Zebra P330i Service Manual

980569-001 Rev.
A
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Card Printer
980569-001 Rev. A P330! Card Printer Service Manual i
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This manual contains service inIormation Ior the Zebra P330! Card Printers manuIactured by
Zebra Technologies Corporation, Camarillo, CaliIornia.
Copyright Notice
2004, 2005 ZIH Corp.
This document contains inIormation proprietary to Zebra Technologies Corporation. This
document and the inIormation contained within is Copyrighted by Zebra Technologies
Corporation and may not be duplicated in Iull or in part by any person without written
approval Irom Zebra. While every eIIort has been made to keep the inIormation contained
within current and accurate as oI the date oI publication, no guarantee is given that the
document is error-Iree or that it is accurate with regard to any speciIication. Zebra reserves the
right to make changes, Ior the purpose oI product improvement, at any time.
Trademarks
P330! is a trademark and Zebra is a registered trademark oI Zebra Technologies Corporation.
Windows and MS.DOS are registered trademarks oI MicrosoIt Corp. All other trademarks or
registered trademarks are marks oI their respective holders.
Product DisposaI
Product DisposaI Information Do not dispose of this product in unsorted municipal
waste. This product is recyclable, and should be recycled according to your local
standards. For more information, please see our web site at:
http://www.zebra.com/environment
ii P330! Card Printer Service Manual 980569-001 Rev. A
Foreword
DecIarations of Conformity
For a Iormal certiIicate, please contact the Compliance OIIice at Zebra`s Camarillo Iacility.
EUROPE: Norway Only: This product is also designed Ior IT power system with phase to phase
voltage 230V. Earth grounding is via the polarized, 3-wire power cord.
FI: 'Laite on liitettv suojamaadoitus koskettimilla varustettuun pistorasiaan
SE: 'Apparaten skall anslutas till jordat uttag
NO: 'Apparatet m tilkoples jordet stikkontakt
SuppIementaI Information:
This equipment has been tested and Iound to comply with the limits Ior a Class B digital
device, pursuant to part 15 oI the FCC Rules. These limits are designed to provide
reasonable protection against harmIul interIerence in a residential installation. This
equipment generates, uses and can radiate radio Irequency energy and, iI not installed and
used in accordance with the instructions, may cause harmIul interIerence to radio
communications. However, there is no guarantee that interIerence will not occur in a
particular installation. II this equipment does cause harmIul interIerence to radio or
television reception, which can be determined by turning the equipment oII and on, the
89/336/EEC
modiIied by
92/31/EEC and
93/68/EEC
EMC Directive
EN 55022 (1998) RF Emissions control
EMC Directive
EN 301489-3 V1.4.1
RF Emissions and Immunity Ior radio
equipment
EMC Directive EN55024 (2001) Immunity to Electro-Magnetic
Disturbances
73/23/EEC modiIied
by 93/68/EEC
Low voltage
Directive
EN 60950-1 (2001) Product saIety
1999/5/CE
R&TTE Directive
EN300330-2 V1.1.1 Radio Frequency InterIerences
Model P330! conIorms to the Iollowing speciIication: FCC Part 15, Subpart A, Section
15.107(a) and Section 15.109(a) Class B digital device.
Foreword
980569-001 Rev. A P330! Card Printer Service Manual iii
user is encouraged to try to correct the interIerence by one or more oI the Iollowing
measures:
Reorient or relocate the receiving antenna.
Increase the separation between the equipment and the receiver.
Connect the equipment into an outlet on a circuit diIIerent Irom that to which the receiver
is connected.
Consult the dealer or an experienced radio/TV technician Ior help.
The user may Iind the Iollowing booklet, prepared by the Federal Communications
Commission, helpIul:
How to identiIy and resolve Radio/TV InterIerence Problems. This booklet is available
Irom the U.S. Government printing OIIice, Washington, D.C. 20402, Stock No. 004-000-
00345-4. Use oI a shielded cable is required to comply within Class B limits oI Part 15 oI
FCC Rules. Pursuant to Part 15.21 oI the FCC Rules, any changes or modiIications to this
equipment not expressly approved by Zebra may cause, harmIul interIerence and void the
FCC authorization to operate this equipment.
Industry Canada Notice
This device complies with Industry Canada ICES-003 class B requirements.
iv P330! Card Printer Service Manual 980569-001 Rev. A
Foreword
Icons
Throughout this manual, diIIerent icons highlight important inIormation, as Iollows:
Note Indicates inIormation that emphasizes or supplements important points oI the main
text.
Important Advises you oI inIormation that is essential to complete a task, or points out the
importance oI speciIic inIormation in the text.
Provides an example or scenario to demonstrate or clariIy a section oI text.
EIectrostatic Discharge Caution Warns you of the potential for electrostatic discharge.
EIectric Shock Caution Warns you of a potential electric shock situation.
Hot Surface Warns you of a situation where excessive heat could cause a burn.
Caution Advises you that failure to take or avoid a specific action could result in
physical harm to you, or could result in physical damage to the hardware.
980569-001 Rev. A Service Manual v
'"()$()*
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
1 GeneraI Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Printer Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Controls, Connectors, and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 InstaIIation and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 General InIormation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Unpacking the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Installing the Print Driver SoItware and Setting Driver Options . . . . . . . . . . . . . 15
2.4 Loading a Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5 Installing the Card Cleaning Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.6 Setting the Card Thickness Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.7 Loading Cards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.8 Card Output Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.9 Connecting the Printer to your Computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.10 Connecting Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.11 Printing a Test Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.12 Packing the P330i Printer Ior Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.13 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1 Card Printing Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2 Card Path Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.3 Card Movement During Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.4 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.5 CPU PCBA Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
vi Service Manual 980569-001 Rev. A
4 TroubIeshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1 Power-Up Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.2 LCD Panel Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.3 Printing a Test Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.4 Card Feed or Transport Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.5 Print Anomalies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.6 Troubleshooting the Ethernet Connection and Adapter . . . . . . . . . . . . . . . . . . . . 56
5 RepIacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.2 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.1 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.2 Removing the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.3 Removing the Print Engine Irom the Lower Cover . . . . . . . . . . . . . . . . . . . . . . . 67
5.4 Removing the Connector Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.5 Removing the Power Supply Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.6 Removing the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.7 Removing the Rear Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.8 Removing the Cam Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.9 Removing the Platen Inertia Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.10 Removing the Printhead Pressure Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.11 Removing the Film/Bracket Sensor PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.12 Removing the Pressure Spring Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.13 Removing the Cam Arm Follower Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.14 Removing the Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
5.15 Removing the Print Head / Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.16 Removing the Print Head LiIt Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.17 Replacing the Print Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.18 Replacing the LCD PCBA and/or LCD Cable Assembly . . . . . . . . . . . . . . . . . 111
5.19 Replacing the Encoder Shroud and Exit Pressure Roller . . . . . . . . . . . . . . . . . . 113
5.20 Replacing the Exit Pressure Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.21 Removing the Balls Retainer Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
5.22 Card Feeder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.23 Power / Filter Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
5.24 Removing the CPU PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.25 Removing the I/O Daughterboard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.26 Removing the RFID Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.27 Replacing the Ribbon O-Ring Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5.28 Replacing the Ribbon Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.29 Removing the Ribbon Motor Pulley and the Ribbon Motor . . . . . . . . . . . . . . . 154
5.30 Replacing the Stepper Motor Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
5.31 Removing the Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.32 Removing the RFID PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
5.33 Replacing the Ribbon Color Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
5.34 Replacing the Card Sensor Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5.35 Removing the Print Head Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
980569-001 Rev. A Service Manual vii
5.36 Removing the Print Head LiIt Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
5.37 Separating the Front Frame Irom the Center Frame . . . . . . . . . . . . . . . . . . . . . . 181
5.38 Magnetic Stripe Encoder Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
5.39 Smart Card Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
5.40 Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
6 Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Appendix A Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Appendix B P330! ModeI Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Appendix C WorIdwide Service & Support . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
viii Service Manual 980569-001 Rev. A
980569-001 Rev. A P330! Card Printer Service Manual 1
!
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1.1 Printer Description
The Zebra P330! Card Printer is a photo ID card printer. It can print at 300 dpi resolution on
10-60 mil (0.25 - 1.5 mm) ISO CR-80 plastic cards. When equipped with a YMCK (Yellow,
Magenta, Cyan, Black) ribbon, it can print Iull-color images. A wide range oI other ribbons,
including monochrome ribbons and ribbons that will additionally apply a protective
transparant overprint, are also available.
The P330! Printer has a USB interIace as standard. In addition to the USB port, it can
optionally be ordered with a 10/100T Ethernet port.
II equipped with the optional Magnetic Encoder, the printer will encode a magnetic stripe on
the card. Other options allow encoding oI 'smart cards, which have embedded logic and/or
memory circuitry.
The Iollowing shows the main Iunctional Ieatures Iound on your P330! Printer.
2 P330! Card Printer Service Manual 980569-001 Rev. A
GeneraI Description
Panel
Button
Print
Head
(Optional)
Smart Card
Contact Station
Output
Hopper
(shown in
open
position)
Card
Feeder
Cover
(shown
open)
Card
Thickness
Control
Card
Cleaning
Cartridge
LCD Display Panel
Print Head
Carriage Latch
Print Head Carriage
(shown in open
position)
Main Cover
(shown open)
(Optional)
Magnetic
Encoding
Station
Ribbon
Supply
Spindle
Ribbon
Take-Up
Spindle
GeneraI Description
1.2 ControIs, Connectors, and Indicators
The P330! Printer has an LCD Display Panel and a Panel Button on the Iront and a power
connector, power switch, and interIace connector(s) on the rear panel. These are shown in the
Iollowing Iigures.
LCD Display
Panel
Panel Button
Power
Switch
Power
Connector
Network
Status /
Activity
LED *
Ethernet
Adapter
Status
LED *
10/100base-T
Connector *
Ethernet Switch *
USB Connector
* These
are on the
optional
Ethernet
Adapter.
Optional DB-9
Connector location
for Smart Card
Contact Station
GeneraI Description
1.2.1 LCD PaneI
The LCD Panel can display the Iollowing messages:
Message Mode
OperationaI
INITIALIZING Scrolling
READY Fixed
DOWNLOADING DATA Fixed
PRINTING MONO Fixed
MAG ENCODING Fixed
CONTACT ENCODING Fixed
PRINTING CYAN Fixed
PRINTING YELLOW Fixed
PRINTING MAGENTA Fixed
PRINTING BLACK Fixed
PRINTING OVERLAY Fixed
DOWNLOADING FW Fixed
CLEANING PRINTER Fixed
Warnings
CLEAN PRINTER Scrolling
REMOVE RIBBON THEN CLOSE HEAD Scrolling
EMPTY FEEDER & PRESS BUTTON Scrolling
LOAD CLEANING CARD IN FEEDER Scrolling
PRESS BUTTON TO CONTINUE Scrolling
FEED LONG CLEANING CARD IN EXIT Scrolling
CLEANING PRINTER Scrolling
ENCODING ERROR (printing stops) Blinking
INVALID MAGNETIC DATA
(encoding stops)
Scrolling
REMOVE RIBBON Fixed
Errors (Printer wiII not operate)
OUT OF RIBBON Blinking
MECHANICAL ERROR Blinking
OUT OF CARDS Blinking
PRINT HEAD OPEN Blinking
GeneraI Description
1.2.2 PaneI Button
During normal printer operation, iI the Panel Button is pressed brieIly nothing happens.
II the Panel Button is held down Ior more than three seconds, the printer will start a cleaning
cycle and the LCD Panel will prompt the operator to load a cleaning card in the Ieeder. (II a
print operation was in process when the Panel Button was pressed and held down, the print
operation will be completed beIore the printer starts a cleaning cycle.)
II the Panel Button is pressed and held down while power is turned on to the printer, the printer
will print a test card. This provides a quick check oI printer operation completely
independently oI a computer or network connection.
In response to LCD Panel prompting messages, press the Panel Button to continue various
operations.
GeneraI Description
1.2.3 Card Thickness ControI
The Card Thickness Control is used to set the P330i printer Ior use with cards oI diIIerent
thicknesses. Use oI the Card Thickness Control is described in Chapter 2.
Card Thickness
Control
GeneraI Description
1.2.4 (OptionaI) Ethernet Adapter
P330i Printers equipped with the optional Ethernet Adapter have the Iollowing additional
controls and indicators:
Ethernet Reset Switch
II the Ethernet Reset Switch is pressed and held while turning the printer power on, and then
released when the Ethernet Adapter Status Indicator turns green, the Ethernet Adapter will be
reset to the Iactory deIault conIiguration parameters.
While power is on, iI the Ethernet Reset Switch is press and held, a conIiguration card
showing the Ethernet Adapter`s current conIuguration settings will be printed.
Ethernet Adapter Status Indicator
The Ethernet Adapter Status Indicator is a bi-color (red - green) LED, that shows the
operational status oI the Ethernet Adapter.
Network Status/Activity Indicator
The Network Status/Activity Indicator is a bi-color (orange - green) LED, that indicates
network speed, establishment oI a link, and network activity.
(Recessed)
Ethernet
Reset Switch
Ethernet
Adapter
Status
Indicator
Network
Status /
Activity
Indicator
10/100Base
RJ45
Ethernet
Connector
Note Detailed inIormation on the use oI these indicators is presented in Chapter 4,
Troubleshooting.
GeneraI Description
"
3(*),--,)1"( ,(& 4$)52
2.1 GeneraI Information
This section will guide you through the installation and setup oI your P330! Card Printer. This
consists oI the Iollowing procedures, which should be perIormed in the order presented.
Unpacking the Printer
Installing the Print Driver SoItware and Setting Driver Options
Loading a Ribbon
Installing the Card Cleaning Cartridge
Setting the Card Thickness Control
Loading Cards
Connecting the Printer to your Computer
Connecting Power
Printing a Test Card to veriIy printer operation
The procedure to be Iollowed Ior Packing the Printer Ior Shipment is given at the end oI this
section.
The printer should be placed in a location that allows easy access to all sides. The printer
should never be operated while resting on its side or upside down.
InstaIIation and Setup
2.2 Unpacking the Printer
Your P330! Card Printer ships in a carton and protective anti-static bag. Keep all packaging
material in case you need to move or re-ship the printer.
Step 1. Inspect the shipping container to ensure that no damage has occurred during
shipment. II any damage is apparent, Iile a claim with the shipper.
Step 2. Unlatch and remove the handles on either end oI the shipping container, as shown in
the Iigure below.
Step 3. (See the Iigure on the next page as you perIorm the Iollowing steps.) LiIt the upper
part oI the shipping container oII oI the lower part (which will still hold the printer
and its packing material).
Step 4. Remove the packing material around the top oI the printer.
EIectric Shock Caution Limit AC power supplied to the P330! Printer to 110 ~ 230
volts, 60 ~ 50 Hertz. Limit excess current draw to 16 amps or less, using an associated
circuit breaker or other such device. Never operate the printer in a location where
operator, computer, or printer can get wet. Personal injury could result. The printer must
be connected to an earthed electrical power source and properly protected against
electrical surges and grounding faults; the electrical reliability of the printer is based on
the reliability of the mains power source and with the earth connection.
The printer's power supply is an internal unit that can only be serviced or replaced by
trained and authorized personnel.
UP
Step 5. LiIt the printer out oI the carton by holding it with both hands.
Step 6. Please ensure that you have a clean and nearly dust Iree environment Ior proper
operation and storage oI the printer.
