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2-14

Theory of Operation

Printhead Settings

A printed card is made up of 1013 discrete vertical (short edge of the card)
columns printed across the length of the card. As each column is printed, the
printhead circuitry activates the necessary pixels to transfer pigment from the
ribbon to the card.

Controlling when and how these pixels heat up is determined by several
parameters: power, base power, and strobe.

Power

In the past, printhead pixels were controlled by varying the voltage to the pixel
element. On the newer generation of printheads, the power to the pixel is
controlled by pulsing the voltage, commonly referred to as Pulse Width
Modulation (PWM). This concept is also known as Duty-Cycle.

The heat of a thermal element on the printhead is controlled by how long it is
turned on versus how long it is turned off. In a sense, the printhead 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 compensate when a new
power supply is required.

Base Power

The Base Power sets the upper limit to the power PWM. In simple terms, this sets
the bandwidth (gamut) of the printing. Increasing the base power darkens the
available colors in the printer, but does not impact the lighter colors. Note that
there is an upper threshold after which increasing the base power has little or no
effect on the final printing. At this point, the image is saturated and cannot be
increased in gamut any further. However, note that this is not the same as
darkening the image in the printer driver control panel, which will darken the
whole image, including the lighter areas.

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Summary of Contents for CP80 Plus

Page 1: ...Datacard CP80 and CP80 Plus Card Printers Service Manual May 2007 Part No 539490 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 CP80 is a trademark...

Page 3: ..._________________________2 13 Printhead Settings____________________________________________________________2 14 Magnetic Cards ___________________________________________________________________2 16 Magnetic Data Principles_____________________________________________________2 16 Encoding Format ____________________________________________________________2 21 Magnetic Stripe Primary Data Standard...

Page 4: ..._____________________4 9 Testing the Smart Card Solenoid__________________________________________4 9 Testing the Duplex Clutch_______________________________________________4 10 Diagnosing the Duplex Interface Board__________________________________4 11 Diagnosing the Ribbon RFID Antenna____________________________________4 11 Performance Problems__________________________________________________...

Page 5: ..._______________________5 18 Viewing Printer Status ________________________________________________________5 19 Testing Motors _______________________________________________________________5 20 Testing Motor Functions ______________________________________________________5 21 Setting Up Step Tests for the Printer ____________________________________________5 22 Running a Magnetic Stripe Test Card...

Page 6: ..._____________6 7 Laminator Front Wire Routing Diagram _________________________________________6 8 Laminator Rear Wire Routing Diagram__________________________________________6 9 Power Supply Wire Routing Diagram __________________________________________6 10 Print Engine Cable Connection Diagram ______________________________________6 11 Laminator Cable Connection Diagram________________________...

Page 7: ..._______________________________________________________6 71 Duplex Entry Sensor __________________________________________________________6 73 Duplex Home Sensor _________________________________________________________6 75 Duplex Interface Board_______________________________________________________6 76 Duplex Entry Rocker__________________________________________________________6 77 Duplex Motor...

Page 8: ...________________6 117 Heater Home Sensor ________________________________________________________6 118 Laminator Motors _________________________________________________________________6 120 Card Transport Motor _______________________________________________________6 120 Foil Advance Motors ________________________________________________________6 122 Heater Lift Motors __________________________...

Page 9: ...art 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 users at their own expense will be required to take whatever measures are necessary to correct the problem Notice for Canada This digital apparatus does not excee...

Page 10: ...ed 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 ran...

Page 11: ...ard CP80 and CP80 Plus card printers and how they function Intended Audience______________________________________________________________ 1 2 Avoiding Electrostatic Discharge _________________________________________________ 1 2 Symbol Conventions_____________________________________________________________ 1 3 ...

Page 12: ...ic 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 enough...

Page 13: ...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 14: ...1 4 Introduction ...

Page 15: ...__________________________________2 10 Default Card Printing Sequence ______________________________________________________2 10 Lamination Process __________________________________________________________________2 12 Graphics Printing _______________________________________________________________ 2 13 Printhead Settings ___________________________________________________________________2 14 Mag...

Page 16: ...ct Smart Cards____________________________________________________________2 33 Types of Cards ___________________________________________________________________2 33 Communication _________________________________________________________________2 34 Signal Modulation ________________________________________________________________2 34 Signal Modulation Summary Diagram _____________________________...

Page 17: ...CP80 and CP80 Plus Service Manual 2 3 Print Engine Functional Block Diagram ...

Page 18: ...2 4 Theory of Operation Laminator Functional Block Diagram ...

Page 19: ... The sensor itself detects when the swingarm is closed but the signal is inverted elsewhere in the system Ribbon Index The ribbon index sensor is used to determine the position of the print ribbon panels The sensor bounces a beam off the reflective sticker on the printhead When the index mark or K panel on the ribbon passes between the sensor and the reflector the beam is broken not reflected The ...

Page 20: ...e in one direction only The duplex step motor operates at 24 volts but the transport step motor operates at 40 volts Name Function Pick Motor The pick motor drives the pick roller to bring a card into the system The motor is wired for unidirectional operation and cannot be reversed by the control board One wire is connected to ground and the other wire is the control This motor is driven by a sing...

Page 21: ...r assembly 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 see page 2 33 using load modulation although the specific details may vary Duplex Interfa...

Page 22: ...2 8 Theory of Operation LCD Service Mode Menu Diagram ...

Page 23: ...at detects index marks on the supply spool It also detects a smart card cutout if present in the foil Heater Home Each heated roller assembly has a heater home sensor This interruption sensor detects a flag on the heater lift cam to determine the vertical position of the heated roller Thermocouple Each heated roller has a thermocouple for determining temperature A thermocouple is made from two dis...

Page 24: ...tor 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 Printing 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 the leading...

Page 25: ...he 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 the card into the module C The clutch is engaged and the motor rotates the flipper to the return position D The c...

Page 26: ...ition 5 The foil and transport motors are activated and the laminate is applied to the card 6 When the length of the card has been laminated the roller is lifted to the home position 7 The transport continues to move the card a short distance past the heated roller 8 The foil motor increases speed and advances slightly to strip the foil from the card 9 If debow is enabled the card is moved back to...

Page 27: ... transfer 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 ...

Page 28: ...ontrol 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 compen...

Page 29: ...rature 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 fo...

Page 30: ...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 31: ...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 32: ...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 33: ... to 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 nort...

Page 34: ...are 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 ...

