 Free up the cable from the retaining tabs ...

Page 194: ...usly press in on the locking tabs and rotate the motor to remove it Replacement Notes When inserting the motor into the duplex chassis make sure the gears mesh properly Print several test cards to verify that the duplex is functioning properly ...

Page 195: ...emoval Procedure 1 Unplug the printer 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure p 6 8 4 Disconnect the duplex interface cable from the interface board 5 Remove the Duplex Module p 6 61 from the printer 6 Remove the duplex motor by simultaneously pressing in on the locking tabs and rotating the motor 7 Disconnect the clutch connector from the clutch ...

Page 196: ...nd until the pivot pin is free from the chassis The stabilizing tab which was previously constrained by the motor will bend as necessary 10 Tilt the flipper assembly up and remove the whole assembly Take care not to break the stabilizing tab Pull it away from the clutch as needed 11 Slide the magnetic clutch off the center pin of the flipper ...

Page 197: ...nd CP60 Plus Service Manual 6 73 12 Squeeze the ends of the spring clutch and pull it off the boss 13 To remove the idler rollers spread the sidewalls of the flipper and pull the roller out one side at a time ...

Page 198: ... the flipper until the spring clutch engages the stop tabs clockwise as viewed from the motor If you rotate the flipper counterclockwise you can feel the drag of the spring clutch but it will not engage the stop tabs When the flipper is rotated clockwise the spring clutch will snap over the stop tabs and will no longer turn in that direction Verify that the clutch is properly engaged When properly...

Page 199: ... encoder cables from the magnetic stripe board 6 Remove the magnetic stripe circuit board from the main control board by lifting the board off all three connectors simultaneously Replacement Notes There is no built in alignment mechanism between the main control board and the daughter board Make sure the connectors between the two boards are aligned properly If not both boards could be damaged Usi...

Page 200: ...sor s cable connector through the opening in the chassis from outside to inside 7 Carefully push down on the sensor from above and remove it through the bottom of the chassis Do not use sharp tools Replacement Notes Make sure the sensor is oriented with the orange wire emitter toward the rear of the printer Be careful not to damage the wires when pushing the sensor into position Make sure the sens...

Page 201: ... reflection off the rocker shaft Removal Procedure 1 Unplug the printer 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure p 6 8 4 Remove the Transport Assembly from the base p 6 29 5 Remove the Magnetic Stripe Rocker Assembly p 6 80 6 Push the sensor s cable connector through the opening in the chassis from outside to inside 7 Carefully push down on the sensor from abov...

Page 202: ...re p 6 8 4 Remove the Transport Assembly from the base p 6 29 5 Unplug the magnetic head from the magnetic stripe board 6 Remove the Magnetic Stripe Rocker Assembly p 6 80 7 Using a spring removal tool small hook pull up on the long pivot arm of the magnetic head 8 Rotate the head so the wires are facing toward the card guide and lower the head through the chassis ...

Page 203: ... Manual 6 79 Replacement Notes The long pin on the head points toward the front of the printer fits only one direction Using the Diagnostics in chapter 5 calibrate the magnetic stripe head as described in Start Sentinel Position ...

Page 204: ... rocker s pivot pin out of the mounting tab on the chassis 5 Rotate the rocker clockwise and remove it through the side of the chassis note that the encoder is pointing straight down during removal Replacement Notes Note that the violet colored wire on the encoder cable is toward the rear of the printer Using the Diagnostics in chapter 5 calibrate the magnetic stripe head as described in Start Sen...

Page 205: ... from the smart card interface board Refer to the Functional Block Diagram p 6 6 for location and details 6 Remove the interface board from the main control board The board needs to be removed straight up to prevent damage to the connector A Squeeze the locking tab on one standoff and lift the board up slightly B Repeat for the other standoff C Gently pry the board off the connector Follow up Proc...

Page 206: ...t slightly from the mounting pocket Do not pry on the release tab any more than is necessary it will break Do not pull the solenoid out too far as this will damage the return spring 5 Unplug the connectors from the solenoid Tip Use a screwdriver to pry the connectors loose and then remove them the rest of the way by hand If the wires need replacement remove the Transport Assembly p 6 29 from the b...

Page 207: ...in place with a pliers Take care not to crush the spring 7 Pull the solenoid out of the mounting pocket 8 To remove the solenoid link rotate it 90 degrees and pull it off the rocker Follow up Procedure Using Diagnostics perform the Smart Card Test Card procedure as described in chapter 5 of this manual ...

Page 208: ...m the base p 6 29 5 Disconnect the interface cable from the smart card interface board Refer to the Functional Block Diagram p 6 6 for location and details 6 Remove the Ribbon Motor p 6 27 7 Remove the Solenoid Link from the rocker p 6 82 8 Remove the smart card contact carrier A Insert a screwdriver between the carrier and the left mounting tab B Twist the blade to pry the carrier out of the moun...

Page 209: ... pry the contact out from along the edge and then a larger screwdriver to pry it out of the carrier Replacement Notes Make sure the contact is fully seated in the carrier Make sure the wires are not routed under the motor Route wire out through the side of the chassis ...

Page 210: ...moval and Replacement Route the wires around the solenoid and connect it to the smart card interface board Using Diagnostics perform the Smart Card Test Card procedure as described in chapter 5 of this manual ...

Page 211: ...pler used but the general procedure remains the same Removal Procedure 1 Unplug the printer 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure p 6 8 4 Remove the Transport Assembly from the base p 6 29 5 Use a screwdriver to press the plastic locking tabs out of the chassis 6 Remove the coupler bracket or plastic cover ...

Page 212: ...ck into the chassis using the four mounting bracket locking tabs Orientation is important for reading the smart card 2 Connect the three connectors Follow Up Procedure Using Diagnostics perform the Smart Card Test Card procedure as described in chapter 5 of this manual ...

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