Step 7. Make sure the Iollowing items are included with your P330! printer:
II any items are missing, please contact your dealer. To reorder, please reIer to Appendix D oI
this manual.
Step 8. Remove packing tape securing the printer`s Main Cover and Card Feeder Cover.
Step 9. Your P330i Printer ships with warning tape where the Card Cleaning Cartridge will
be installed, and a pad that protects the print head Irom possible damage in shipment.
To remove the tape and pad, Iollow the Iollowing steps:
a. Open the printer`s main cover by liIting at its lower Iront lip.
Power Cables (2)
Cleaning Kit
CD-ROM with Driver Wizard
and User's Manual
Card Cleaning Cartridge
USB Cable
b. Locate the Print Head protection pad and the Card Cleaning Cartridge location tape
(see below).
c. Release the Print Head Carriage by pushing the Print Head Carriage Latch to the leIt,
and raise the Print Head Carriage. It will remain open at about a 45 angle.
INSTALL
Remove me
Print Head
Protection Pad
Location Tape
d. Remove the print head protection pad. Keep the pad, as well as the other packing
material and the shipping carton, in case the printer is shipped or moved. II the
original material is lost, a replacement Shipping Kit can be ordered Irom Zebra;
please reIer to the Media List on the Windows Drivers and User Documentation CD
supplied with this printer.
Print Head
Carriage
Latch
2.3 InstaIIing the Print Driver Software and Setting Driver
Options
Printing with the P330! Printer requires the Windows Printer Driver and your card design/
issuing soItware or printer command level programming through the printer interIace.
The P330! Card Printer can be used with any Windows 2000 or Windows XP computer, using
the drivers provided on CD with the printer.
This section contains inIormation on the printing oI a sample card in color (using the 5-panel
color ribbon YMCKO and the Windows Printer Driver).
Note II updating the printer driver Irom a previous version, beIore installing the updated
printer driver version, always delete the existing version Irom your computer.
2.3.1 InstaIIing the P330! Print Driver
To install the P330! Printer Driver automatically on all Operating Systems, use the Zebra
Install Wizard.
The Install Wizard will walk you through the appropriate installation steps. The Wizard will:
Delete previous versions oI the driver and clean up any necessary Registry entries. You
must select 'Remove Irom the install options to remove any previous driver versions.
Automatically launch when the driver CD is inserted.
From the main menu oI your documentation CD, select your desired language and then
select 'DRIVERS Irom the subsequent menu. The Install Wizard will walk you through
the appropriate steps.
2.4 Loading a Ribbon
! Series Printers require the use oI ! Series ribbons Ior Iull color printing. The Resin Thermal
TransIer and Dye Sublimination ribbons Ior P330! are speciIically designed Ior your P330!
Printer.
Step 10. Place the printer power switch in the OFF (0) position.
Step 11. II the printer`s Main Cover is closed:
a. Open the printer`s Main Cover; liIt it by the lip at the bottom Iront as shown in the
Iigure below leIt.
Note Ensure that you have administrative privileges to perIorm this installation, or contact
your IT department.
b. Raise the Print Head Carriage by pressing the release latch to the leIt (toward the
output hopper) and liIting as shown below to about a 45 angle. The Print Head
Carriage will stay in that position, as shown at the right below.
EIectrostatic Discharge Caution DO NOT TOUCH the Print Head or the electronic
components on the Print Head Carriage. Discharges of electro-static energy that
accumulate on the human body or other surfaces can damage the Print Head or other
electronic components used in the printer.
Note Avoid any direct contact with the print head to prevent transIer oI oils or
contamination. Outside oI normal operation, only the Zebra-approved cleaning materials
should come in contact with the print head.
Ribbon Supply
Spindle
Ribbon Take-up
Spindle
Step 12. Locate the Ribbon Supply Spindle and the Ribbon Take-up Spindle (see above).
Load ribbon onto the supply spindle (under the print head carriage) flange side in,
and load the empty core (with tape attached) onto the take-up spindle. Make sure the
ribbon comes oII the top oI the supply spindle and Ieeds to the top oI the take-up
spindle.
Flange
Supply Spool
Take-up
Spool
Hot Surface Do not touch the print head if the printer has been in service within the
last 10 minutes. t could be very hot and cause a burn.
EIectrostatic Discharge Caution A static discharge is possible if you touch any
exposed metal parts. Use of an anti-static wrist strap or comparable anti-static protection
is required.
Step 13. Gently press the print head carriage down until it is Iully lowered, as shown below.
Very little Iorce is neccessary to perIorm this step.
Note During normal operation (with power connected and turned on), the ribbon would
automatically synchronize when the Print Head is restored to its Iully-down position. The
ribbon would be identiIied and the corresponding parameters sent to the driver.
Since power is not connected at this point in the Installation and Setup Procedure, nothing
will happen when the Print Head Carriage is closed. The ribbon will synchronize when power
is turned on.
2.5 InstaIIing the Card CIeaning Cartridge
The Card Cleaning Cartridge cleans the cards entering the printer. The Card Cleaning
Cartridge consists oI a Cartridge Frame and an Adhesive Roller, which are packed together.
Step 1. Remove the Cartridge Frame and the Adhesive Roller Irom their packaging. Insert
the Adhesive Roller into the Cartridge Frame, as shown below. To avoid
contamination, always hold the Irame and the roller by the ends.
.
Step 2. Peel the protective wrapper Irom the Adhesive Roller.
Step 3. II the printer`s main cover is closed, open it. Locate the area where the Card Cleaning
Cartridge will be installed (initially, this area was covered by a warning tape).
Card Cleaning
Cartridge Mounting
Location
Step 4. Locate the slot at the rear oI the Card Cleaning Cartridge mounting location; see
below.
Step 5. Hold the Card Cleaning Cartridge by the extended 'handle (so the large arrow on
the top is pointing away Irom you). With the cartridge at about a 30 angle (pointing
downward), insert the lip oI the cartridge into the slot, until the cartridge seats against
the back wall. Then press the Iront oI the cartridge down until it seats all the way
down and latches with an audible 'click. See below.
Card Cleaning
Cartridge
Positioning Slot
Slot
Step 6. Close the printer`s Main Cover.
2.6 Setting the Card Thickness ControI
The Card Thickness Control is set by the user to adjust the gap as cards enter the printer, to
prevent double-Ieeds (which could cause a jam) or mis-Ieeds.
Step 1. Open the Card Feeder cover. The cover is hinged; liIt it by the lip at the right Iront
corner.
Card Cleaning Cartridge in final position
Note Set the Card Thickness Control beIore loading cards.
Note To reduce contamination and ensure better print quality, minimize the time the Card
Feeder cover is open.
Step 2. The Card Thickness Control Lever is at the Iront oI the leIt-side opening oI the Card
Feeder area.
Step 3. There are Iour detents to set the position oI the Card Thickness Control. Slide the
Card Thickness Control to the position corresponding to the Iollowing:
Detent Position Card Thickness
Highest 50 mil (1.27 mm) to 60 mil (1.52 mm)
3rd position 30 mil (0.76 mm) to 50 mil (1.27 mm)
2nd position 20 mil (0.51 mm) to 40 mil (1.02 mm)
Lowest 10 mil (0.25 mm) to 20 mil (0.51 mm)
Card Thickness
Control
Note The overlap in settings above accomodates variations in environmental conditions
(especially humidity) and cards Irom diIIerent manuIacturers. In general, start at the lowest
position and move the lever up until cards Ieed reliably.
2.7 Loading Cards
This section shows how to load plastic cards into the P330! Printer. The P330! can use cards
with a range oI thickness Irom 10 mil (0.25 mm) to 60 mil (1.5 mm).
The P330! Printer can also load and print cards Ied individually. InIormation on this is given in
the next chapter.
The plastic cards generally come in decks oI 100 cards; the Card Feeder can hold a Iull deck oI
100 30-mil cards. Cards sometimes will stick together; this can cause mis-Ieeding or double-
Ieeding. To avoid this, separate the cards beIore loading, as described in steps 2 through 4
below.
Step 1. II the Card Feeder cover is closed, open it. The cover is hinged; liIt it by the lip at the
right Iront corner.
Note '60 mil ('1.524 mm) cards may have a signiIicant variation (over 10) in the actual
thickness oI the cards; do not use these cards unless each card has been measured to have a
thickness less than 66 mil (1.676 mm).
Note Do not mix cards oI diIIerent thicknesses!
Note DO NOT bend cards or touch print surIaces as this can reduce print quality. The
surIace oI the cards must remain clean and dust Iree. Always store cards in an enclosed
container. Ideally, use cards as soon as possible.
Note For cards with magnetic stripe, reIer to Appendix A Ior loading instructions.
Note To reduce contamination and ensure better print quality, minimize the time the Card
Feeder cover is open.
Step 2. Remove all wrapping Irom the card deck.
Step 3. Holding the card deck by the sides, hold it vertically against a Ilat surIace such as a
desktop. II the deck is too thick Ior your hand to hold it comIortably, use about halI a
deck at a time.
Step 4. Push the stack back and Iorth to an angle oI about 45 Irom vertical, so as to separate
all oI the cards.
Caution Do not touch print surfaces of the cards; this can reduce print quality
Note Static charges and edge burrs Irom the card die-cutting process can render individual
cards stuck together with signiIicant adhesion Iorce. These cards must be physically separated
Irom each other beIore inserting into the Ieeder; iI not separated, Ieeding or printing problems
may occur.
Step 5. Restore the card stack to its original squared-oII condition, and place the cards in the
input hopper.
Step 6. Note that there will be a 'gap in the card stack, with several cards lying Ilat and the
cards above angled upward, as shown in the exaggerated drawing below. This is
normal and ensures proper Ieeding.
2.8 Card Output Hopper
The card output hopper is normally extended to receive the printed cards. The printer may be
operated with the card output hopper in its closed position; in this case the cards will not be
collected in the output hopper.
Step 1. Pull the card output hopper out to place it in its Iunctional position.
Note Do not try to eliminate the gap by pressing down on the card stack in the input hopper;
this can cause misIeeds.
Note The output hopper is a very snug Iit to prevent it Irom moving during shipping or
operation; Iirm Iorce is required to change its position.
Step 2. When not using the printer, slide the card output hopper back into its closed position
to protect the printer Irom dust and protect the output hopper Irom damage.
Step 3. The output hopper can be completely removed Irom the printer iI necessary by
inserting a thin, blunt object (such as a pencil) up through the hole in the bottom oI
the printer enclosure and pressing (up) to release the hopper while simultaneously
pulling the hopper out. To re-install the output hopper, simply slide the output hopper
in until it locks in place.
2.9 Connecting the Printer to your Computer
The P330i Printer includes a standard USB interIace.
As an option, the printer can be ordered with a 10/100base-T Ethernet Adapter (in addition to
the USB interIace). The Ethernet Adapter can also be ordered as an add-on option and
installed in the Iield by a Zebra Iactory certiIied technician.
Step 1. II using the USB interIace, use the supplied USB cable to connect between the USB
connector on the printer and a USB port on the computer, as shown below. (Note that
the Iigure below shows the optional Ethernet Adapter directly above the USB
Connector; this may not be present on your printer.)
Step 2. II your printer includes the optional Ethernet Adapter as well as the standard USB
connection, use either the supplied USB cable or a standard Ethernet cable to
connect the printer to a corresponding port on the computer or network.
2.10 Connecting Power
The P330! Printer includes an internal AC power supply that accepts nominal input voltage in
the range Irom 110 to 230 volts at 50 to 60 Hertz. The power source must be grounded.
Depending on speciIic model number, your P330! Printer will include one or two power cords;
use the one that is appropriate Ior the AC power source connection at your location. II neither
has an appropriate connector, AC power cords may be purchased locally; make sure it is a
three-wire (grounded) cord.
USB Connector
Power
Connector
Power
Switch
(Optional)
Ethernet
Connector
Important Do not use both USB and Ethernet connections at the same time!
Important Intermittent or unpredictable operation may occur Irom unsecured connectors. II
damaged, the power cable must be replaced by an exact equivalent.
Step 1. Place the Printer`s power switch in the OFF ( O ) position.
Step 2. Depending on your local AC voltage, plug the appropriate power cord into the
printer`s power connector and a grounded AC power source connection.
Step 3. To turn the Printer on, set the Printer`s power switch to the ON ( [ ) position.
Power
Connector
Power
Switch
Caution f the power cord appears damaged in any way, or if the power cord will not
securely plug into the Printer's power connector or the AC power source connection,
STOP! Use of a damaged or incorrect power cord could cause equipment damage, result
in an electrical fire, or possibly cause injury.
2.11 Printing a Test Card
With ribbon and cards loaded, your P330! Printer is ready to print. To check the operation oI
the printer, you should print a test card. (Printing a test card does not require that the printer be
connected to your computer or network, but power must be applied.)
Step 1. Set the printer`s power switch (on the back oI the printer) to the OFF ( O ) position.
Step 2. While pressing the Printer`s Iront panel button (next to the LCD display panel),
switch the printer ON ( [ ).
Step 3. Hold the panel button until the LCD display panel reads 'SELF TEST.
Step 4. Release the panel button, and the test card will print.
This is an example oI the test card:
2.12 Packing the P330! Printer for Shipment
II the P330! Printer is to be shipped, it is important to use the original packing and shipping
material to prevent damage to the Printer. II the original material is lost, a replacement
Shipping Kit can be ordered Irom Zebra; please reIer to the Media List on the Windows
Drivers and User Documentation CD supplied with this printer.
Step 1. Remove cards in the card Ieeder:
PRINTER: P330iM
Serial N: XXXXX
Firmware: XXXXXXX
Head resistance: XXXX
Offset: XXXX-XXXX
EC:XX
Printing counter: XXXXX
300 dpi
PLASTIC CARD PRINTER
TEST CARD
Note The speciIics oI the shipment and the printer`s condition may inIluence which oI the
Iollowing steps are Iollowed; common sense should prevail.
a. While the printer still has power applied and is turned on, and is still connected to the
host computer, remove cards Irom the card Ieeder. The last card may be diIIicult to
remove. II so, use the Eject Card command available through the driver on the host
computer to eject the last card that is staged in the Ieeder.
b. Close the Card Feeder Cover.
Step 2. II the printer still has power applied and is turned on, and is still connected to the host
computer, set the printer`s power switch (on the back oI the printer) to the OFF ( O )
position, and disconnect the interIace and power cables to the printer.
Step 3. Open the Main Cover. Open the Print Head Carriage and remove the Ribbon. (II you
wish to save the ribbon Ior Iuture use, you may want to put it in a plastic bag Ior
storage.)
Step 4. Insert the print head protection pad, and close the Print Head Carriage. Remove the
Card Cleaning Cartridge and place it in the upper Ioam insert. Close the Main Cover.
Step 5. Slide the Output Hopper in all the way against the Printer.
Step 6. Place the Printer in its protective plastic bag.
Step 7. Place the lower Ioam insert in the lower part oI the shipping carton.
Step 8. Use both hands to careIully place the Printer into the recess in the lower Ioam insert.
Step 9. Place the upper Ioam insert onto the Printer and gently press it down so it makes a
snug Iit on the Printer; the top oI the upper Ioam insert should be even with the upper
edge oI the lower part oI the shipping carton.
Step 10. Slide the upper part oI the shipping carton down over the lower part.