Page 35: ...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 36: ...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 37: ...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 38: ... 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 39: ...of times This is to ensure that the beginning and end of the record has been detected Number of Nulls Between duplicate data records empty non recorded space is permitted 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 stripe cards and identifies two distinct card forma...

Page 40: ...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 41: ... Manual 2 27 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 42: ...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 43: ...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 44: ...5 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 various device manufacturers S E F Reserved characters for Start Sentinel End Sentinel and Field Separator ...

Page 45: ...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 46: ...ommunication 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 li...

Page 47: ... dwindled as designs were standardized The same is true with smart card technology except many off standard card types still exist The primary information in this section is geared toward the ISO IEC 14443 Type A and Type B cards However recognition should be given to a few other formats that are still widely used The photograph on page 2 31 shows a combicard with both a 125 kHz antenna and the st...

Page 48: ...the signal An audio signal for example would require an antenna of approximately 300 Km in length This wouldn t fit very well in the trunk of your car for listening to your favorite music and a portable radio would be totally out of the question Instead the lower frequency the data signal is combined with a higher frequency the carrier The higher frequency is more easily transmitted and received C...

Page 49: ...y remains 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 swit...

Page 50: ... Communication The communication method back to the reader is elegantly simple but a little more complicated to understand It is a passive communication because the card doesn t really send a signal back to the reader it modifies the signal emanating from the reader This is called Load Modulation and is based on a loosely coupled transformer two coils separated by distance and without an iron core...

Page 51: ...wer than this 1 128th of the carrier frequency so each data bit will have several transitions from modulation to non modulation of the carrier Type B Card Modulation A Type B card uses a combination of amplitude modulation and phase modulation called Binary Phase Shift Keying BPSK This method sends a constant subcarrier frequency of 847 kHz using amplitude modulation but shifts the phase of the su...

Page 52: ...2 38 Theory of Operation ...

Page 53: ...lean the Interior of the Printer ________________________________________________________3 3 Mechanical Inspection________________________________________________________________3 5 Laminator Routine Maintenance Procedure _______________________________________ 3 8 Clean the Interior of the Laminator_____________________________________________________3 8 Mechanical Inspection_____________________...

Page 54: ...inter Cleaning Card isopropanol 552141 001 Laminator Cleaning Card sticky card 558436 001 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 t...

Page 55: ...any electrical 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...

Page 56: ...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 57: ... 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 58: ...ssette has a plastic encoder wheel inspect it for scratches and missing lines Check the spindles for proper movement and to be sure 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 59: ...CP80 and CP80 Plus Service Manual 3 7 9 Inspect all sensors to make sure they are properly seated in their mounting locations 10 Continue with the Laminator Routine Maintenance Procedures listed below ...

Page 60: ...f the Laminator 1 Unplug the printer 2 Remove the printer enclosures 3 Remove the printer from the laminator 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 5 If the grease on the platen roller shafts has accumulated dirt and debris wipe off the ...

Page 61: ...Inspect the spindle and capstan drive gears for wear and missing teeth Inspect the encoder wheel for missing teeth Check the spindles for proper movement and to be sure the clutches are providing a slight drag Inspect the foil path for nicks or burrs that could damage the foil 5 Reassemble the printer 6 Wipe the exterior of the printer with a cloth dampened with a non abrasive general purpose clea...

Page 62: ...just below the static brush A The printer will pull the card into the laminator B When the cleaning is complete you may have to manually pull the card from the exit roller 5 Load the isopropyl cleaning card in the input hopper 6 Open the Printer Toolbox Dialog and click on Clean Printer 7 If additional cleaning is required wipe the rollers with the isopropanol cleaning pen or 99 isopropanol 8 Put ...

Page 63: ..._____________________________________4 10 Diagnosing the Duplex Interface Board____________________________________________4 11 Diagnosing the Ribbon RFID Antenna______________________________________________4 11 Performance Problems__________________________________________________________ 4 12 Printer Initialization Errors______________________________________________________________4 12 Card Ja...

Page 64: ..._______________4 25 Laminator Errors OP _________________________________________________________________4 30 Print Errors PR _______________________________________________________________________4 34 Smart Card Errors SC ________________________________________________________________4 36 ...

Page 65: ...shooting the system such as print quality and software communication problems To open Info Central click on the icon installed to the desktop when the SmartDriver was installed on the computer If Info Central was not installed insert the printer driver CD click on User Information and then CP Series Info Central and e Guide to install it ...

Page 66: ...ys 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 not allow it to begin production clearing the error message may result in the printer continuing to test for the same error condition This will result in a repetitive error message that prevents the customer engineer fro...

Page 67: ...on cartridge and open and close the swingarm Also verify that the reflector is in position on the printhead To test the magnetic stripe registration sensor slide a card between the sensor and the reflector on the rocker arm Because the ribbon motion sensor has two channels the only way to verify that both channels are functioning is with a voltmeter Use the test points in the figure below to test ...

Page 68: ...unblock 4 If the replacement sensor functions then the original sensor is defective Verify this by reconnecting the original sensor 5 If the replacement sensor is non functional and other sensors in the printer are observed to be functional then the main control board is defective If none of the sensors are functional you may have a communication problem between the printer and Diagnostics ...

Page 69: ...it 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 ...

Page 70: ...th 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 receive a rep...

Page 71: ...is limited due to the cable lengths of the wires The best solution for testing a motor in the laminator section is to connect a spare motor from parts inventory Except for limitations in cable length the two heater lift motors are interchangeable and the two foil transport motors are interchangeable However it is important to note that the main transport motor is not interchangeable with any other...

Page 72: ...pper 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 as described on page 4 4 when the printer is powered up 3 In Diagnostics set the motor test durat...

Page 73: ...o if a sensor 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 ant...

Page 74: ...ated 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 the sensor ...

Page 75: ...excessive debris Check to see if the transport is working Inspect the cleaning rocker assembly springs to make sure they are tensioning the rocker assembly Check for double card pick A card is picked and appears 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 t...

Page 76: ... 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 stops past t...

Page 77: ...o 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 not too dark On an edge to edge image when the leading edge of the image uses 100 of a color Y M or C the ribbon may get burned if the card is not ...

Page 78: ...heater and thermocouple wires are not so tight that the heater is not able to rock side to side Verify that the heater slide is free to move on both sides Make sure the whole heater assembly is installed properly Patch material is extending past the leading edge of the cards Either the card did not move as far as expected or the patch material moved farther than expected It is best to look for mec...