Step 11. Insert and close the handles/latches.
Caution Do not physically pull the last card out of the feeder staging area. This could
damage the printer and void the warranty, as well as damage the card.
2.13 Operation
Printing with the P330! Card Printer is similar to printing with any other printer in a Windows
environment.
The Printer Driver SoItware is installed on your computer (see Chapter 2).
The P330! Printer is connected to the power source and the computer (see Chapter 2).
The P330! Printer is selected by either the Operating System or the appropriate application
soItware program.
Printer Properties are set (the Iactory deIault values will be appropriate Ior many
applications).
Card printing is directed by the appropriate application soItware program.
2.13.1 Setting Printer Properties
Printer Properties can be set either at the Operating System level or within the application
soItware program used Ior printing cards.
PreIerences settings can conIigure the P330! Card Printer Ior Landscape (wide) or Portrait
(tall) printing orientation, and allow the user to veriIy that the desired ribbon is installed in the
printer. (Monochrome ribbons are selected via the drop-down menu.) Detailed instructions on
setting printer parameters is presented in Appendix A.
II the P330! Printer includes the optional magnetic card stripe encoder, encoding parameters
and coercivity can be set.
Printer cleaning can be initiated Irom the Tools window (printer cleaning can also be initiated
at the printer; see Chapter 4).
Also Irom the Tools window, the Test Card can be selected Irom several pre-loaded styles.
'Single Feed Options allows Disabling or Enabling Single Feed Support.
II 'Disable Single Feed Support is selected, when the P330! Card Printer runs out oI
cards in the Ieeder, the LCD display will read OUT OF CARDS. To continue, press the
panel button.
II 'Enable Single Feed Support is selected, when the P330! Card Printer runs out oI cards
in the Ieeder it will wait until a card is inserted in the single-card slot or cards are loaded in
the Ieeder, and then will automatically continue.
Note In the Iollowing description oI setting Printer Properties, only those properties and
options that are suitable Ior being set by the User are described. The User should not make
selections or set parameters unless they are speciIically described in this section
2.13.2 Printing a SampIe Card
Sample card designs are installed with the printer driver. Sample cards require MicrosoIt Word
or MicrosoIt Paint application soItware. The cards are accessed via the Start menu. Select
Start, select Programs, select Zebra Card Printers, and select a sample card, or Iollow the
directions below to design a card.
Follow these steps to design and print your Iirst card:
Step 1. Launch MicrosoIt Word SoItware. Depending on your computer conIiguration this
may be done by double-clicking an icon on your desktop, or by clicking the
Windows Start icon, selecting Programs, and navigating to MicrosoIt Word
Step 2. Go to the File menu and choose Page Setup.
Step 3. Select the Paper Size tab, choose Card. Under orientation, select Landscape.
Step 4. Select the Margins tab, and set the Top, Bottom, LeIt, and Right margins to 0 (zero).
Step 5. Click OK to close the Page Setup window.
Step 6. The card appears on the screen.
Step 7. Design a card with both black and colored text and with colored pictures (see
example below).
Step 8. Once you are ready to print, go to the File menu and select Print.
us!
http://www.zebracard.com
Note For cards thinner than 20 mils (0.51 mm), the card design must be limited to (1) no
more than two 30 mm x 30 mm areas oI Iull color, (2) black inIormation (text and barcode,
Ior example) must cover no more than 50 oI the card area, and (3) there must be at least a
5mm unprinted border along all edges.
For cards thicker than 40 mils (1.02 mm), the card design must have at least a 5mm unprinted
border along all edges.
For cards with thickness between 20 mils (0.51 mm) and 40 mils (1.02 mm), these
restrictions do not apply; Iull color printing is permitted edge to edge in both directions.
Step 9. II the printer was not selected as the deIault printer, go to the File menu, select Print
Setup and choose Zebra P330! Card Printer Irom the printer names list. Then
Close the Print Setup dialog box.
Step 10. The printer will Ieed in a card and start printing (the data download time will vary
depending on the complexity oI the card design and the processing speed oI your
computer).
Step 11. Once the printing job is complete, the card is ejected Irom the printer.
2.13.3 Feeding One Card at a Time
A Manual Feed Slot is available below the Card Input Hopper Ior Ieeding single cards. The
Card Input Hopper must be empty Ior single-card Ieeding to work properly.
Step 1. Open the Card Feeder cover. VeriIy that there are no cards in the Ieeder, then close
the Card Feeder cover.
Step 2. Insert a single card into the slot below the Card Feeder. Do not Ieed more than one
card at a time.
Note II single-card Ieeding will be the normal mode oI operation, you may select that mode
through the driver soItware. In single-card Ieed mode, the card will not be printed until the
print job has been sent to the printer and the card to be printed has been inserted into the
single-card Ieed slot.
#
67$"#8 "9 :2$#,)1"(
This chapter includes Iive major topics:
Card Printing Basics
Card Path Elements
Card Movement During Printing
Block Diagram
CPU PCBA Connections
3.1 Card Printing Basics
This section provides an overview description oI how images are printed on plastic cards by
the Zebra P330! Card Printer.
Print Head
The Print Head is a thin-Iilm device that consists oI a row oI individually addressable heating
elements. Each heating element is approximately 0.0033 inch (0.08 mm) wide, giving a print
resolution oI 300 dots per inch.
Heating
Elements
Theory of Operation
There are a total oI 672 heating elements. Since the width oI the plastic card is 2.125 inches
(54 mm), 638 elements provide Iull-width coverage. The 'extra 34 elements (17 on either
side oI the card`s nominal width) are present to support programmable image centering and
Iull bleed imaging even iI a card is slightly oversize.
The Print Head Assembly mounts in the Print Head Carriage Assembly. The Print Head
Carriage assembly can be raised Ior ribbon installation.
The Print Head Assembly and Print Head Carriage Assembly hold the Print Head at a right
angle to the card`s long surIace, while allowing the tilt angle oI the Print Head to be adjusted to
give optimum print quality.
Platen Roller Ribbon Supply Spindle Ribbon Take-Up Spindle
Print
Head
Print Head
Carriage
Assembly
(Shown
Raised)
Print
Head
Assembly
Print Head Assembly
Tilt Adjustment Range
Theory of Operation
3.1.1 Printing TechnoIogies and Ribbons
There are two types oI printing technology used in the Printer: Dye Sublimation and Thermal
TransIer. The technology to use is determined by the type oI dyeor ink on the ribbon.
Monochrome Ribbons have a single color ink on the length oI the ribbon. The Printer is
programmed to use Thermal TransIer printing Ior monochrome ribbons.
Multi-Panel Ribbons have a repeating sequence oI panels oI diIIerent dye. RFID Multi-Panel
Ribbons have an RFID tag on the supply spool; the RFID code identiIies the ribbon typr and
panel count. (Note that the lack oI an RFID tag will be interpreted by the Printer as being a
Monochrome Ribbon.) Printing with a Multi-Panel Ribbon requires multiple passes oI the card
under the Print Head, once per panel.
For Iull-color printing, a 'YMCKO Multi-Panel Ribbon is generally used. A YMCKO ribbon
will have successive panels as Iollows:
Color Technology Function / Usage
Yellow ('Y) Dye Sublimation Full-Color Printing and Dye
Sublimation Black Printing
Magenta ('M) Dye Sublimation Full-Color Printing and Dye
Cyan ('C) Dye Sublimation Full-Color Printing and Dye
Black Resin ('K) Thermal TransIer K Resin Black Printing
Varnish Overlay ('O) Thermal TransIer U. V. Protective Coating
Other ribbons are available Ior the P330! Card Printer; see the Supplies List on the Driver and
Documentation CD that came with your printer, or go to the Zebra Card Printer Solutions
website at http://www.zebracard.com.
Ribbon Movement From Supply Spool
(YMCKO
Pattern
Repeats)
Yellow ("Y)
Dye
Cyan ("C)
Dye
Magenta
("M) Dye
Black
("K)
Resin
Varnish for
Overlay
("O)
Dye Sublimation Printing Process Thermal Transfer
Printing Process
Theory of Operation
The ribbon synchronizes to it`s 'starting position whenever the Print Head is opened and then
closed. For a YMCKO ribbon, the starting position will be with the leading edge oI a Yellow
Panel at the Print Head location.
The Iollowing Iigure shows how the ribbon and card move relative to each other during
printing.
1. Ribbon Moves Yellow
Panel into Position at
Print Head
Print Head at
Fixed Position
2. Card is Fed to Printing
Position Under the Print
Head
3. Card and Ribbon Move Together
as Yellow Panel is Printed
4. Card and Ribbon Stop at
End of Yellow Panel
5. Ribbon is Stationary; Card is
Moved Back to Printing Position
6. Card and Ribbon Move Together
as Magenta Panel is Printed
Theory of Operation
Dye SubIimation Printing
In Dye Sublimation Printing, each Print Head heating element is applied voltage at one oI a
number oI pulse widths. A wider pulse results in the element getting hotter, which converts
more oI the dye (at that pixel location) to a gas and diIIuses it into the surIace oI the card (a
wider pulse gives more intense color at that pixel). This is repeated Ior each oI the dye panels
(i.e., Yellow, Magenta, and Cyan), to result in Iull-color images.
ThermaI Transfer Printing
In Thermal TransIer, voltage is either applied or not applied to each Print Head printing
element. II voltage is applied, the ink at that location is transIerred to the surIace oI the card.
Each pixel is either printed (i.e., the ink transIerred to the card) or not; there are no
intermediate levels.
Thermal TransIer printing with a resin ribbon is used Ior printing bar codes, since contrast
between the light and dark areas is the highest and the edges are the sharpest.
Print Head
Platen Roller
Ribbon
Carrier
Layer
Ribbon
Dye
Layer
Card
Gaseous Dye
is Absorbed by
Card
Print Head
Platen Roller
Ribbon
Carrier
Layer
Ribbon
nk Layer
Card
nk Transfered to
Surface of Card
Theory of Operation
3.2 Card Path EIements
The Iigure below shows the rollers that transport Cards as they make their way through the
P330i printer. The rollers keep the card on a horizontal path, reducing the chance oI a card
edge catching on anything.
The Iigure below shows the sensors that track card and ribbon position and movement.
Card
Path
Card Feed
Rollers
Cleaning
Roller
Transport and
Platen Rollers
Single
Card Feed
Sensor (on
enclosure)
Ribbon
Color
Sensor
Card
Entry
Sensor
Feeder
Sensor
Cam
Sensor
(PCBA)
Magnetic Encoder
Sensor (if equipped)
Smart Card
Sensor (if
equipped)
Head
Open
Sensor
Ribbon
Sync.
Sensor
Theory of Operation
3.3 Card Movement During Printing
The P330i printer moves a card through a speciIic sequence oI movements as it encodes and
prints the card.
The card is Ied Irom the bottom oI the stack in the Card Input Hopper, or in through the
Single Card Feed Slot.
The card moved along in contact with the exposed sticky area oI the Cleaning Cartridge;
this cleans dust or dirt particles Irom the (upper) card surIace.
II the printer includes an optional Smart Card Encoder (either contact-style or contactless),
the smart card is encoded.
II encoding Iails, the card is moved directly to the card exit, without printing. This is
done to avoid wasting time and ribbon panels on a deIective card.
Card
nput
Hopper
Single
Card
Feed
Slot
Cleaning
Cartridge
(Optional)
Smart Card
Contact Station
Print
Head
(Optional)
Magnetic Stripe
Encoding Station
Output
Hopper
Card
Exit
Theory of Operation
II the printer includes an optional Magnetic Stripe Encoder, the card is moved past the
print head to the magnetic encoder, and the stripe is encoded.
Note that the card goes past the print station without being printed at this time. AIter
magnetic encoding, the card is moved back to just beIore the print head.
As with smart-card encoding, iI magnetic encoding Iails, the card is moved directly to
the card exit, without printing.
The leading edge oI the card is moved under the Print Head, and the print head is lowered.
When the printer was turned on, the ribbon was automatically 'synchronized, bringing
the leading edge oI the yellow ribbon panel under the print head.
Lowering the print head reduces space between the print head, the ribbon, and the card,
reducing spread oI the printed spot and giving sharper images.
As the card and ribbon move along, each element oI the print head is energized to one oI
32 levels (Irom completely oII to maximum heat), which melts a corresponding amount oI
yellow dye onto that particular spot on the card.
II using a resin ribbon (used when printing a bar code on a card), the head elements
are energized to either on or off. The on level actually transIers the spot oI resin under
the print head element to the card. This results in the sharpest possible images; Ior bar
codes you want the sharpest edges and highest contrast between dark and unprinted
areas.
AIter this yellow pass is completed, the print head is raised, the card is moved back, and
printing continues with the Magenta ribbon panel, then the Cyan panel, then the Black
('K) panel iI present, then an Overlay panel.
When using a monochrome ribbon, the card makes a single pass under the print head.
When printing is completed, the card is moved (past the magnetic encoder, iI present) to
the Card Exit, where it Ialls into the Output Hopper.
Theory of Operation
3.4 BIock Diagram
Most oI the circuitry in the P330! is on the CPU PCBA. Since the CPU PCBA is not a
serviceable unit, circuit analysis to the component level is pointless.
Below is a block diagram oI the Iunctional circuits oI the P330! Printer; the block diagram also
shows how signals are passed to and Irom the CPU PCBA to the rest oI the printer.
(Mag Encoder Option Components)
(Smart Card Option Components)
Ribbon RFID
Circuitry
Power
Control
AC Voltage
Power
Supply
24 VDC
Magnetic
Encoder
LCD Display
Panel
Printhead
Printhead
Circuitry
Smart Card
Encoder
Circuitry
Contact or
Contactless
Smart Card
Encoder
Sensor
Calibration
Circuitry
Ribbon and
Card Transport
Motors
Motor
Drivers
I/O
Daughter-
board
A/D Circuitry
for Optical
Sensors
Optical
Sensors
USB
Circuitry
USB Port
Ethernet
Connection
Circuitry
Ethernet
Extension
Board
Ethernet
Printserver
Board
Ethernet
Port
Memory
for CPU
Clock
CPU
RFID
Transponder
(Ethernet Option Components)
Magnetic Encoder
Circuitry
RFID Tag in
Ribbon Core
LCD Display
and Panel
Button
Circuitry
Panel
Button
P330i CPU PCBA
Theory of Operation
3.5 CPU PCBA Connections
Most oI the circuitry in the P330! is on the CPU PCBA. Since the CPU PCBA is not a
serviceable unit, circuit analysis to the component level is pointless; but a basic understanding
oI how the CPU PCBA connects to the rest oI the printer helps to better understand the P330!
printer.
J11
(Ribbon RFID)
J7
(Smart Card)
J1
(Mag Encoder Head)
J8
(Auxiliary RS-232;
factory use only)
J6
(USB Port)
J12
(+24 VDC
Input from
Power Supply)
J3
(Out of Cards Sensor)
J4
(Not Used)
J10
(LCD Panel)
J9
(Print Head,
Head Lock,
Head Temp. Sensor)
J13
(Motors and Sensors -
Connects to
I/O Daughterboard)
J2
(Mates with Ethernet
Extension Board)
$
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The objective oI troubleshooting is to relate a problem to an associated assembly or system
Iunction, in order to most eIIiciently isolate and repair the problem. Typically this involves
determining the Iailure symptom and then checking one or more possible causes oI the Iailure.