Page 79: ... Registration and or Foil Advance offsets Inspect the laminate cartridge for any problems that would cause the laminate slip against the capstan roller Inspect the capstan and spindle drive gears for missing teeth Inspect the capstan roller for wear or build up of debris Make sure the backup roller loading spring is in place and not distorted applying pressure to the capstan roller Make sure the l...

Page 80: ... For errors considered to be routine the solution presented is based on the assumption that the error is repetitive 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 ne...

Page 81: ... the Datacard printer Select the CP80 or CP80 Plus printer AP 00809 Internal printer driver API error Contact the print application developer AP 00810 The application used a Datacard printer function 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 T...

Page 82: ...uch as Defective port Defective main control board and its connections Wrong printer or communication parameters are set DR 00906 Printer driver error Click Help for more information Perform hard drive maintenance DR 00907 The printer driver cannot access the required PC resources Click Help for more information The print processor has an error opening or reading the temporary files Make sure the ...

Page 83: ...her applications a Close all applications you are not using The card creation application and the printer driver are the only 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 ...

Page 84: ...n place and working correctly Check the transport belt and pulleys for damage Check the belt tensioner to make sure it is putting tension on the transport timing belt Check the rocker arm springs to make sure they are placed correctly and not damaged Test the card input sensor to see if it toggles Test the pick motor functions Test the transport motor functions Duplex Module Errors DM Error Code S...

Page 85: ...e sensor transitions were not detected Check the flipper for obstructions Check if the clutch is functioning Check if the sensor is functioning Check the duplex motor DM 00770 The card is lost in the lower duplex unit ERR_OPT1_DUPLEX_LOST The duplex exit sensor was not blocked when expected Check the sensor Check the duplex motor System Errors SY Error Code Symptom Comments SY 01305 The setting se...

Page 86: ...SY 01325 The options or supplies installed do not match settings or card data ERR_SYS_SEQ_STR A color card job was sent to the printer but the ribbon is monochrome If the ribbon is not monochrome Check the RFID antenna Check the supplies ID by swapping with another ribbon SY 01327 The request sent to the printer is not supported ERR_SYS_UNIMPLEMENTED SY 01331 Data transmission error ERR_SYS_COMM P...

Page 87: ...ack 1 2 or 3 MS_T1_PAR_ERR MS_T2_PAR_ERR MS_T3_PAR_ERR If this occurs frequently Run a cleaning card Try different card stock Check the printer s coercivity setting to make sure it matches the card stock being used Run the Calibrate MS Head in Diagnostics Check the magnetic stripe head Check the magnetic stripe optical encoder Check the magnetic stripe daughter board MS 01407 MS 01408 MS 01409 LRC...

Page 88: ...ock Check the printer s coercivity setting to make sure it matches the cards being used Run the Calibrate MS Head in Diagnostics Verify that the data does not extend past the end of the card Check the magnetic stripe head Check the magnetic stripe optical encoder Check the magnetic stripe daughter board MS 01417 A card jam occurred when attempting to write magnetic stripe data on the card MS_MOVE1...

Page 89: ...nsor transitions are observed in Diagnostics the control board needs to be replaced MS 01419 A card was lost outside of the magnetic stripe area when attempting to read data encoded on the card MS_MOVE3_ERR The card was not returned from the rear of the printer or the card has been read but did not reach the input sensor The read cycle is not complete until the card is passed off to the input sens...

Page 90: ...d Check the magnetic stripe mechanical assembly Possible failed components are the magnetic stripe head the cable assembly the magnetic stripe encoder cable assembly the magnetic stripe control board and the main control board MS 01425 Unexpected magnetic stripe coercivity value MS_CURRENT_ERR The coercivity value stored in the printer is out of range This should not happen and indicates a possibl...

Page 91: ...application is sending the correct data Verify printer driver is loaded and configured correctly Check data cable connection between PC and printer MS 01431 Magnetic stripe module settings EEPROM read error MS_OPS_READ_ERR Try the operation again Reboot the computer and printer If the error continues replace the main control board MS 01432 Magnetic stripe module settings EEPROM read error MS_FAC_R...

Page 92: ...ble Make sure it is plugged in to the board and both ends of the heater Use Diagnostics to see what heater temperature is being reported If the heater is hot but the reported temperature is low then the thermocouple is bad If the heater is not heating check replace the heater OP 01611 The heated roller is not ready in the L1 laminator ERR_OPT1_ROLLER_POSITION Inspect the heater lift motor and gear...

Page 93: ...nator ERR_OPT1_EE_READ Power cycle the printer If the problem continues replace the laminator control board OP 01619 The L1 laminator is unable to communicate with the printer ERR_OPT1_COMM_ERROR The serial communication between the printer and laminator is not working Inspect the serial interface cable OP 01620 Please wait while the laminator reaches temperature ERR_PRN_WARMUP This is normal but ...

Page 94: ...e problem in the L2 laminator ERR_OPT2_THERMO_FAILURE Check the thermocouple wire for damage If the thermocouple was recently replaced verify that it is not installed backward Verify that the thermocouple connector is not unplugged or plugged in backward OP 01655 Heater problem in the L2 laminator ERR_OPT2_HEATER_FAILURE The heater temperature is not what is expected Inspect the heater cable Make ...

Page 95: ...supply cassette for damage to the encoder wheel Check the function of the encoder sensor When less than 10 of the supply remains a broken ribbon will be reported as out of supply OP 01669 The L2 laminator is unable to communicate with the printer ERR_OPT2_COMM_ERROR The serial communication between the printer and laminator is not working Inspect the serial interface cable OP 01671 Supply material...

Page 96: ...eck the main control board assembly Possible failed components are the printhead the cable and the main control board 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 ...

Page 97: ...pping YMC K T power Check the swingarm assembly it may not be secure or may be 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 P...

Page 98: ...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 99: ...ort Speed__________________________________________________________________5 14 YMC K T F Strobe Duty ________________________________________________________5 14 YMC K T and F Power and Base Power ___________________________________________5 15 Duplex Infeed Offset _____________________________________________________________5 15 Duplex Home Offset_________________________________________________...

Page 100: ..._______________________________________________5 38 Duplex Debow Offset_____________________________________________________________5 38 Duplex Horizontal Infeed Offset ___________________________________________________5 38 Duplex Vertical Infeed Offset _____________________________________________________5 38 MFG Card Registration Baseline ___________________________________________________5 39 ...

Page 101: ...ure change in temperature this manual will adhere to standard notation Absolute temperatures are indicated by C degrees Celsius and a change in temperature is indicated by C Celsius degrees For example 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 mult...

Page 102: ...stalled on the computer Diagnostics will not run without the print driver Procedure 1 Insert the printer driver CD into your CD drive The CD should run automatically and display the following window If the CD does not auto start run the setup exe file from the CD When running click the Printer Support button ...

Page 103: ... begin the 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 104: ...ble 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 printer s se...

Page 105: ...ter when exiting 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 cha...

Page 106: ...ser It is for configuring Start Sentinels etc as described in Configuring the Magnetic Stripe Magnetic Stripe Diagnostics This option provides access to functions for troubleshooting the magnetic stripe module Smart Card Test Card The smart card test is a built in routine to simulate smart card personalization A card is picked from the hopper personalized and transported to the smart card module S...

Page 107: ...o change from 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 ...

Page 108: ...ent 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 permanently writ...

Page 109: ... script whether 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 makin...

Page 110: ... 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 46 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 printer driver u...

Page 111: ...lls the printer 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 51 Range 0 to 10 000 in thousandths of an inch Value Too L...

Page 112: ...000 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 Columns wit...

Page 113: ...g is used to 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 t...

Page 114: ... 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 contactless progra...

Page 115: ...ling edge of 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 50 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 Solutio...

Page 116: ... 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 messages During the...

Page 117: ...ormation is 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 available only for the CP80 and CP80 Plus p...

Page 118: ... 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 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 Use the Printer values...

Page 119: ...it back out 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...

Page 120: ... 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 test ...

Page 121: ...User login 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 da...

Page 122: ...e 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 is read dur...

Page 123: ... magnetic media 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 26 ...

Page 124: ...bout 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 send the chang...

Page 125: ...s of steps 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 di...

Page 126: ... 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 Set the numb...

Page 127: ...er 3 From the 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 contact...

Page 128: ...he values Some settings affect others as indicated in Laminator Parameter Dependencies Important Some laminator parameters are dependant on the foil type loaded in the laminator Any changes made will affect only the same type of material To change the value for other materials first load that material into the laminator Changing Laminator Values Use the following procedure to change a laminator s ...

Page 129: ...encies Parameter Name Laminator Foil Type Temperature 2 2 Patch Size 2 2 Foil Advance Offset 2 2 Card Registration Offset 2 2 Debow Enable 2 Roller Down Distance 2 Transport Apply Speed 2 2 Foil Control 1 2 2 Foil Control 2 2 2 Foil Control 3 2 2 Duplex Vertical Offset Duplex Home Offset Duplex Flipped Offset Duplex Reject Offset Duplex Debow Offset Duplex Horizontal Infeed Offset Duplex Vertical ...

Page 130: ...and topcoat materials This setting is affected by the Card Registration Offset Range 250 to 4000 mils Increase Value The heated roller remains down for a longer period of time and the laminate is applied closer to the trailing edge of the card or beyond Decrease Value The heated roller remains down for a shorter period of time and the laminate is applied further away from the trailing edge of the ...

Page 131: ...ase Value Moves the patch further from the heated roller or decreases the spacing between topcoat images Printing artifacts are observed on the leading edge of a topcoated card Increase the patch size Even if there is a gap between topcoat images it may not be enough The beginning of the topcoat is reusing some of the topcoat material that was already heated but not applied at the trailing edge of...

Page 132: ...er is coming down before the card reaches the nip of the rollers Topcoat applied too far from leading edge of card Decrease the card registration offset The card is too far into the rollers Patch applied too far from leading edge of card Decrease the card registration offset The card is too far into the rollers Symptom Solution Patch material overhanging the leading edge of the card Increase the c...

Page 133: ...distance downward Laminate does not adhere to the card Increase the down distance However if the cam has rotated past center increasing the distance will actually have the opposite effect Symptom Solution Laminate stripping problems Decrease the down distance There may be a timing issue in which it takes too long to retract the heated roller Transport Apply Speed The Transport Apply Speed setting ...

Page 134: ...d and the foil application speed The foil application speed is determined as a percentage of the Transport Apply Speed At 100 the foil speed matches the card transport speed Because the foil application speed is represented as a percentage of the Transport Apply Speed changing the transport speed automatically changes the foil application speed Range 50 to 200 Increase Value At values greater than...

Page 135: ...the Lower Duplex Rotational Adjustment procedure on page 5 54 Range 1 to 200 steps Increase Value The index pointer moves toward the lower letters see the adjustment procedure Decrease Value The index pointer moves toward the higher letters see the adjustment procedure Duplex Home Offset The Duplex Home Offset controls where the duplex flipper stops when in the home position Adjust the Duplex Hand...

Page 136: ... minus 42 Duplex Horizontal Infeed Offset The Duplex Horizontal Infeed Offset controls how far a card will travel into the duplex after it leaves the duplex entry sensor If this value is incorrectly set the card may bind as the duplex rotates Range 1 to 200 steps Increase Value The card travels further into the duplex Decrease Value The card travels less distance into the duplex Duplex Vertical In...

Page 137: ...s MFG Temperature Baseline The Manufacturing MFG Temperature Baseline calibrates the output of the thermocouple to represent actual temperature in degrees Celsius This adjustment is available only to the Advanced User It requires special temperature measurement equipment and should not be altered Range 20 to 20 C MFG Patch Registration Baseline The Manufacturing MFG Patch Registration Baseline det...

Page 138: ... 40 Adjustments Viewing Laminator Sensors and Enabling Heaters The Laminator Sensor Display dialog box displays information about the laminator sensors It also allows you to enable or disable the heaters ...

Page 139: ... duration Procedure 1 Select Laminator 1 upper or Laminator 2 lower 2 Select the test to use Transport Forward Transport Reverse Heater Down Up Foil Advance Fan Duplex Clutched rotates the flipper 3 Enter the number of seconds to run the test 4 Click Start to begin the test 5 Click Reset printer It is good practice to reset the printer before returning to card production ...

Page 140: ...inistrator 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 and Down arro...

Page 141: ...P assigned 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 ...

Page 142: ...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 key again ...

Page 143: ... To change 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 144: ...mber 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 some entries...

Page 145: ... the control board is being replaced enter the printer s serial number read from the side of the transport C Locate the entry Ribbon Type xx and delete the whole line If this line 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 m...