Only a symptom-related list oI possibilities appears. In general, Ior a given Iailure symptom
one or more possible causes are listed, with suggested corrective action to take. These causes
should be checked and corrective actions taken in the order given; they are listed in order oI
likelihood and complexity.
When the suggestions presented Iail to lead to a repair, a CPU Board replacement, iI not
prescribed, should nevertheless be tried. A check Ior broken or disconnected cables and any
loss oI power should also take place along with checks Ior obvious mechanical damage.
The Test SoItware described in Appendix A includes selections to exercise most printer
Iunctions. Beyond this, Zebra Card Printer Solutions oIIers Technical Support and Iactory
repair as options.
TroubIeshooting
4.1 Power-Up FaiIures
Some problems are evident as soon as power is applied to the printer. The Iollowing table will
help in diagnosing these problems.
4.2 LCD PaneI Messages
The LCD Panel on the Iront oI the printer continuously displays messages as to what operation
the printer is perIorming as well as certain Iault messages. The Iollowing table lists possible
causes and solutions to the Iault messages.
Symptom Possible Cause Corrective Action
When power is turned on,
nothing at all happens (no sound,
LCD panel stays dark).
1. No power to printer.
2. DeIective EMI Iiltering
components.
3. Check Fuse in Power Supply.
4. DeIective Power Supply.
1. Check AC power source,
veriIy power cord is plugged
into printer, try a diIIerent
power cord.
2. Check EMI Iiltering
components.
3. II Fuse in Power Supply is
blown, replace it. II
replacement Iuse blows,
replace Power Supply.
4. Replace Power Supply.
sounds are heard inside printer
and ribbon advances, but LCD
Panel stays dark.
1. Cable Irom CPU PCBA to
LCD Panel unplugged at either
end.
2. DeIective LCD Panel.
3. DeIective CPU PCBA.
1. VeriIy cable Irom CPU PCBA
to LCD Panel securely
plugged in at both ends.
2. Replace LCD Panel.
3. Replace CPU PCBA.
sounds are heard inside printer,
LCD Panel lights up and
INITIALIZING message scrolls,
but LCD Panel message does not
change to a steady READY
message within about 30
seconds.
1. DeIective CPU PCBA. 1. Replace CPU PCBA.
TroubIeshooting
Problem / Description Cause / Solution
The LCD Panel displays OUT
OF CARDS message.
1. Check Ior cards in the card
Ieeder. II no cards present,
load cards.
2. Check that Card Thickness
Control lever is properly
adjusted (see Loading Cards in
Chapter 2).
3. Press the Panel Button Ior 1
second. The printing job will
restart.
The LCD Panel displays OUT
OF RIBBON message.
1. Check ribbon. Replace iI
deIective or entirely used.
Ribbon will automatically
synchronize and printing will
restart with a new card.
The LCD Panel displays PRINT
HEAD OPEN message.
1. Check that Print Head
Carriage is closed and latched.
II not, close and latch it.
The LCD Panel displays
MECHANICAL ERROR
message.
1. Check that you are using the
correct card type (see
Technical SpeciIications).
2. Check that Card Thickness
Control lever is properly
adjusted (see Loading Cards in
Chapter 2).
3. II two cards are Ied into the
printer at the same time: Open
cover and remove Card
Cleaning Cartridge, empty the
Card Feeder, and pull the
jammed cards out. Replace the
Card Cleaning Cartridge.
Separate the cards as shown in
Loading Cards in Chapter 2,
and replace.
4. Check that ribbon is loaded
correctly.
ENCODING ERROR message.
1. Check that you are using the
correct magnetic card type (Ior
low or high coercivity
encoding).
2. VeriIy command syntax.
3. Contact Zebra technical
support.
CLEAN PRINTER message.
1. Clean the printer (see Chapter
4).
TroubIeshooting
4.3 Printing a Test Card
Printing a Test Card is an eIIicient way to determine iI there is a card transport problem or a
printing problem.
Test Card
Emerges
from Printer?
Print a Test Card
(See Section 2.11)
No
Check Problems
Associated With
Card Transport.
See Section 4.4.
Yes
No
Check Problems
Associated With
Print Anomalies.
See Section 4.5.
Yes
No Problem
With Basic
Printing.
Test Card
OK?
P75i
TroubIeshooting
4.4 Card Feed or Transport FaiIures
Troubleshooting oI card Ieed or transport Iailures generally involves seeing where the Iailure
occurs or what type oI Iailure it is. That determination leads to checking certain assemblies or
components.
Symptom Possible Cause Corrective Actions
Cards don`t Ieed at all. 1. Card Thickness Control is
improperly adjusted.
2. DeIective Feeder Sensor.
3. Dirty or torn/missing Card
Feeder Belt.
4. DeIective Card Feed Roller.
5. Broken Card Feed Drive Belt.
6. DeIective Card Feed Motor.
1. Set Card Thickness Control
correctly (see section 2.6).
2. Replace Feeder Sensor.
3. Clean or replace Card Feeder
Belt.
4. Replace Card Feed Roller.
5. Replace Card Feed Drive Belt.
6. Replace Card Feed Motor.
Multiple card jam. 1. Card Thickness Control is
2. Cards are sticking together.
2. Be sure to separate the cards
when loading them into the
Card Feeder, as described in
section 2.7.
Partial Card Feed. 1. Card Thickness Control is
Card stalls near Cleaning
Cartridge.
1. Dirty or deIective Clean Drive
Roller.
2. DeIective 63T x 4mm Stepper
Motor Belt.
3. DeIective Stepper Motor.
1. Clean or replace Clean Drive
Roller.
2. Replace 63T x 4mm Stepper
Motor Belt.
3. Replace Stepper Motor.
TroubIeshooting
4.5 Print AnomaIies
A careIul examination oI the cards that are printed will lead to eIIicient troubleshooting oI
printing problems.
Keep in mind that cleanliness and the card stock are two Iactors that strongly aIIect print
quality.
Card stalls at Platen (i.e., under
the Print Head).
1. Dirty or deIective Print Head
Platen Roller.
2. DeIective 56T x 1/8 Timing
Belt.
1. Clean or replace Print Head
Platen Roller.
2. Replace 56T x 1/8 Timing
Belt.
Card doesn`t exit printer 1. DeIective 104T x 1/8 Timing
Belt.
2. Dirty or deIective Exit
Pressure Roller.
3. Dirty or deIective Exit Card
Drive Roller.
1. Replace 104T x 1/8 Timing
Belt.
2. Clean Exit Pressure Roller or
replace Exit Pressure Roller
Assembly.
3. Clean or replace Exit Card
Drive Roller.
Symptom Possible Cause Corrective Actions
Note For optimum print quality, always keep the Main Cover and the Card Feeder Cover oI
the printer closed,
TroubIeshooting
No Image. 1. Ribbon is not an !-Series
Ribbon.
2. Ribbon incorrectly installed.
3. Cards may not meet
speciIications.
4. Print Head elements may be
scratched or burnt.
5. Print Head not being
positioned correctly.
1. Always use !-Series Ribbons
in the P330! printer.
2. Check that ribbon is installed
3. Use a diIIerent supply oI cards.
4. Replace Print Head.
Replace Print Head Up/Down
Motor.
Check Print Head Position
Sensors, replace iI deIective.
Faint Image. 1. Dirty Print Head.
2. Low Print Head Voltage.
1. Clean Print Head.
ArtiIacts. 1. Particles on Feed or Transport
Rollers.
Horizontal Lines. 1. Dirty or damaged Print Head
element.
1. Clean the Print Head (see
Chapter 4). II horizontal lines
are still present, replace the
Printhead Assembly.
Multiple Evenly-Spaced
Horizontal Lines.
1. Print Head Registers on CPU
PCBA
Wavy horizontal lines (these will
be especially noticeable in solid
blocks oI color).
1. Printhead Assembly out oI
alignment.
1. Align Printhead Assembly (see
Printhead Replacement
Procedure).
Replace Printhead Assembly.
Vertical Lines.
Sticking Ribbon. 1. Peel Bar on Print Head
Assembly out oI adjustment.
1. Adjust Peel Bar or replace
Print Head Assembly.
Washout. 1. Peel Bar on Print Head
Assembly out oI adjustment.
1. Adjust Peel Bar or replace
Print Head Assembly.
Sheared Ribbon 1. X-OIIset value incorrect. 1. Adjust X-OIIset value.
TroubIeshooting
Image OII-Center
1. Excessive border at trailing
edge oI card.
2. Excessive border at leading
edge oI card.
3. Excessive border at card
edge nearer Iront oI printer.
4. Excessive border at card
edge nearer back oI printer.
1. X-OIIset value too low.
2. X-OIIset value too high.
3. Y-OIIset value too low.
4. Y-OIIset value too high.
1. Increase X-OIIset value.
2. Decrease X-OIIset value.
3. Increase Y-OIIset value.
4. Decrease Y-OIIset value.
CYMK Not Aligned.
Abrupt Color Change.
Small spots appear on the
printed card with a non-printed
area or a diIIerent color.
1. Contamination on the card
surIace.
2. Dust inside the printer and/or
dirty Cleaning Cartridge.
1. Check that cards are stored in a
dust Iree environment.
2. Clean the printer (see Chapter
4).
3. Replace Cleaning Cartridge
(see Chapter 4).
There are non-printing
horizontal lines (white) on the
card surIaces.
1. Ribbon not correctly
positioned.
3. Print Head is dirty.
4. Print Head elements are
damaged (e.g., scratched or
burnt).
1. Ensure that the ribbon is
properly rolled onto the ribbon
spindles and that there are no
wrinkles in the ribbon.
2. Replace ribbon.
3. Clean the Print Head
4. Replace Print Head Assembly.
TroubIeshooting
Printing shows very pale, very
dark, or inconsistent results
1. DeIective ribbon.
speciIications.
3. Contrast and/or Intensity may
be set to incorrect values.
4. Head Settings are too low /
high.
5. Dust or embedded
contamination on elements oI
the Print Head.
1. Change ribbon and print again.
3. Adjust Contrast and/or
Intensity values in soItware.
4. Adjust Head Settings higher /
lower.
5. Clean the Print Head (see
Chapter 4). II contamination
cannot be removed, replace the
Printhead Assembly.
Printing shows blurry printed
image.
1. Ribbon cartridge may not be
correctly positioned.
2. Ribbon may not be
synchronized on the correct
color panel position.
speciIications.
4. Dust or embedded
contamination inside the
printer and/or dirty Cleaning
Cartridge.
1. Check that the ribbon is
properly rolled onto the
spindles.
.
Replace ribbon and print
again.
2. Open the Print Head Carriage,
then close it. This will cause
the ribbon to re-synchronize.
4. Clean the Printer.
Replace the Cleaning
Cartridge.
Only one panel oI a color ribbon
prints.
1. Using the wrong type oI
ribbon.
1. Use only ! Series ribbons Ior
Iull color printing.
Text prints ok but graphics have
image distortion, blotches oI
color, color dots or grid.
1. Graphics incompatibility. 1. Use diIIerent Iormat Ior
graphics.
Use higher-resolution
graphics.
TroubIeshooting
4.6 TroubIeshooting the Ethernet Connection and Adapter
4.6.1 Resetting to Factory DefauIts
To reset the Ethernet Adapter conIiguration parameters to the Iactory deIaults, press the
Ethernet Switch and hold it in while turning the printer power on. Keep the Panel Button
pressed until the Status Indicator light turns green, then release the Ethernet Switch. To print a
conIiguration card, press and hold the Ethernet Switch until a card starts to print.
Ethernet
Reset
Button
Ethernet
Adapter
Status
ndicator
Network
Status /
Activity
ndicator
TroubIeshooting
4.6.2 Ethernet Adapter Status Indicator
A bi-color Status Indicator displays the operational status oI the Ethernet Adapter. The
Iollowing conditions might occur:
During normal operation, the LED is solid green Ior more than 30 seconds. This indicates all
the hardware is Iunctioning properly and the Ethernet Adapter has detected the presence oI the
network. It does not mean the Ethernet Adapter has an IP address or is attached to a printer
queue.
II the LED is rapidly Ilashing green (9 times/sec), the Ethernet Adapter has not detected the
presence oI a network cable. To solve the problem:
VeriIy that the network cable is appropriate Ior the network and has an RJ-45 connector.
Turn the printer power oII (O). Remove the network cable Irom the Ethernet Adapter. Plug the
network cable back in until you hear a positive click. Check the other end oI the cable in the
same manner. Turn the printer power on; iI the Ethernet Adapter still does not detect a cable,
continue.
Connect the Ethernet Adapter to a known good network connection. II the Ethernet Adapter is
still unable to detect the network cable, contact Technical Support Ior assistance.
II the LED is slowly Ilashing green (1 time/sec), the Ethernet Adapter is trying to print a job. II
the job does not print, check the Iollowing:
VeriIy that the printer has media and ribbon. II the printer is showing any errors, it is unlikely
that the Ethernet Adapter can send data to the printer. The LED continues to blink until the
printer malIunction is resolved or until the printer is turned oII (O).
Flashing red indicates the Power On SelI Test (POST) is in progress.
II the LED is solid red Ior more than 30 seconds, the Ethernet Adapter has Iailed the POST. A
Iailed POST can be caused by any oI the Iollowing:
The printer attached to the Ethernet Adapter device is malIunctioning. Turn the printer power
oII, wait 10 seconds, then turn the printer back on ( | ).
II the Ethernet Adapter still Iails the POST, the Ethernet Adapter has a hardware problem that
can be Iixed only by replacing or returning the unit. Contact Technical Support Ior repair or
replacement inIormation.
II the LED is alternately Ilashing red and green Ior longer than 2 minutes, the Ethernet
Adapter is in Iirmware-download mode. This means it is waiting Ior new Iirmware data to be
sent beIore it continues normal Iunctioning. PerIorm the Iollowing:
Important Cables with a rating higher than CAT-6 have not been tested.
TroubIeshooting
II the Ethernet Adapter was purposely put into Iirmware-download mode, Iinish the download
with the proper update utility. Contact the Zebra web site at
http://www.zebra.com to download this utility.
Contact Technical Support Ior help recovering this unit.
TroubIeshooting
4.6.3 Network Status/Activity Indicator
A bi-color Status/Activity LED indicates network speed, established link, and network
activity.
II the LED is oII, no link was established.
II the LED is solid green, a 100Base link is established.
II the LED is Ilashing green, a 100Base link is established and network activity has been
detected.
II the LED is solid orange, a 10Base link is established.
II the LED is Ilashing orange, a 10Base link was established and network activity has been
detected.
Network activity detected by this LED does not mean the activity is data Ior the print server.
The activity is all activity on the network as seen by the Ethernet Adapter.
TroubIeshooting
%
=$2-,0$>$() ?#"0$&5#$*
5.1 Introduction
The Iollowing sections describe removing both major assemblies and, where applicable,
subassemblies and/or components that are considered replaceable. In general, only removal
directions are presented; unless otherwise noted, replacement would be perIormed by
reversing the removal steps. Replacement instructions Ior some items are not presented;
removal and replacement oI these items are considered too obvious to warrant a detailed
description.
EIectric Shock Caution Before performing any of the procedures in this chapter, set
the printer power to OFF (O) and disconnect the power cord.
Caution Before beginning any of the procedures that follow, read completely through
the procedure. f you do not have the specified tools, or if any step(s) seem beyond your
skill or experience level, do not attempt the procedure. You may cause additional damage
to the printer.
Note Some oI the photographs in this section may show printers with diIIerent
conIiguration or options than your particular printer. They may also show additional parts
removed in addition to removals Ior the process being described. Please disregard these
diIIerences; the inIormation pertaining to the replacement process being described will still
apply to your printer.
still
RepIacement Procedures
5.2 Required TooIs
This section lists the tools required Ior the replacement procedures described in this chapter.
Naturally, not all tools are required Ior a particular procedure; speciIic tools are called out in
each step as appropriate.
blah
1. Flat-Blade Screwdrivers, Irom 1/16 inch (2 mm) to 1/4 inch (6.5 mm)
2. Numbers 0, 1, and 2 Phillips Screwdrivers
3. Torx T10 and T15 drivers
4. Small Gear Puller (strongly recommended)
5. Small Crescent Wrench or locking pliers
6. Fine-Point, OIIset Fine-Point, and Needle-Nose pliers
7. Small Diagonal Cutters or other cutter Ior cutting cable ties
8. 1.5 mm and 2.0 mm hex keys
9. 5.5 mm hex driver (this can also be used Ior securing push nuts)
10. Small and Medium Spring Hook Tools
11. Soldering Iron with Iine pointed tip
Important When removing any oI the nylon or plastic pulleys or gears, the use oI a gear
puller is strongly recommended. II a gear puller is not available, use pliers and/or a Ilat-blade
screwdriver to pry the gear or pulley oII its shaIt.
In either case, remove any loctite residue Irom the shaIt and the gear/pulley.
Inspect the old gear/pulley very careIully. II any teeth have burrs, are missing, or are
damaged, or iI the center hole is distorted or enlarged, the gear/pulley must be replaced rather
than the old one re-installed.
Note Unless speciIically stated, all screws noted in this document use the Torx T10 driver.
5.1 RemovaI Sequence
This Iigure shows the recommended removal sequence. For example, to remove the CPU
PCBA, you would remove the Top Cover (procedure given in section 5.2 on pg 64), remove
the Print Engine Irom the Lower Cover (section 5.3 on pg 67), remove the Connector Plate
(section 5.4 on pg 68), and then remove the CPU PCBA (section 5.24 on pg 142).
5.2 Top Cover (pg 64)
5.3 Remove Print Engine
from Lower Cover (pg 67)
5.4 Connector Plate (pg 68)
5.5 Power Supply Cover (pg
71)
5.6 Power Supply (pg 73)
5.7 Rear Plate (save bear-
ings and wavy washers) (pg
75)
5.8 Cam Lever (pg 78)
5.9 Platen Inertia Roller (pg
79)
5.10 Printhead Pressure
Spring (pg 80)
5.11 Film/Bracket Sensor
PCBA (pg 81)
5.12 Pressure Spring Plate
(pg 82)
5.13 Cam Arm Follower Assy
(pg 83)
5.14 Clutch Assembly (pg 84)
5.15 Print Head / Carriage
Assembly (pg 88)
5.16 Print Head Lift Cam (pg
92)
5.19 Encoder Shroud
& Exit Pressure Roller
(pg 113)
5.20 Exit Pressure
Roller Assy (pg 116)
5.21 Balls
Retainer
Plate,
Springs,
Balls (pg
125)
5.22.1 Card
Sensor Cable
Assy (pg 127)
5.22.2 Card
Feeder Drive
Belt, Card
Feeder Motor
(pg 129)
5.22.3 Card
Feeder Assy,
ESD Brush,
Card Feeder
Belt, Card
Feeder Roll-
ers (pg 134)
5.18 LCD PCBA (pg 111)
5.23 Power
and Filter
Components
(pg 141)
5.24 CPU
PCBA (pg
142)
5.25 I/O Daughterboard (pg 145)
5.37 Replace Parts that Require Separating the
Front Frame from the Center Frame (pg 181)
5.30 Stepper Motor
Drive Belt (pg 156)
5.31 Stepper Motor
(pg 157)
5.34 Card
Sensor
Cable Assy
(pg 166)
5.35 Print Head Cable
Assy (includes Sensor
& Fan) (pg 171
Start Here
CompIete P330i Printer
5.38 Magnetic
Stripe Encoder
Option (pg 186)
5.39 Smart
Card Options
(pg 188)
5.36 Print Head
Lift Motor (pg 180)
5.32 RFID PCBA
(pg 160)
5.33 Ribbon Color
Sensor (pg 162)
5.27 Ribbon O-Ring
Drive Belt (pg 149)
5.28 Ribbon Pulley
Assy, Ribbon Take-Up
Spindle (pg 151) 5.29 Ribbon Motor Pulley,
Ribbon Motor (pg 154)
5.17 Print Head Assembly (pg 94)
5.18 LCD
Cable Assy
(pg 111
5.26 RFID
Cable (pg 147)
Remove I/O Daughterboard if not
already removed (pg 145)
Remove Print Head
Assembly if not
already removed (94)
5.2 Removing the Top Cover
Step 1. Turn the printer power oII, and disconnect the power cord. II an interIace cable (USB
or ethernet) is plugged into the printer, disconnect it. Remove any plastic cards Irom
the Card Input Hopper.
Step 2. Turn the printer over, and rest it upside-down on a work surIace.
Step 3. Press a screwdriver or similar tool into the Hopper Release Hole and slide the Card
Output Hopper out oI the printer.
Step 4. Remove Iive screws securing the top cover Irom underneath. Four oI them are at the
Card Input Hopper end oI the printer, as shown below.
Step 5. The IiIth Top Cover attachment screw is located above the card output opening (this
is why the Card Output Hopper was removed). See below.
Top Cover
Attachment
Screws
Hopper
Release
Hole
Step 6. Turn the printer over, so it is right-side up. Remove two screws into the upper part oI
the back oI the printer.
Step 7. Remove one remaining screw attaching the top cover.
Top Cover
Attachment
Screw
Remove
These
Screws
Step 8. CareIully remove the top cover. Be careIul to avoid damaging the cable to the LCD
Panel PCBA or the wires to the card sensor.
Remove This Screw
Top
Cover
5.3 Removing the Print Engine from the Lower Cover
Step 1. Remove two screws Irom the back oI the lower cover to release the print engine.
Step 2. Remove the print engine Irom the lower cover.
Remove These 2 Screws
5.4 Removing the Connector PIate
Step 1. Remove the two Phillips-head screws shown in the Iigure below.
Step 2. Disconnect the ground lug as shown below.
Remove These 2 Phillips-head Screws
Ground Lug
Step 3. Remove the screws attaching the print engine to the Connector Plate as shown in the
two pictures below.
Remove This Screw
Remove This
Screw
Step 4. Swing the Connector Plate away Irom the Print Engine as shown below. II your
printer includes the 'Contact Station Smart Card Option, disconnect wires to the
Smart Solenoid PCBA as you swing the Connector Plate.
Step 5. Then detach the wires at the Power Switch that go to the Power Supply, Ireeing the
Connector Plate Irom the Print Engine.
Connector Plate
Smart Solenoid PCBA
(Part of "Contact Station Smart Card Option)
5.5 Removing the Power SuppIy Cover
Step 1. Remove Iour screws holding the Power Supply Cover in place, as shown in the next
two pictures, and remove the Power Supply.
Power
Supply
Cover
Remove
These
Two
Screws
Remove These Two
Torx T-10 Screws, then
Remove the Power
Supply Cover.
5.6 Removing the Power SuppIy
Step 1. Unplug the two connectors shown in the picture below. The mating part oI each
connector has a tab/latch that must be moved out oI the way to allow removal oI the
connector; this is easier with the use oI a small Ilat-blade screwdriver.
Step 2. Remove Iour Torx T-10 screws shown in the picture below, and remove the Power
Supply.
Power Supply
Unplug These Connectors
5.7 Removing the Rear PIate
The Rear Plate is removed to provide access to the I/O Daughterboard and many other
mechanical and electrical components oI the printer.
Step 1. This step only applies Ior printers that include a Magnetic Stripe Encoder.
Using a small Ilat-blade screwdriver, pry open the Cable Clip that secures the
Magnetic Encoder cable.
Note In the pictures that Iollow, the Power Supply has been removed Irom the Rear Plate.
The Rear Plate can be removed without removing the Power Supply, but it is suggested that
you remove the Power Supply Cover so the wires to the Power Supply can be disconnected.
1. Use small flat-blade
screwdriver to pry the Cable
Clip open, being VERY careful
to not crush any of the wires.
2. Then unplug this
connector from the
CPU PCBA.
(These wires
are present
only if your
printer has a
Magnetic
Stripe
Encoder
Option.)
Remove these 3 screws, and lift
the Rear Plate back from the
Print Engine.
As you remove the Rear
Plate, pass this cable
through the rectangular
cutout.
Important When you remove the Rear Plate, take careIul note oI the Wavy Washers and
Bearings as shown in the picture below. They are held in place by the Rear Plate; when the
Rear Plate is removed they can Iall oII their shaIts. It is suggested that you remove them and
store them until the Rear Plate is to be replaced. When you replace them, make sure each
Bearing`s Ilange side is 'inward and that the Wavy Washer is centered and seated on the
Bearing`s body.
5.8 Removing the Cam Lever
Step 1. Remove the Cam Lever The upper (smaller) hole in the Cam Lever Iits over a peg in
the Upper Cam; the lower (larger) hole Iits over the raised cam oI the Printhead LiIt
Cam. (The Cam Lever is not attached at either end; it is held in place by the Rear
Plate.)
Platen nertia Roller Cam Lever Print Head Lift Cam
Upper
Cam
5.9 Removing the PIaten Inertia RoIIer
Step 1. The Platen Inertia Roller is secured to the Step Motor shaIt with a small setscrew.
Since access to the setscrew is limited, turn the Platen Inertia Roller so the setscrew
is accessible, and use an L-shaped 2-mm hex key to loosen the setscrew; then slide
the Platen Inertia Roller oII the shaIt.
Platen
nertia
Roller
Shaft That Held
Platen nertia Roller
5.10 Removing the Printhead Pressure Spring
Step 1. With a heavy Spring Hook or similar tool, Iree the Printhead Pressure Spring Irom
the Pressure Spring Plate, as shown below. The Printhead Pressure Spring is under a
lot oI tension, it will snap oII the Pressure Spring Plate when Ireed.
Step 2. Then remove the Printhead Pressure Spring Irom the Cam Arm Follower Assembly.
Spring Hook Tool
Printhead
Pressure
Spring
Pressure Spring Plate
Cam Arm Follower Assembly
5.11 Removing the FiIm/Bracket Sensor PCBA
Step 1. Open the Aluminum 'Cable Tie to Iree the Film/Bracket Sensor PCBA`s cable.
Step 2. Follow the Film/Bracket Sensor PCBA`s cable to where it plugs into the I/O
Daughterboard. Unplug it. Then work it out Irom behind the RFID Cable Assembly.
Step 3. Remove the screw securing the Film/Bracket Sensor PCBA to the Print Engine
Center Frame, and remove the Film/Bracket Sensor PCBA.
Aluminum "Cable Tie Film/Bracket Sensor PCBA
Film/Bracket Sensor
PCBA's Cable
RFD
Cable
Assembly
Screw that Secures the Film/
Bracket Sensor PCBA
5.12 Removing the Pressure Spring PIate
Step 1. AIter removing the Film/Bracket Sensor PCBA, remove the screw securing the
Pressure Spring Plate to the Print Engine Center Frame, and remove the Pressure
Spring Plate
Pressure Spring Plate
Mounting Screw
5.13 Removing the Cam Arm FoIIower AssembIy
Step 1. Remove the two Torx T15 screws that hold the Cam Arm Follower Assembly in
place, as shown below. The upper one screws into the threaded end oI the Print Head
U-Support Assembly; it can be removed easily.
Step 2. The lower T15 screw goes into the threaded end oI the Printhead Bracket ShaIt; to
remove this one it will be necessary to prevent the Printhead Bracket ShaIt Irom
turning. The best way to do this is to hold the shaIt in place with a medium Ilat-head
screwdriver Irom the 'Iront oI the Print Engine, as shown in the next picture.
Cam Arm Follower Assembly
Torx
T15
Screws
Printhead
Bracket
Shaft
5.14 Removing the CIutch AssembIy
Important Do not attempt to take the Clutch Assembly apart! II the Clutch Assembly is
damaged, it is replaced as a unit.
Clutch Assembly
Step 1. Hold the Ribbon Supply Spindle, and use a Number 1 Phillips screwdriver to remove
the screw securing the Ribbon Supply Spindle to the Clutch Assembly ShaIt, as
shown in the next picture. II necessary to prevent the shaIt Irom turning, use a small
crescent wrench on the Ilat oI the Clutch Assembly ShaIt to prevent the shaIt Irom
turning, as shown in the second picture.
Remove
Phillips-
Head
Screw
Prevent the
Clutch
Assembly
Shaft from
turning
Step 2. Remove the Ribbon Supply Spindle Irom the Clutch Assembly ShaIt by pulling and
turning the spindle.
Step 3. Now pull the Clutch Assembly straight out Irom the rear oI the Print Engine. II the
Clutch Assembly is to be re-installed, be careIul to avoid bending the Flag Disk.
Flag Disk
When replacing or re-installing the Clutch Assembly, make sure the hole in the tab on the
Clutch Assembly Iits over the raised pin through the RFID PCBA, as shown below.
Clutch Assembly Tab
Raised Pin Through RFD PCBA
5.15 Removing the Print Head / Carriage AssembIy
Step 1. Note that when the Clutch Assembly is removed, the entire Print Head / Carriage
Assembly can be removed Irom the Print Engine (the shaIt which had held the Clutch
Assembly will be sticking through the Center Frame, and the Printhead Bracket
Assembly will rest against the Front Frame, as shown in the next two pictures).
Shaft which
had held
the Clutch
Assembly
Printhead
Bracket/Fan
Cable
Assembly
Step 2. As you remove the Print Head / Bracket Assembly, gently pull the Print Head Cable
Assembly through the opening in the Center Frame.
Hole that the
Printhead
Bracket
Shaft
normally
passes
through
Print Head
Cable
Assembly
(Normally
Plugs into
CPU PCBA)
Caution Don't touch the Print Head Elements, shown in the picture below.
Print Head Elements
5.16 Removing the Print Head Lift Cam
Step 1. Rotate the Print Head LiIt Cam clockwise until the Setscrew lines up with the cut out
in the Center Frame, as shown in the second picture below.
The best way to rotate the Cam is to place both index Iingers on the inner surIace
(toward the Iront oI the printer) and both thumbs on the outer surIace (nearest you).
Do not try to rotate the Cam in a counter-clockwise direction; this could damage the
Print Head LiIt Motor.
Print Head
Lift Cam
Setscrew
"Cut Out
in Center
Frame
Rotate
CIockwise
OnIy
Step 2. Use a Number 0 Phillips Screwdriver to loosen the Print Head LiIt Cam Setscrew.
Then pull the Print Head LiIt Cam oII the Motor shaIt.
Setscrew
Important When re-installing the Print Head LiIt Cam, do not over-tighten the Setscrew; it
should only be snug against the shaIt.
5.17 RepIacing the Print Head AssembIy
5.17.1 RepIacement Procedure
Step 1. Turn the printer power oII, and disconnect the power cord.