Page 146: ...en prompted enter 42360 for the password If this procedure resulted in a duplicate instance Null serial number of the driver the only way to fully remove this instance is to uninstall ALL Datacard printers from the PC at which time the Clean up Utility removes leftover files ...

Page 147: ...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 148: ... 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 149: ...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 150: ... 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 151: ...on 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 setting by re homing the duplex in diagnostics 6 Set the other para...

Page 152: ...cation of the pointer is at the letter G on the duplex chassis If the pointer is below the G add the number of units to the current setting each letter represents 2 units because every other letter is shown If the pointer is above the G subtract the number of units from the current setting 5 Set all of the other parameters based on the handoff offset The table below shows what should be added or s...

Page 153: ...______________________________________________________________6 15 Input Hopper ________________________________________________________________________6 17 LCD Display _________________________________________________________________________6 19 Output Hopper ______________________________________________________________________6 22 Swingarm Assembly ______________________________________________...

Page 154: ... Card Guide ____________________________________________________________________6 68 RFID Antenna________________________________________________________________________6 70 Upper Duplex Module __________________________________________________________ 6 71 Duplex Entry Sensor __________________________________________________________________6 73 Duplex Home Sensor ________________________________...

Page 155: ...Index Sensor______________________________________________________________6 115 Lower Foil Index Sensor______________________________________________________________6 116 Foil Motion Sensors __________________________________________________________________6 117 Heater Home Sensor ________________________________________________________________6 118 Laminator Motors _______________________________...

Page 156: ...owing symbols are used frequently in this chapter and are repeated here for convenience This symbol is used to designate a procedure that involves electrostatic discharge 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 ...

Page 157: ...tor 8 0 8 Cam motor 8 0 8 Ribbon take up motor 8 0 8 680 coupler cable screws 0 9 0 1 Magnetic stripe encoder set screw 1 2 0 1 Magnetic stripe encoder mounting screws 0 9 0 1 Laminator transport motor 8 0 8 Heater lift motor 8 0 8 Swingarm cover screws locking option 12 1 2 Key lock barrel nut 16 1 6 Key lock cam nut 12 1 2 ...

Page 158: ...6 6 Removal and Replacement Print Engine Front Wire Routing Diagram ...

Page 159: ...CP80 and CP80 Plus Service Manual 6 7 Print Engine Duplex and Printhead Wire Routing Diagram ...

Page 160: ...6 8 Removal and Replacement Laminator Front Wire Routing Diagram ...

Page 161: ...CP80 and CP80 Plus Service Manual 6 9 Laminator Rear Wire Routing Diagram ...

Page 162: ...6 10 Removal and Replacement Power Supply Wire Routing Diagram ...

Page 163: ...CP80 and CP80 Plus Service Manual 6 11 Print Engine Cable Connection Diagram ...

Page 164: ...6 12 Removal and Replacement Laminator Cable Connection Diagram ...

Page 165: ...er Removal Procedure 1 If the printer is equipped with locking covers you will need to remove the two security screws from the inside of the swingarm just below the printhead fan 2 Place your fingertips under the back of the cover and pull back to release the retaining tab ...

Page 166: ...6 14 Removal and Replacement 3 Push the cover toward the swingarm latch and then rotate it upward to release the forward retaining tab 4 Pull the cover back and lift it off the swingarm ...

Page 167: ...ngarm Cover page 6 13 3 Release the rear locking tabs A Open the duplex access door and locate the two locking tabs just above the upper duplex assembly B Gently pry down on the two locking tabs and separate the two halves of the enclosure slightly 4 Press down on the upper locking tab located behind the input hopper and separate the two halves of the chassis ...

Page 168: ... output hopper by flexing the enclosure inward and then tilting the enclosure away from the printer Replacement Notes Make sure the four retaining tabs at the bottom of each enclosure are fully inserted into the base Starting from the bottom and working up align the two halves and re engage all of the latches described above Just before engaging the upper rear locking tabs install the duplex acces...

Page 169: ...inter and unplug the power cord 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure page 6 15 4 Press in on the transport chassis locking tabs and lift up on the back of the transport assembly 5 Disconnect the LCD display s data cable from the main control board ...

Page 170: ...6 18 Removal and Replacement 6 Simultaneously pull back on the transport chassis and forward on the input hopper Remove the hopper from the chassis ...

Page 171: ...printer and unplug the power cord 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure page 6 15 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 172: ...opper A Place your fingertips between the main hopper body and the rear edge of the lower cover see Lift Here below B Gently pry up on the edge of the cover slightly Note that a set of ribs inside the cover prevents it from being pried up too much refer to the picture on the following page C Slide the cover forward off the main body 8 Remove the LCD from the hopper main body ...

Page 173: ...CP80 and CP80 Plus Service Manual 6 21 Replacement Note When replacing the lower cover line up the guide rails and slide the two pieces together ...

Page 174: ... Remove the Main Enclosure page 6 15 4 Press up on the hopper retaining latches one on either side of the hopper and pull the hopper straight out to remove it You will feel a little resistance until the upper retaining hooks release from the transport chassis Replacement Note When reinstalling the hopper make sure both lower retaining latches snap into position ...

Page 175: ...ve the Upper Printer Assembly from the interstage platform page 6 38 B Disconnect the printhead power and data cable connectors from the main control board C Cut the cable tie near the ferrite bead D Disconnect the printhead fan connector from the main control board E Pull the cables back through the cable guides in the transport chassis 5 Unhinge the swingarm by pulling each side off the hinge pi...

Page 176: ...bon cartridge and cleaning roller 3 Remove the Main Enclosure page 6 15 and the Swingarm Cover page 6 13 4 Unplug the fan from the main control board 5 To remove the fan press in on the two retaining tabs and lift the fan out from the top of the swingarm Note that the label on the fan is facing toward the inside of the printer ...

Page 177: ...plug the power cord 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 178: ...further is it okay to pull the sensor out with the wires 5 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 the edg...

Page 179: ...he chassis 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 Print Engine Front Wire Routing Diagram...

Page 180: ...tly twist to 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 D...

Page 181: ...e Ribbon Guide page 6 53 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 Print Engine Front Wire Routing Diagram and Print Engine Cable Connection Diagram for replacement details Use the sensor display in D...

Page 182: ...the sensor 7 Place a screwdriver into the removal access slot and push the sensor out Only when the sensor is partially removed loose is it acceptable to push against the sensor arm or pull with the wires 8 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 chassis Ref...

Page 183: ...driver 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 15 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 ...