Step 2. Open the printer`s main (translucent blue) cover. Then remove the cover by pressing
inward and twisting at the pivot points.
Step 3. Press the Print Head Carriage Latch to the leIt, and open (raise) the Print Head
Carriage.
EIectrostatic Discharge Caution The Print Head is extremely susceptible to
Electrostatic Discharge (ESD) damage. Do not touch the bottom surface of the Print
Head. The replacement must be performed at a static-free work station, an anti-static
wrist strap must be worn and properly terminated, or other appropriate protection must
be used.
Important This procedure describes replacing the Print Head Assembly. The Print Head
Assembly is supplied with components in correct alignment with each other. These
alignments are critical to proper operation oI the printer. Do not deviate Irom the procedure
given here, do not loosen or tighten any screws except those speciIically noted in this
procedure, and do not attempt to adjust any part oI the Print Head Assembly.
Step 4. Remove the ribbon by pulling both the supply and take-up spools straight out.
Step 5. Using the Torx T10 driver, remove the retaining screw on the Iront side oI the Print
Head Carriage.
Step 6. While removing the retaining screw, the Print Head Adjustment Screw may slip out
oI the notch in the Iront oI the Print Head Carriage. Whether it has slipped or not, use
a medium Ilat-blade screwdriver to remove the Print Head Adjustment Screw and its
associated washer and spring.
Step 7. Looking at the Print Head Carriage Irom the rear oI the printer, note that the Print
Head Assembly ShaIt has a notch just 'inside the slotted end. That notch will be
riding in a reduced-size cutout in the Print Head Carriage Frame, as shown below.
Print Head
Adjustment
Screw
Washer
Spring
End of Print Head
Assembly Shaft
Cutout in
the Print
Head
Carriage
Frame
Step 8. Gently rock the Print Head Assembly back and Iorth (the Print Head Assembly ShaIt
will be the pivot) until the end oI the Print Head Assembly ShaIt lines up with the
circular opening in the Print Head Carriage Frame.
Step 9. Slide the Print Head Assembly ShaIt out oI the Print Head Carriage. It can be slid out
toward the Iront or the rear oI the printer; you may need to press on the end oI the
ShaIt, and it may be a snug Iit.
End of Print Head
Assembly Shaft
Print Head
Assembly Shaft
Step 10. Disconnect the Ground Lug Spade Connector, as shown in the picture below (this is
more easily done by using needle-nose pliers). Gently use a small Ilat-blade
screwdriver to pry the Print Head Cable Connector up and unplug it.
Step 11. Rock the Print Head back and Iorth while gently separating the sides oI the Print
Head Carriage until the Print Head can be slid Iree Irom the Print Head Carriage.
Print Head Cable Connector Ground Lug Spade Connector
Step 12. Remove the replacement Print Head Assembly Irom its protective packaging.
Step 13. Slide the Print Head Assembly ShaIt through the holes in the Print Head Assembly
Frame as shown.
Caution When handling the Print Head Assembly, be careful to avoid touching the
active surface of the Print Head. The Print Head is extremely susceptible to damage from
static discharge. Also, oil from your fingers can cause poor print quality and/or shorter
Print Head life.
Active Surface of
Print Head
Slotted and
Notched End of
Print Head
Assembly Shaft
Goes Through
This Hole
Step 14. The Print Head Assembly ShaIt should stick through both sides oI the Print Head
Assembly Frame.
Step 15. Turn the Print Head Assembly ShaIt so the threaded hole in the center is accessible
through the center cutout in the Print Head Assembly Frame. Start the Print Head
Adjustment Screw (with its associated Spring and Washer in place) into the threaded
hole in the center oI the Print Head Assembly ShaIt. Run it in two or three turns; it
must stay engaged in the ShaIt during the steps that Iollow.
Step 16. Position the Print Head Assembly as shown below. Gently separate the sides oI the
Print Head Carriage while rocking the Print Head Assembly back and Iorth and slide
it into approximate position within the Print Head Carriage. See the Iollowing
pictures. You want the Print Head Assembly ShaIt to (Iirst) engage the circular
cutout in the 'back side oI the Print Head Carriage, and then (at the same time)
engage the large cutout in the Iront oI the Print Head Carriage.
Keep the Print Head Assembly Screw Below the
Notch in the Print Head Carriage as You Rock the
Print Head Assembly nto Place
Step 17. When the Print Head Assembly ShaIt is in position at the circular cutout (above),
press the ShaIt toward the back oI the printer (i.e., so it sticks out about 1/16 inch or
2mm); this will make it easier to rock the Iront end oI the shaIt into position, as
shown below. Then press the ShaIt (Iorward) so it is approximately centered within
the Print Head Carriage.
Print Head Assembly is in Proper
Position when the End of the Shaft
Sticks Through the Circular Cutout
End of Print Head Assembly Shaft
Sticks Through this Large Cutout
Step 18. Plug in the Print Head Cable Connector, and use a small Ilat-blade screwdriver to
press the connector evenly and Iirmly into place. Connect the Ground Lug Spade
Connector (this is more easily done by using needle-nose pliers).
Step 19. See the Iollowing pictures. With your Iingertips or a small Ilat-blade screwdriver,
slightly compress the Print Head Adjustment Screw Spring and slide the Washer
down; now pivot the Print Head Adjustment Screw upward so it is within the notch
in the Iront oI the Print Head Carriage (and the Washer and Spring are inside the
Carriage, as shown in the second picture.
Step 20. With a medium Ilat-blade screwdriver, turn the Print Head Adjustment Screw
clockwise. (Don`t let the screw head slip out oI the notch in the Print Head Carriage.)
Note that as the Screw is turned, the Print Head Assembly pivots about the Print
Head Assembly ShaIt.
As the Print Head Adjustment Screw is driven
clockwise, the Print Head Assembly Shaft
Moves nto the Narrower Part of the Cutout
Print Head
Shaft in
Position,
roughly
centered
laterally and
within the
middle curved
slot.
Step 21. Drive the Print Head Adjustment Screw in (clockwise) until the single raised bump
on the Print Head just makes contact with the Iront end oI the curved slot in the Print
Head Carriage.
Step 22. Turn the screw out (counter-clockwise) exactly four and one-half turns. The
(upper) single raised bump will be somewhere within the arc oI the curved slot. (The
Print Head will rotate on its shaIt and the two lower raised bumps; ignore their
positions as long as they are within their respective curved slots.)
Single Raised
Bump at Front
of Curved Slot
Single Raised
Bump
Somewhere
Within Curved
Slot
Step 23. Insert and tighten the Torx head retaining screw.
Step 24. Re-install the ribbon; lower the Print Head Carriage until it clicks into place; re-
install the printer cover. Connect the power cord, and turn the printer power on.
5.17.2 Enter the Print Head Resistance
BeIore proceeding to the Final Adjustment, the resistance value oI the replacement must be
entered, since the resistance will aIIect the physical adjustment.
Step 1. From the Windows Start button or Irom the Printers or Printers and FAXes Control
Panel, select the P330i printer. Right click to bring up Properties, select Device
Settings, and select Tools / Properties. This will bring up the Tools window, as shown
below.
Step 2. As shown above, in the 'Command to send to printer area, enter !R Iollowed by a
space Iollowed by the resistance value oI the replacement print head. (The resistance
value will be shown on the replacement print head.) Then click the Execute button,
then close the Tools window.
5.17.3 Print Head FinaI Adjustment
Print Head Iinal adjustment involves printing a card, inspecting it, and iI necessary adjusting
the Print Head Adjustment Screw. This sequence is repeated until the card print quality is
acceptable.
Step 1. From the Windows Start button or Irom the Printers or Printers and FAXes Control
Panel, select the P330i printer. Right click to bring up Properties, select Device
Settings, and select Tools / Properties. This will bring up the Tools window, as shown
below.
Step 2. II your printer has a color ribbon, enter IM in the 'Command to send to printer area,
then click the Execute button.
A card like the Iollowing one will be printed.
Step 3. II your printer has a monochrome ribbon, enter IMB in the 'Command to send to
printer area, then click the Execute button.
A gray (ideally) or moire-pattern card like the Iollowing one will be printed.
Step 4. II the card print quality is acceptable, no additional adjustment is necessary.
II the card print quality is not acceptable, loosen the Torx head retaining screw and
turn the Print Head Adjustment Screw one-quarter turn clockwise or counter-
clockwise. Print another card.
a. II the print quality is better, turn the Print Head Adjustment Screw one-eighth turn in
the same direction.
b. II the print quality is worse, turn the Print Head Adjustment Screw one-halI turn in the
other direction.
Step 5. Continue making smaller adjustments in either direction until the print quality is
optimized. Then tighten the Torx head retaining screw.
5.18 RepIacing the LCD PCBA and/or LCD CabIe AssembIy
Step 1. Unplug the LCD Cable Assembly Irom the LCD PCBA. It may help to use a small
Ilat-blade screwdriver to gently pry the cable connector out oI the PCBA connector;
iI you do this be very careIul to avoid damaging either connector or bending any
pins.
Step 2. II replacing the LCD Cable Assembly, unplug it Irom J10 on the CPU PCBA.
Note To replace the LCD PCBA, detach the Top Cover and proceed as Iollows. II the LCD
Cable Assembly is to be replaced, the Print Engine must be removed Irom the Lower Cover.
Unplug LCD
Cable
Assembly
LCD Cable
Assembly
Plugs into J10 on
CPU PCBA.
Step 3. While liIting on the right-hand end oI the LCD PCBA, use a small Ilat-blade
screwdriver to gently pry the support clip to the right as shown below. Use just
enough Iorce to Iree the PCBA; too much Iorce could damage or break the support
clip.
Step 4. When installing the LCB PCBA, place it in position on the Top Cover and press to
snap it into place.
Support
Clip
5.19 RepIacing the Encoder Shroud and Exit Pressure RoIIer
Step 1. Remove the protective Encoder Shroud that protects the Magnetic Encoder Sensor
and Head (iI present). (Note that the Shroud is present whether or not there is a
Magnetic Encoder.) Press the two removal tabs toward the rear oI the printer, and liIt
the shroud by the liIt tab.
Note This procedure covers replacing the Exit Pressure Roller only, not the complete Exit
Pressure Roller Assembly (which also includes the Pivot ShaIt and Spring). For instructions
on replacing the complete Exit Pressure Roller Assembly, see the next procedure.
The instructions given in this procedure also apply in general terms to the other Pressure
Rollers.
Protective
Shroud
Removal
Tabs
Lift Tab
Step 2. With the shroud removed, note the position oI the Exit Pressure Roller.
Step 3. LiIt the 'legs oI the Exit Pressure Roller so they disengage Irom the Pivot ShaIt.
Exit
Pressure
Roller
Exit Pressure Roller
Assembly Pivot Shaft
Exit
Pressure
Roller
Assembly
Spring
Step 4. Push the Exit Pressure Roller outward, then pull it the rest oI the way out Irom under
the Pressure Spring.
Step 5. When the Exit Pressure Roller has been removed, the Pressure Spring on the Pivot
ShaIt will look like the picture below.
Pressure
Spring
5.20 RepIacing the Exit Pressure RoIIer AssembIy
Note This procedure covers replacing the complete Exit Pressure Roller Assembly (which
also includes the Pivot ShaIt and Spring). For instructions on just replacing the Exit Pressure
Roller, see the previous procedure.
The instructions given in this procedure also apply in general terms to the other Pressure
Roller Assemblies.
Important Do not even attempt this procedure iI you do not have a thin spring hook tool
like the one shown below (shown next to a Pressure Roller Ior size reIerence).
Note This procedure can also be perIomed with the Exit Pressure Roller already removed,
as described in the previous procedure. The pictures and steps are so similar that diIIerences
will be readily apparent.
Step 1. Note the location oI the components oI the Exit Pressure Roller Assembly shown in
the Iollowing pictures.
Exit
Pressure
Roller
Exit Pressure Roller
Assembly Pivot Shaft
Exit
Pressure
Roller
Assembly
Spring
Exit
Pressure
Roller
Pivot Shaft
(See Next
Picture)
Step 2. Remove the screw that covers and secures the end oI the Pivot ShaIt, shown in the
picture below.
Step 3. In the next picture, you can see the end oI the Pivot ShaIt aIter the securing screw has
been removed.
Screw Head Securing End
of Pivot Shaft
End of
Pivot
Shaft
Step 4. With Iine-point pliers, grab the Pivot ShaIt between the legs oI the Pressure Roller
and slide it out oI the Front Frame. It will be a snug Iit; it may help to simultaneously
rotate the Pivot ShaIt and slide it out. (II the Pressure Roller has already been
removed, grab the Pivot ShaIt anywhere along its length and slide it out.)
Step 5. II you will be replacing the Exit Pressure Roller Assembly, be sure to keep the three
parts as shown in the picture below.
Caution As the Pivot Shaft is freed from the bearing in the Front Frame, keep in mind
that the Exit Pressure Roller Spring is under tension.
Pivot
Shaft
Pressure
Roller
Spring
Step 6. Feed the Pivot ShaIt through the hole in the Front Frame.
Step 7. As you Ieed the Pivot ShaIt inward, place the Spring on the ShaIt as shown below.
The two ends and the large central portion all come Irom the bottom oI the Spring,
and the two 'legs oI the Spring must be Iacing as shown.
Step 8. Continue Ieeding the Pivot ShaIt until it is engaged in its bearing on the Center
Frame.
Step 9. With Iine-nose pliers, bring the 'leg oI the Spring over the Pivot ShaIt as shown in
the next two pictures. This may be somewhat easier iI you slide the Spring away
Irom the Center Frame about 1/8 inch (4 mm).
Step 10. Reach in under the Pivot ShaIt with the spring hook tool and grab the end oI the
spring. Then let go with the pliers.
Step 11. Pull the end oI the Spring under the Pivot ShaIt (again, this may be easier iI you slide
the spring away Irom the Center Frame). Continue pulling the end oI the Spring
around the Pivot ShaIt until the Spring`s 'leg can rest in the detent oI the ridge as
shown below. There is a small hole in the side oI the Irame next to the detent; the
very end oI the Spring`s 'Leg should be pressed into that hole.
Detent of Ridge
Step 12. Then Iollow the same steps with the end oI the Spring closer to the Front Frame, as
shown in the Iollowing series oI pictures.
Step 13. Then replace the Exit Pressure Roller as described in the previous procedure.
Lift End of
Spring onto
Flat Area
5.21 Removing the BaIIs Retainer PIate
The Balls Retainer Plate is located below the Ribbon Supply Spindle. It covers the access hole
Ior the pivot shaIt oI a pressure roller assembly. It also holds a pair oI springs in place, which
in turn provide spring pressure to a pair oI Delrin Balls that precisely position the card within
the card path.
Step 1. The Balls Retainer Plate is held in place below the ribbon supply spindle by a Ilat-
head Phillips screw. Using a Number 0 Phillips screwdriver, remove the screw and
remove the Balls Retainer Plate.
Important When the Balls Retainer Plate is removed, be careIul to not lose the springs and/
or balls that it holds in place.
Balls
Retainer
Plate
Step 2. The next picture shows the Balls Retainer Plate removed.
Step 3. The Iollowing picture is a magniIied view oI the springs and Delrin Balls. Actual
size oI the Balls is 5 mm (about 1/5 inch).