Page 184: ...the transport motor is 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 Print Engine Cable Connection Diagram for replacement details ...

Page 185: ...idge and cleaning roller 3 Remove the Main Enclosure page 6 15 4 Unplug the wires from the motor 5 To access the motor mounting screws it is necessary to remove the Input Hopper page 6 17 A Unsnap the rear transport feet from the base B Slide the transport chassis back and simultaneously pull forward on the input hopper Remove the card hopper ...

Page 186: ...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 187: ...atform page 6 38 5 Rotate 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 Print Engine Cable Connection Diagram for replacement details Run the Printhead...

Page 188: ...he ribbon cartridge and cleaning roller 3 Remove the Main Enclosure page 6 15 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 189: ...hown below Make sure the wires are not routed under the motor Refer to the Print Engine Front Wire Routing Diagram and Print Engine Cable Connection 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 190: ...cedure 1 Turn off the printer and unplug the power cord 2 Remove both halves of the Main Enclosure page 6 15 3 Unplug the print assembly s power supply connector from the main control board and pull the wire back out of the interstage platform 4 Disconnect the serial data and serial power connectors from the main control board and pull the wires back out of the interstage platform ...

Page 191: ...om the back of the printer simultaneously pull out on the side latches and lift the rear of the printer off the laminator 6 With the rear of the printer free slide the printer back to disengage the front retaining hook from the laminator chassis ...

Page 192: ...ent 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 Turn off the printer and unplug the power cord 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure page 6 15 4 Press in on the transport chassis locking tabs and li...

Page 193: ...ort chassis 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 Pull back on the duplex assembly and lift it off the transport chassis 7 Disconnect all cable connectors from the main control board ...

Page 194: ...ngle and continue to make connections A Smart card contact 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 card tray and duplex assem...

Page 195: ...inter 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 196: ...inter and unplug the power cord 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure page 6 15 4 Remove the Upper Printer Assembly from the base page 6 38 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 page 6 84 from the main control board ...

Page 197: ... open the original configuration script you saved in step 3 on page 6 43 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 Diagnostics software 5 From the Printer menu select Configuration Script 6 Click on the Load Configuration Script button and select the configuration file Before running the script verify that the Printe...

Page 198: ...elow 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 the next field in the value and repeat the process ...

Page 199: ...and unplug the power cord 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure page 6 15 4 Release the belt tension and remove the transport belt Replacement Notes Follow the belt routing shown below Print a couple of test cards to verify that the printer is functioning properly ...

Page 200: ...er and unplug the power cord 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure page 6 15 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 201: ...e the idler pulleys by 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 ensur...

Page 202: ... as well Removal Procedure 1 Turn off the printer and unplug the power cord 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 203: ... printer and unplug the power cord 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 204: ... refer to page 6 88 When replacing the rocker assembly it is a good idea to replace the springs as well Removal Procedure 1 Turn off the printer and unplug the power cord 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 205: ...hassis 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 mounti...

Page 206: ...ble through the ribbon guide as shown below Refer to the Print Engine Front Wire Routing Diagram and Print Engine Cable Connection Diagram for replacement details Use the sensor display in Diagnostics to verify the sensor changes state as the ribbon is advanced ...

Page 207: ...artridge and cleaning roller 3 Remove the Main Enclosure page 6 15 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 208: ...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 209: ...artridge and cleaning roller 3 Remove the Main Enclosure and card hopper page 6 15 4 Remove the Transport Timing Belt page 6 47 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 210: ...6 58 Removal and Replacement 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 211: ...osure page 6 15 4 Lift the Ribbon Guide page 6 53 out and set it aside 5 Remove the Front Rocker Assembly page 6 51 6 Remove the Front Card Guide page 6 67 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 212: ...acement 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 213: ... 15 4 Depending on the configuration of the printer remove either the Rear Rocker Assembly page 6 52 or the Magnetic Stripe Rocker Assembly page 6 88 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 214: ...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 page 6 47 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 215: ...p B Slide 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 216: ...manual advance 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 locati...

Page 217: ...page 6 15 4 Remove the Upper Printer Assembly from the interstage platform page 6 38 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 218: ...closure page 6 15 4 Depending on the configuration of the printer remove either the Rear Rocker Assembly page 6 52 or the Magnetic Stripe Rocker Assembly page 6 88 5 Remove the Platen Roller page 6 64 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 219: ...cord 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Ribbon Guide page 6 53 4 Remove the Front Rocker Assembly page 6 51 5 Remove the front 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 220: ... on the configuration of the printer remove either the Rear Rocker Assembly page 6 52 or the Magnetic Stripe Rocker Assembly page 6 88 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 221: ...P80 Plus Service Manual 6 69 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 222: ...connect the cable 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 rib...

Page 223: ...cedure for many other procedures Removal Procedure 1 Turn off the printer and unplug the power cord 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure page 6 15 4 Press in on the transport chassis locking tabs and lift up on the back of the transport assembly ...

Page 224: ...6 72 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 225: ...nd unplug the power cord 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure page 6 15 4 Disconnect the duplex interface cable from the interface board 5 Remove the Upper Duplex Module page 6 71 from the printer 6 Disconnect the entry sensor connector from the interface board ...

Page 226: ... Rocker from the module page 6 77 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 227: ... and cleaning roller 3 Remove the Main Enclosure page 6 15 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 228: ...emove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure page 6 15 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 229: ...e interface board and remove the Upper Duplex Module page 6 71 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 1 Insert the spring over the guide pi...

Page 230: ...Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure page 6 15 4 Disconnect the duplex interface cable from the interface board 5 Remove the Upper Duplex Module page 6 71 from the printer 6 Disconnect the motor connector from the interface board 7 Free up the cable from the retaining tabs ...

Page 231: ...taneously 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 232: ...f the printer and unplug the power cord 2 Remove the ribbon cartridge and cleaning roller 3 Remove the Main Enclosure page 6 15 4 Disconnect the duplex interface cable from the interface board 5 Remove the Upper Duplex Module page 6 71 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 clutc...

Page 233: ...tch end 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 234: ... 82 Removal and Replacement 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 235: ...otate 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 pro...

Page 236: ...pe head and 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 Caution Make sure the connectors between the two boards are aligned properly If not both boards c...

Page 237: ...page 6 88 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 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 pos...

Page 238: ...e page 6 15 4 Remove the Upper Printer Assembly from the interstage platform page 6 38 5 Unplug the magnetic head from the magnetic stripe board 6 Remove the Magnetic Stripe Rocker Assembly page 6 88 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 239: ... Manual 6 87 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 240: ...ewdriver pry the 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 descri...

Page 241: ...m the smart card interface board Refer to the Print Engine Cable Connection Diagram p 6 11 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 Foll...

Page 242: ... 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 Upper Printer Assembly p 6 38 from th...

Page 243: ... in place with 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 244: ... base p 6 38 5 Disconnect the interface cable from the smart card interface board Refer to the Print Engine Cable Connection Diagram p 6 11 for location and details 6 Remove the Ribbon Motor p 6 36 7 Remove the Solenoid Link from the rocker p 6 90 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...

Page 245: ... 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 246: ...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 247: ...er 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 15 4 Remove the Upper Printer Assembly from the base p 6 38 5 Use a screwdriver to press the plastic locking tabs out of the chassis 6 Remove the coupler bracket or plastic cover ...

Page 248: ...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 ...

Page 249: ...15 3 Remove the Upper Printer Assembly page 6 38 4 Disconnect both power supply connections from the control board 5 Simultaneously pull back on the two latches and lift the back end of the chassis off the base 6 Slide the chassis back slightly and lift the chassis and control board out of the base 7 Disconnect the cable connectors from the control board as necessary to perform further work on the...

Page 250: ...r and unplug the power cord 2 Remove the Main Enclosure page 6 15 3 Disconnect the DC power cord from the control board 4 Disconnect the AC power cord from the power supply 5 Remove first the horizontal hook and loop strap and then the vertical strap by lifting the end of the strap and feeding it back through the eyelet 6 Lift the power supply out of the base Replacement Note When replacing the ho...

Page 251: ...oil Drive Assembly page 6 126 4 Optional For easier access remove the Upper Heater Assembly page 6 124 from the laminator 5 Remove the laminator entry and exit idler rollers A Simultaneously pull the shaft to the left and the chassis wall toward the right as viewed in the photograph B When the tip of the shaft clears the pocket in the chassis lift the shaft out Be careful not to pull so hard on th...

Page 252: ... A Open the retaining flap above the roller B Lift the gear end of the roller and pull it out the side of the chassis Follow up Procedure Refer to the Laminator Cable Connection Diagram and Laminator Rear Wire Routing Diagram for replacement details Print several laminate test cards ...

Page 253: ...7 4 Remove the Lower Foil Drive Assembly page 6 128 5 Turn the laminator chassis upside down 6 Optional For easier access remove the Lower Heater Assembly page 6 125 from the laminator 7 Remove the laminator entry and exit idler rollers A Simultaneously pull the shaft to the left and the chassis wall toward the right as viewed in the photograph B When the tip of the shaft clears the pocket in the ...

Page 254: ...iate roller drive gear so it disengages from the other transport gears Note the extra space to the right of the roller in the photograph below 10 Remove the laminator entry and exit drive rollers A Open the retaining flap above the roller B Lift the gear end of the roller and pull it out the side of the chassis Follow up Procedure Refer to the Laminator Cable Connection Diagram and Laminator Rear ...

Page 255: ... and the Upper Printer Assembly page 6 38 3 Remove the Upper Foil Drive Assembly page 6 126 4 Remove the intermediate idler roller A Simultaneously pull the shaft to the right and the chassis wall toward the left as viewed in the photograph B When the tip of the shaft clears the pocket in the chassis lift the shaft out 5 Carefully lift up on the card guide to remove it and the bias spring ...

Page 256: ...ull outward on the drive gear so it disengages from the other transport gears C Lift the gear end of the roller and pull it out the side of the chassis Follow up Procedure Refer to the Laminator Cable Connection Diagram and Laminator Rear Wire Routing Diagram for replacement details Print several laminate test cards ...

Page 257: ...laminator 5 Remove the upper platen roller A Open the retaining flap above the platen roller B Lift the gear end of the platen roller and pull it out the side of the 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 ...

Page 258: ...ator 5 Remove the upper platen roller A Open the retaining flap above the platen roller B Lift the gear end of the platen roller and pull it out the side of the 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 gr...

Page 259: ...g the power cord 2 Remove the Main Enclosure page 6 15 3 Remove the Upper Printer Assembly page 6 38 4 Simultaneously press outward on the two retaining tabs and lift the fan out Replacement Notes Route the wires according to the two pictures below Use the Laminator Motor Tests in Diagnostics to test the fan ...

Page 260: ...and guard in any sequence other than that described below will complicate the procedure and may even damage the retaining posts 1 Turn the laminator chassis upside down on a stable surface 2 Remove the guard from the first post A Push the guard down off the post Note that there is a ridge on the inside of the post so don t bend the guard until after it is off the post B Make the guard narrower by ...

Page 261: ... A Push the guard down off the post Again because there is a ridge on the inside of the post don t pull the guard away from the chassis wall until it is off the post B Lift the corner only the corner of the guard past the edge of the chassis 4 Remove the guard from the lower rear post ...

Page 262: ...t 5 Finish removing the guard by freeing it from the slotted retainer A Bend the guard in the middle B Move the back edge of the guard past the sensor pocket C Continue to rotate the guard until it is free from the retaining slot ...

Page 263: ...6 15 3 While lifting the retaining tab slightly pull out on the circuit board 4 Disconnect the cable from the connector Replacement Notes Refer to the Laminator Front Wire Routing Diagram and Laminator Cable Connection Diagram for replacement details Go to the advance setup in the printer tool box to verify that the printer properly identifies the laminate supply ...

Page 264: ...rd 5 Gently push against the tip of the sensor to free it from the chassis 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 the edge of the chassis Refer to the Lam...

Page 265: ...ently push against the tip of the sensor to free it from the chassis 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 the edge of the chassis Refer to the Laminator...

Page 266: ...ree it from the chassis 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 the edge of the chassis Refer to the Laminator Front Wire Routing Diagram and Laminator Cab...

Page 267: ... 38 4 Disconnect the sensor cable from the laminator control board 5 Gently pry against the bottom of the sensor body to free it from the chassis Replacement Notes Make sure the sensor is fully seated and locked into position Refer to the Laminator Front Wire Routing Diagram and Laminator Cable Connection Diagram for replacement details Print several laminate test cards to verify that the sensor i...