Springs (Delrin Balls not visible)
Pivot Shaft Access
5.22 Card Feeder Components
This section describes replacing various components oI and associated with the Card Feeder.
Some oI these procedures involve detaching and disassembling the Card Feeder Assembly,
others do not.
5.22.1 RepIacing the Card Sensor CabIe AssembIy
The Card Sensor Cable Assembly can be replaced with or without disassembling the Card
Feeder Assembly; it can even be replaced without detaching the Card Feeder Assembly Irom
the Print Engine.
Step 1. The Card Sensor Cable Assembly in turn plugs into a Cable Assembly that goes to
the I/O Daughterboard. Unplug the connector.
Step 2. The Card Sensor Cable Assembly snaps into a recess in the side oI the Card Feeder
Assembly Irame, as shown in the picture below.
Card
Sensor
Cable
Assembly
(Card Feeder
Assembly
shown detached
from the Print
Engine)
Unplug this connector from the
Cable Assembly that goes to the
/O Daughterboard.
Step 3. To remove the Card Sensor Cable Assembly, hold the Iour wires close to the sensor
and push up while liIting away Irom the Card Feeder Irame, as shown in the next
picture.
5.22.2 RepIacing the Card Feeder Drive BeIt and/or Card Feeder
Motor
The Card Feeder Drive Belt and/or Card Feeder Motor can be replaced with or without
disassembling the Card Feeder Assembly; either or both can even be replaced without
detaching the Card Feeder Assembly Irom the Print Engine; the procedure Ior detaching the
Card Feeder Assembly is given in paragraph 5.24.3.
(The pictures in this section show the Card Feeder Assembly disassembled.)
Step 1. In the Iollowing picture, note the location oI the push nut on the Roller ShaIt.
(Card Feeder
Assembly
shown detached
from the Print
Engine)
Card
Feeder
Drive
Belt
Step 2. With a small Ilat-blade screwdriver, gently pry the pushnut oII the shaIt.
Step 3. This will allow you to slip the Timing Belt oII the Pulleys.
Push
Nut
AIter removing the Card Feeder Drive Belt, the Card Feeder Motor can be replaced.
Step 4. There is a very small E-Ring that secures the Feeder Pulley to the Motor shaIt (see
below). With a small Ilat-blade screwdriver, push this E-Ring around the shaIt until
the center oI the E-Ring is at the Ilat oI the shaIt (this will give maximum access to
the E-Ring). Then, with a very small Ilat-blade screwdriver, Iree the E-Ring Irom the
groove oI the Motor shaIt.
Step 5. With the E-Ring removed, liIt the Feeder Pulley and two spacer washers Irom the
Card Feeder Motor shaIt.
Step 6. Then remove three screws as shown below to Iree the Card Feeder Motor. (II the
Card Feeder Assembly has not been disassembled, remove the Card Feeder Motor by
reaching up through the open bottom oI the Card Feeder Assembly.
5.22.3 Detaching and DisassembIing the Card Feeder AssembIy
Step 1. The Card Feeder Assembly is attached to the Print Engine by two screws, as shown
in the picture below.
Step 2. Unplug the spade lug on the green ground wire at the location shown in the next
picture.
Remove
This Screw
on Front
Remove
This Screw
on Back
Detach Green
Wire at the
Spade Lug on
This End
Step 3. Slide a medium Ilat-blade screwdriver into the gap below the leIt side oI the ESD
Brush as shown in the picture below. Then turn the screwdriver clockwise to push the
leIt side oI the ESD brush upward, as shown in the next picture.
Step 4. LiIt the leIt end oI the ESD Brush just enough to clear the protective lip oI the Irame.
Step 5. Gently bring the leIt end oI the ESD Brush in Iront oI the protective lip, so it is
approximately in its original horizontal orientation.
Protective
Lip
Caution Handle the ESD Brush carefully to avoid bending or otherwise damaging it.
Step 6. Gently push the ESD Brush to the right, so the elongated hole at the right end can
disengage Irom the post on the Irame, and remove the ESD Brush.
Step 7. Remove Iour screws inside the counterbores as shown in the picture below.
Important II the ESD Brush appears damaged in any way, replace it.
Step 8. Use a small Ilat-blade screwdriver to gently pry the two parts oI the Card Feeder
Assembly Irame apart. (It will probably be necessary to go around the entire 'seam
several times to gradually separate the parts.)
Step 9. With the Card Feeder Assembly Frame apart, the Card Feeder belt can be removed
oII its rollers (turning the rollers back and Iorth will make this somewhat easier).
(Note that the picture also shows the Card Feeder Motor in place.) AIter the Card
Feeder Belt is removed, the Card Feeder Rollers can be removed iI desired. (II the
Roller over the Card Feeder Motor is to be removed, remove the gear Irom its shaIt.)
Card
Feeder
Belt
Card
Feeder
Rollers
Step 10. Reassembling the Card Feeder Assembly is shown in the Iollowing series oI pictures.
First, hold the two sides oI the Frame together as shown, and place the Feeder Gate
Lever in position. Note that the Feeder Gate Lever must be placed so the hole in the
'arm Iits over the raised pin on the Irame.
Step 11. Place the Ruber Gate over the raised pins on the Irame as shown in the next picture.
Feeder
Gate
Lever
Hole in
Feeder
Gate Lever
fits over
Raised Pin
on Feeder
Frame
Rubber
Gate
Fits
Over
Raised
"Pins
Step 12. Place the Feeder Gate Plate in approximate position. Make sure the slot in the Feeder
Gate Plate engages the raised pin on the Feeder Gate Lever, then press the Feeder
Gate Plate inward on each side to snap it into the groove on each side oI the Irame.
Step 13. Replace the screws into the counterbores that were removed in step 7.
Step 14. Reinstall the ESD Brush, or install a new one.
Feeder Gate Plate Make Sure Slot in Feeder Gate
Plate Engages Pin on Feeder
Gate Lever, then Snap Feeder
Gate Plate into place.
5.23 Power / FiIter Components
Step 1. The Power / Filter Components are mounted on the Connector Plate, and are shown
in the picture below. The two 'unused lugs on the leIt side oI the Power Switch
connect to the Power Supply.
Power
Switch
AC Power
Connector
EM
Filter
EM
Ferrite
Cable
Assembly
5.24 Removing the CPU PCBA
The CPU PCBA can be removed whether you remove the Connector Plate (as described in
section 5.4) or not. II you do not remove the Connector Plate, be careIul to avoid damaging
components on the Connector Plate or wires to/Irom it.
Step 1. The CPU PCBA rests on slides below the Rear Plate, as shown below. Note that the
CPU PCBA is not secured by any mounting hardware; it is simply held in place by
the wires to/Irom it (and, when the Print Engine is in place on the Lower Cover, by
the Lower Cover itselI).
Step 2. Slide the CPU PCBA straight out, careIully unplugging connectors as you slide the
board out, as shown in the next three pictures.
CPU PCBA
This Cable goes to
the LCD Screen
Use a Small Flat-blade
Screwdriver to Remove
the Restraining Clip on this
connector
RFD Cable
To Card Feeder
Sensor
Step 3. The next Iigure shows Ior reIerence the primary Iunctions oI the various connectors
on the CPU PCBA.
Step 4. When sliding the CPU PCBA back into position, make sure it is between the guides
on either side. Re-attach connectors as you slide the board in.
J11
(Ribbon RFID)
J7
(Smart Card)
J1
(Mag Encoder Head)
J8
(Auxiliary RS-232;
factory use only)
J6
(USB Port)
J12
(+24 VDC
Input from
Power Supply)
J3
(Out of Cards Sensor)
J4
(Not Used)
J10
(LCD Panel)
J9
(Print Head,
Head Lock,
Head Temp. Sensor)
J13
(Motors and Sensors -
Connects to
I/O Daughterboard)
J2
(Mates with Ethernet
Extension Board)
Slide CPU PCBA Between Guides On Either Side
5.25 Removing the I/O Daughterboard
Step 1. When the Rear Plate is removed (see section 5.7), the I/O Daughterboard is visible. It
is directly above the CPU PCBA, but it is hidden (and held in position) by the very
bottom oI the Rear Plate.
/O Daughterboard CPU PCBA (Shown with Ethernet Adapter)
/O Daughterboard
(Rear
Plate
Removed)
Step 2. Unplug as many oI the connectors to the I/O Daughterboard as you can reach beIore
starting to slide it out; unplug other connectors as they become accessible.
Step 3. The Iollowing Iigure shows the connectors on the I/O Daughterboard.
J04 J09
J05
J01 J08 J06
J07
J02
J03
Color
Sensor
1
Color
Sensor
2
(To J13
on CPU
PCBA)
Position
Bracket
Sensor
Synchro
Film
Sensor
Stepper
Motor
DC
Motor
DC
Motor
DC
Motor
Synchro
Card
Sensor
5.26 Removing the RFID CabIe
The RFID Cable connects the RFID PCBA to the CPU PCBA.
RFD Cable
RFD PCBA
CPU PCBA
Step 1. Use a small Ilat-blade screwdriver to remove the restraining clip on the connector at
each end oI the RFID Cable. Open the Aluminum 'Cable Ties that hold the RFID
Cable in place on the Center Frame. Remove the RFID Cable.
Retaining Clip (on connector at each end of RFD Cable)
Aluminum "Cable Ties
5.27 RepIacing the Ribbon O-Ring Drive BeIt
Step 1. Remove the Ribbon O-Ring Drive Belt by slipping it oII the Ribbon Motor Pulley
and the Ribbon Pulley.
Step 2. To install the Ribbon O-Ring Drive Belt, seat it in the groove oI the Ribbon Pulley,
pass it around both sides oI the Upper Cam, and roll it into the groove oI the Ribbon
Motor Pulley.
Ribbon
O-Ring
Drive
Belt
Important Make sure that the Ribbon O-Ring Drive Belt passes on the inside oI the shield,
as shown in the picture below.
CORRECT -- Ribbon O-Ring
Drive Belt nside Shield
INCORRECT -- Ribbon O-Ring
Drive Belt Outside Shield
Ribbon
Pulley
Ribbon Motor
Pulley
Upper
Cam
Shield
5.28 RepIacing the Ribbon PuIIey AssembIy
Step 1. The Ribbon Pulley Assembly ShaIt is secured by a screw in the middle oI the Ribbon
Take-Up Spindle.
Ribbon
Pulley
Assembly
Step 2. While holding the Ribbon Take-Up Spindle, use a No. 1 Phillips screwdriver to
remove the screw attaching the Ribbon Take-Up Spindle to the Ribbon Pulley
Assembly ShaIt, and slide the Spindle oII the shaIt (it may be a snug Iit).
Step 3. Slide the Ribbon Pulley Assembly (which includes the shaIt) out oI the bearing in the
center Irame.
5.29 Removing the Ribbon Motor PuIIey and the Ribbon Motor
Step 1. The Ribbon Motor Pulley is secured to the Ribbon Motor ShaIt with a setscrew. Use
a 1.5 mm hex key to loosen the setscrew, and remove the Ribbon Motor Pulley.
Ribbon
Motor
Pulley
Ribbon
Motor
Shaft
Step 2. Cut the Cable Tie holding the bundle oI Cables at the I/O Daughterboard
Step 3. Unplug the Connector Ior the Ribbon Motor Irom the I/O Daughterboard.
Step 4. The Ribbon Motor is held in position by three Torx T10 screws. Remove them.
Cut This
Cable Tie
These
wires go
to the
Ribbon
Motor
Ribbon
Motor
Mounting
Screws
Step 5. Now reach up into the lower cavity between the Center Frame and the Front Frame
and remove the Ribbon Motor.
5.30 RepIacing the Stepper Motor Drive BeIt
The Stepper Motor Drive Belt should be very snug so it will not slip oII the Stepper Motor
Drive Pulley during printer operation. Also, iI the belt is too loose, vertical lines may appear
on cards printed.
A limited amount oI tensioning adjustment can be made as Iollows.
Step 1. Loosen the three 5.5 mm hex nuts securing the Stepper Motor to its Mounting Plate.
Step 2. Reach up into the space between the Front Frame and the Center Frame, and move
the Stepper Motor (the holes in the Center Frame are slightly enlarged, permitting
some movement).
Step 3. Tighten the three 5.5 mm hex nuts.
Step 4. When pressing with a Iinger against the mid-point oI the Stepper Motor Drive Belt,
there should be less than 1/8 inch (3 mm) deIlection.
5.31 Removing the Stepper Motor
Step 1. Remove the Stepper Motor Drive Belt.
Stepper
Motor Drive
Belt
Stepper Motor Drive Pulley
Stepper
Motor
Mounting
Plate
Step 2. Remove the Stepper Motor Pulley. (II the 'old Stepper Motor will be re-installed
and there is no apparent damage to the Stepper Motor Pulley, the Stepper Motor
Pulley does not need to be removed.)
Step 3. Remove the three 5.5 mm hex nuts securing the Stepper Motor to its Mounting Plate.
Step 4. Reach up into the space between the Front Frame and the Center Frame, and remove
the Stepper Motor.
Stepper
Motor Drive
Belt
Stepper
Motor
Mounting
Plate
5.5 mm Hex Nuts
5.32 Removing the RFID PCBA
Step 1. II the RFID Cable is still plugged into the RFID PCBA, use a small Ilat-blade
screwdriver or Iine-point plierst remove the retaining clip on the RFID Cable
connector, as shown in the picture below. Unplug the RFID Cable.
Step 2. With a Number 1 Philips screwdriver, remove two screws as shown in the next
picture.
Retaining
Clip
RFD
Cable
Note that
this pin on
the Center
Frame
passes
through a
hole on the
RFD
PCBA.
RFD
PCBA
Mounting
Screws
Step 3. Remove the RFID PCBA.
5.33 RepIacing the Ribbon CoIor Sensor
The Ribbon Color Sensor is located under the Ribbon Supply Spindle, as shown below. Note
that the Ribbon Color Sensor cannot be removed until items have been removed Irom the
Center Frame through the RFID PCBA.
Ribbon Color Sensor
Step 1. See the two pictures below. With a small Ilat-blade screwdriver, gently pry up toward
the Iront oI the Ribbon Color Sensor until it pops Iree oI the Print Engine.
Step 2. The wires Irom the Ribbon Color Sensor are held in place on the Center Frame by
two aluminum 'Cable Ties, as shown in the next picture. The wires are also routed
through two guides, and secured in the guides by glue.
Step 3. Open the 'Cable Ties. Scrape the glue oII the surIace oI the guides, being careIul to
avoid nicking or crimping the wires. Free the wires Irom the guides.
Step 4. Unplug the wires Irom the Ribbon Color Sensor Irom the I/O Daughterboard. The
connectors are behind the Ribbon LiIt Cam.
Aluminum
"Cable Ties
Guides
with glue
holding
the wires
in place
Ribbon Lift Cam
Step 5. Unplug the wires Irom the Ribbon Color Sensor Irom the I/O Daughterboard. The
connectors are behind the Ribbon LiIt Cam.
Step 6. The Ribbon Color Sensor can now be removed by passing its wires through the
rectangular cutout in the Center Frame.
5.34 RepIacing the Card Sensor CabIe AssembIy
Step 1. The Card Sensor is located just inside the support Ior the Print Head Carriage, as
shown in the picture below. The picture also shows the location oI the Mounting
Screw; the Mounting Screw location is also shown in the Iollowing picture.
.