Page 268: ...closure page 6 15 3 Remove the Upper Printer Assembly page 6 38 4 Remove the Laminator Transport Assembly from the base and control board page 6 97 5 Lift against the bottom of the sensor body to free it from the chassis Replacement Notes Make sure the sensor is fully seated in position Refer to the Laminator Front Wire Routing Diagram and Laminator Cable Connection Diagram for replacement details...

Page 269: ...ure page 6 15 3 Disconnect the sensor from the laminator control board 4 Press against the inside corner of the sensor to remove it Replacement Notes Make sure the sensor is fully seated in position The small tab on the chassis should be flush with the edge of the sensor Refer to the Laminator Front Wire Routing Diagram and Laminator Cable Connection Diagram for replacement details Print several l...

Page 270: ... 6 15 and the Upper Printer Assembly page 6 38 3 Remove either the Upper Heater Assembly page 6 124 or the Lower Heater Assembly page 6 125 from the laminator 4 Remove the heater slide from the heater assembly A Compress the heater slide spring by squeezing the assembly B Remove the idler gear and rotate the cam so the sensor flag is clear of the sensor body note the orientation of the cam in the ...

Page 271: ...ter and thermocouple wires place the slide over the end of the spring C With the cam pre inserted into the heater slide align the heater slide guide pins with the slots in the frame D Compress the heater slide until the cam lines up with its retaining points E Insert the cam into its retaining points 2 Follow the replacement notes for the Upper Heater Assembly page 6 124 or the Lower Heater Assemb...

Page 272: ...Upper Printer Assembly page 6 38 3 Remove the Upper Foil Drive Assembly page 6 126 4 Remove the Upper Heater Assembly page 6 124 from the laminator 5 Remove the upper platen roller A Open the retaining flap above the platen roller B Lift the gear end of the platen roller and pull it out the side of the chassis 6 Remove the two screws that secure the transport motor to the chassis ...

Page 273: ...es the bottom of the cutout in the chassis B Rotate the motor 45 degrees so the flat side of the motor is lined up with the corner of the chassis C Tilt the motor downward so the top of the drive gear clears the cutout in the chassis and remove the motor Follow up Procedure Refer to the Laminator Cable Connection Diagram and Laminator Rear Wire Routing Diagram for replacement details Use the lamin...

Page 274: ... 2 Remove the Main Enclosure page 6 15 3 Disconnect the motor from the laminator control board 4 Press in on the two retaining tabs and rotate the motor counterclockwise to remove it Follow up Procedure Refer to the Laminator Cable Connection Diagram and Laminator Rear Wire Routing Diagram for replacement details Use the laminator motor tests in Diagnostics to verify the motor is functioning prope...

Page 275: ...ve the Upper Printer Assembly page 6 38 4 Remove either the Upper Heater Assembly page 6 124 or the Lower Heater Assembly page 6 125 from the laminator 5 Disconnect the wires from the motor 6 Remove the idler gear to access the motor mounting screws 7 Remove the two screws that secure the motor to the heater assembly and remove the motor Replacement Notes Make sure the wires are connected properly...

Page 276: ...heater lift motor 6 To access the wire routing for the lift home sensor remove the Upper Foil Drive Assembly page 6 126 7 Free the wires from their cable guides 8 Gently pry the two retaining tabs away from the heater assembly and slide the assembly up to remove it Follow up Procedure Make sure the motor wires are connected properly Reversing the wires will reverse the rotation of the motor The po...

Page 277: ...ng all of the cable connectors 5 Disconnect the two wires from the heater lift motor 6 Free the wires from their cable guides 7 Gently pry the two retaining tabs away from the heater assembly and slide the assembly up to remove it Follow up Procedure Make sure the motor wires are connected properly Reversing the wires will reverse the rotation of the motor The polarity is shown above Refer to the ...

Page 278: ...ctor from the laminator control board 4 Free up the following cables from the cable guides on the face of the drive assembly Heater Lift Motor Thermocouple Heater 5 Press in on the two retaining tabs and pull the assembly away from the laminator chassis The two gears and the pressure spring on the back of the drive assembly are not retained Refer to the replacement notes for a picture and descript...

Page 279: ...l 6 127 Replacement Notes The plastic gears are not retained on their shafts Make sure the gear train is replaced according to the image below Re route the wires according to the image above and the Laminator Rear Wire Routing Diagram ...

Page 280: ...inator control board 4 Free up the heater wires from the cable guide on the face of the drive assembly 5 Press in on the two retaining tabs and pull the assembly away from the laminator chassis Replacement Notes The plastic gears are not retained on their shafts Make sure the gear train is replaced according to the image below Re route the wires according to the image above and the Laminator Rear ...

Page 281: ... the Upper Printer Assembly page 6 38 4 Remove either the Upper Heater Assembly page 6 124 or the Lower Heater Assembly page 6 125 from the laminator 5 Remove the heater slide from the heater assembly A Compress the heater slide spring by squeezing the assembly B Remove the idler gear and rotate the cam so the sensor flag is clear of the sensor body note the orientation of the cam in the photo bel...

Page 282: ...able guides you need to rotate the connector so the connector latch is in line with the opening as shown 7 Remove the heater wires Hint If you temporarily leave one of the two wires in place the heater will not fall loose in step 8 A Slide the connectors off the heater s terminals B Retract the connector into the center area and then out the side ...

Page 283: ...down on the retaining latch B Separate the two halves just enough to keep the latch from re engaging see inset photo below Separate the two halves of the heater slide slowly When the two halves are separated all of the components are free to fall loose C Repeat this for the other latch and separate the two halves completely ...

Page 284: ...en the glass tube and ceramic caps will turn a caramelized brown The glass tube and heating element will darken slightly This is not a high intensity light bulb so fingerprints will not damage the glass However if the glass is dirty it should be wiped down before replacement Abnormal Appearance If part of the glass tube is greatly discolored this may indicate uneven heating The heater may function...

Page 285: ...e connection terminal is facing toward the wire connector see inset photo below 3 Slide the heated roller over the heater and onto the boss of the heater slide 4 Insert the stripper bar and wiper into the heater slide 5 Slide the second half of the heater slide over the heater heated roller and stripper bar Snap the two halves together 6 Feed the first heater wire back through the heater slide ...

Page 286: ...ater and thermocouple wires place the slide assembly over the end of the spring C With the cam pre inserted into the heater slide align the heater slide guide pins with the slots in the frame D Compress the heater slide until the cam lines up with its retaining points E Insert the cam into its retaining points 10 Finish reassembling the printer Make sure to follow any replacement notes from either...

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