Step 2. Looking up Irom under the Print Engine, note the routing oI the wires in the Card
Sensor Cable Assembly. When replacing or re-installing the Card Sensor, the wires
must be routed the same way. II it has not already been done, unplug the Card Sensor
Cable Assembly Irom the I/O Daughterboard.
The picture also shows the location oI the Card Sensor Mounting Screw.
Important The Torx T10 driver used in this procedure must have a blade at least 4 inches
(100 mm) long to reach through the access hole to the Card Sensor Mounting Screw.
Card
Sensor
Card
Sensor
Mounting
Screw
2. White and Black Wires come out on this
side, then bend over the Card Sensor and
route over the Red and Green Wires.
3. All
Four
Wires
then
pass
"under
this
post.
1. Red and
Green
Wires come
out on this
side, and
stay "below
the White
and Black
Wires.
Card Sensor
Mounting Screw
Step 3. See the Iollowing picture. II necessary, turn the Print Head LiIt Cam and deIlect the
belt as shown to clear the Card Sensor Mounting Screw Access Hole. With a long-
bladed Torx T10 driver, go straight through the Access Hole until the Torx head
engages the head oI the Mounting Screw. Remove the Mounting Screw (the Card
Sensor will remain in place).
Step 4. The Iollowing picture (Irom underneath) shows the Torx T10 driver bit in the Card
Sensor Mounting Screw.
Card
Sensor
Mounting
Screw
Access
Hole
Print
Head
Lift
Cam
Card
Sensor
Mounting
Screw
Step 5. Using a Number 0 Phillips screwdriver, remove the Balls Retainer Plate and the
springs and Delrin Balls it holds in place (more detailed inIormation is given in
section 5.21). Be careIul to not lose the springs and/or balls.
Step 6. The next picture shows the Balls Retainer Plate, springs, and balls removed. The
Card Sensor Cable Assembly is barely visible.
Balls
Retainer
Plate
Card
Sensor
Cable
Assembly
Step 7. Using a small Ilat-blade screwdriver, gently pry the Card Sensor toward the back oI
the Print Engine, as shown in the next picture. Be very careIul to avoid crimping or
breaking any oI the wires. Pushing the wires upward (Irom underneath) will make
prying the Card Sensor easier.
Step 8. The Iollowing picture shows the Card Sensor pried toward the back oI the Print
Engine.
Use Small
Flat-Blade
Screwdriver
Here...
... To Pry the Card
Sensor This Way.
Step 9. Use a small Ilat-blade screwdriver to gently pry the Card Sensor upward, while
rocking it back and Iorth until the Card Sensor clears the card path, as shown in the
next picture.
Step 10. LiIt the Card Sensor Iree oI the Print Engine. Be careIul to avoid damaging any oI
the wires. Continue liIting until the connector clears the hole in the card path.
Rock the Card Sensor back and forth
while gentIy lifting / prying it upward.
5.35 Removing the Print Head CabIe AssembIy
The Print Head Cable Assembly includes the Print Head Fan and the Ribbon Sync Sensor.
Step 1. II you have not already done so, remove the Print Head Assembly Irom the Printhead
Bracket Assembly (steps are given in detail in section 5.19, but are repeated here in
simpliIied Iorm Ior convenience).
a. With a medium Ilat-blade screwdriver, remove the Print Head Adjustment Screw (and
its washer and spring).
Caution During this procedure, be careful to avoid touching the Print Head Elements.
b. With a Torx T10 driver, remove the retaining screw on the Iront side oI the Print Head
Carriage. (You may need to use a Ilat-blade screwdriver on the other end oI the Print
Head Assembly ShaIt to remove the retaining screw.)
c. Remove the Print Head Assembly ShaIt.
d. Unplug the Print Head Cable (you may need to use a small Ilat-blade screwdriver to
pry the plug apart Irom the connector). Disconnect the Ground Lug Spade Connector.
Print Head Cable
Connector
Ground
Lug Spade
Connector
e. Rock the Print Head Assembly back and Iorth while gently separating the sides oI the
Print Head Carriage until the Print Head Assembly can be slid Iree oI the Print Head
Carriage.
Step 2. Cut the Cable Tie and remove the screw that holds the Ribbon Sync Sensor in place,
as shown in the picture below.
Cable
Tie
Screw
Attaching
Ribbon
Sync
Sensor
Step 3. Push the Print Head Cable Connector, the Ground Lug, and the Ribbon Sync Sensor
out oI the way so you can see the Iour latches (two on each side) that hold the Print
Head Fan in place, as shown in the next two pictures.
Fan Motor
Attachment
Latches
Step 4. Through the cutouts in the Print Head Bracket, note the Iour Fan Motor 'mounting
holes (even though they are not used to mount the Fan Motor).
Step 5. While in turn pressing the Iour Fan Motor Attachment Latches away Irom the Fan
Motor, use a Number 2 Phillips Screwdriver (the blade is too big to go through the
Fan Motor Mounting Holes) to press against the Fan Motor Mounting Holes). You
may need to go around the Iour latches and holes more than once, but eventually the
Fan Motor will be Ireed by all Iour Latches.
Fan Motor "Mounting Holes
Step 6. Then the Fan Motor can be pulled clear oI the Attachment Latches.
Step 7. Remove two screws, shown in the next picture, that attach the Print Head Pivot
Bracket to the Print Head Carriage.
Remove These Screws
Step 8. Press and hold the Print Head Carriage Latch; twist and gently pull the Print Head
Pivot Bracket until it separates Irom the Print Head Carriage.
Step 9. Work the Print Head Cable Assembly through the cut-outs in the Print Head
Carriage. Bend the cable so the connector is roughly parallel to the cable to get it
through the cut-outs.
1. Press and Hold Print
Head Carriage Latch
2. Separate Head Pivot Bracket
from the Print Head Carriage
5.36 Removing the Print Head Lift Motor
Step 1. The I/O Daughterboard and the Print Head LiIt Cam must be removed to access the
Print Head LiIt Motor Mounting Screws. With a Number 0 Phillips screwdriver,
remove three Mounting Screws as shown in the picture below.
the Print Head LiIt Motor.
Print Head
Lift Motor
Mounting
Screws
5.37 Separating the Front Frame from the Center Frame
There are only a limited number oI parts that would require separating the Front Frame Irom
the Center Frame. These are:
The Clean Drive Roller
The Card Drive Roller
The Platen Drive Roller
The Exit Drive Roller
The three Transport Rollers past the Platen
The Card Pressure Plate attached to the Front Frame
The Magnetic Encoder Station Roller attached to the Front Frame (Roller is present
whether the printer includes the Magnetic Stripe Encoder Option or not)
Separating the Front Frame Irom the Center Frame constitutes a signiIicant dismantling oI the
printer! The suggested procedure Iollows; procedures that are described in greater detail have
reIerences to the appropriate sectiion.
Step 1. Remove the Top Cover (5.2)
Step 2. Remove the LCD PCBA (5.18)
Step 3. Remove the Print Engine Irom the Lower Cover (5.3)
Step 4. Remove the Card Feeder Assembly (5.22.3)
Step 5. Remove the Connector Plate (5.4)
Step 6. Remove the CPU PCBA (5.24)
Step 7. Remove the Power Supply Cover (5.5)
Step 8. Remove the Power Supply (5.6)
Step 9. Remove the Rear Plate (5.7)
Step 10. Remove the Cam Lever (5.8)
Step 11. Remove the Platen Inertia Roller (5.9)
Step 12. Remove the I/O Daughterboard (5.25)
Step 13. Remove the Printhead Pressure Spring (5.10)
Step 14. Remove the Film/Bracket Sensor PCBA (5.11)
Step 15. Remove the Pressure Spring Plate (5.12)
Step 16. Remove the Cam Arm Follower Assembly (5.13)
Step 17. Remove the Clutch Assembly (5.14)
Step 18. Remove the Print Head / Carriage Assembly (5.15)
Step 19. Remove the Ribbon Color Sensor (5.32)
Step 20. Remove the Smart Card Contact PCBA, iI present
Step 21. Remove the Card Sensor Cable Assembly (5.33)
Step 22. Remove the Encoder Shroud and Exit Pressure Roller (5.19); remove all other
Pressure Rollers using the same procedure.
Step 23. Remove the Balls Retainer Plate, Springs, and Balls (5.21)
Step 24. Remove Exit Pressure Roller Assembly (5.20); remove all other Pressure Roller
Assemblies using the same procedure.
Step 25. Remove the Stepper Motor Drive Belt (5.30.1)
Step 26. Remove the ESD Brush at the Card Exit. Use a soldering iron to melt the Ilattened
plastic posts and gently pry oII the push nuts. When replacing, use the soldering iron
to Ilatten the plastic posts to secure the push nuts.
Step 27. Remove the items shown in the next two pictures in the order shown. Do not
remove the Pulleys and Push Nut speciIied in the second picture.
1. Stepper Motor Drive Belt
2. Pulley
3. Timing Belt
4. Front Pulley
5. Timing Belt
6. Push
Nut,
then
Rear
Pulley
7. Pulley
8. Timing
Belt
9. Pulley
11. Timing
Belt
10. Push
Nut
13. Position Front Frame/Center Frame with Center Frame Flat on
work surface, then remove 7 Torx T10 Screws at bottom of these
bores and lift the Front Frame straight up off the Center Frame.
(Do NOT remove Front PuIIey,
Push Nut, and Rear PuIIey)
12. Pulley
Step 28. LiIt the Front Frame straight up oII the Center Frame, and note the orientation oI the
Rollers shown in the next picture. The Rollers simply slip into their bearings in the
Center Frame; they are held in place by corresponding bearings in the Front Frame
when the Front Frame is attached.
Step 29. The Card Pressure Plate is held in position (inside the Front Frame) by two springs,
which provice slight pressure inward to the card in the card path. The Card Bias
Guide limits the travel oI the Card Pressure Plate
Exit Drive
Roller
Clean
Drive
Roller
Platen Drive
Roller
Card Drive
Roller
Card Pressure Plate
Magnetic Encoder
Station Roller
Card Bias Guide
Step 30. To remove the Card Pressure Plate, detach the Springs, then remove the Card Bias
Plate (it is held by 3 Torx T10 screws).
Step 31. To remove the Magnetic Encoder Station Roller, remove (in order) the outer Pulley,
Push Nut, and inner Pulley shown in the picture below. Then slide the Magnetic
Encoder Station Roller on its shaIt through the bearing in the Front Frame.
Card
Pressure
Plate
Springs
Card Bias Guide Magnetic Encoder
Station Roller
1. Outer Pulley 2. Push Nut 3. nner Pulley
5.38 Magnetic Stripe Encoder Option
The Magnetic Stripe Encoder Option consists oI a Magnetic Encoder Sensor and Magnetic
Encoding Head. These can be located below the card path ('regular) or above the card path
('reverse encoding). The instructions presented here are general enough that they can be
applied to either.
Step 1. Remove the protective shroud that protects the Magnetic Encoder Sensor and Head.
Press the two removal tabs toward the rear oI the printer, and liIt the shroud by the
liIt tab.
Protective
Shroud
Removal Tabs
Lift Tab
Step 2. When the shroud is removed, the Magnetic Encoder Sensor and Magnetic Encoding
Head are visible, as shown below.
Step 3. The Magnetic Encoding Head and the Magnetic Encoder Sensor are attached with
Torx T10 screws.
Step 4. II the Rear Plate has not been removed, remove it (see section 5.7).
Step 5. The wires Ior either type oI Encoding Head and Encoder Sensor pass through a
rectangular cut-out in the Center Frame.
ReguIar:
Reverse:
Magnetic Encoder Sensor
Magnetic Encoding Head
5.39 Smart Card Options
There are Iour diIIerent 'Smart Card Options available Ior the P330!. These can be
summarized as Iollows:
'Contact Smart Card options use a Solenoid below the Card Path and a Contact PCBA
above the Card Path. The Solenoid presses the card upward so the Contact PCBA`s pins
make electrical contact with the appropriate pads on the smart card.
For the 'Contact Station version, wires Irom the Contact PCBA connect to a 'Smart
Solenoid PCBA which mounts on the Connector Plate and includes a db9 connector
Ior an external serial interIace.
For the 'GEM PLUS version, wires Irom the Contact PCBA (which includes logic
Ior the GEM PLUS version) connect to the CPU PCBA. Additional logic circuitry on
the CPU PCBA allows passing 'Smart Card signals via the USB connector, along
with the normal Iunctions oI the USB interIace.
'Contactless Smart Card options use either oI two short-range radio technologies ('HID
or 'MiFARE) to communicate with the smart card. One component is a combination
antenna and PCBA Ior the speciIic technology; this is mounted below the Card Path.
There is also an Auxiliary PCBA, which is mounted on the bottom oI the Center Frame,
which provides an interIace between the Antenna/PCBA and the CPU PCBA.
Removal oI most oI these items is readily apparent.
5.40 SoIenoid AssembIy
II your printer includes a Contact Smart Card Option, it will include a Solenoid Assembly,
which will be apparent by the two mounting screws shown in the Iollowing picture.
Solenoid
Assembly
Mounting
Screws
Step 1. With a Number 0 Phillips screwdriver, remove the two Solenoid Assembly Mounting
Screws.
the Solenoid Assembly.
Solenoid
Assembly
Mounting
Holes
Solenoid
Assembly
&
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Introduction
The Model P330! Printer is designed Ior operation with minimal maintenance. II the printer is
cleaned on a regular basis, as described in this section, it should provide trouble-Iree
operation.
There are no periodic measurements, adjustments, or other preventive maintenance procedures
required in normal usage.
CIeaning the Printer
Clean your P330! Printer using Pre-Saturated Cleaning Cards provided. The regular use oI
these cards will clean and maintain important parts oI your printer that cannot be reached,
including the Print Head, Transport Rollers, and optional Magnetic Encoder Station.
Caution PROTECT YOUR FACTORY WARRANTY!
The recommended cIeaning procedures must be performed to maintain your
factory warranty. Other than the recommended cIeaning procedures described in
this manuaI, aIIow onIy Zebra authorized technicians to service the P330i Printer.
Preventive Maintenance
Cleaning the Printer
When to CIean the Printer
Clean the printer when either oI the Iollowing occurs:
When the LCD Panel displays the message CLEAN PRINTER.
Approximately every 1000 cards when using 5-panel color ribbon, or every 5000
cards when using a monochrome ribbon.
How to CIean the Printer
Step 1. Leave the Printer power on, or turn it on iI it was oII.
Step 2. Initiate the cleaning process by either oI the Iollowing methods:
At the printer, press and hold the panel button Ior several seconds, until the LCD
Panel displays the message REMOVE RIBBON THEN CLOSE HEAD.
From the computer, enter the P330! Printer Tools soItware, and click on the
CLEAN button. The LCD Panel will display the message REMOVE RIBBON
THEN CLOSE HEAD.
Step 3. Open the Main Cover, release the Print Head Carriage, and remove the ribbon. Then
close the Print Head Carriage. (For details, see Chapter 2.) The LCD Panel will
display the message EMPTY FEEDER & PRESS BUTTON.
Step 4. Open the Card Feeder Cover and remove cards Irom the Card Feeder. The last card is
diIIicult to remove; leave it in place. Press the Panel Button on the Iront oI the
printer. The card remaining in the Ieeder will be ejected. The LCD Panel will then
display the message LOAD CLEANING CARD IN FEEDER.
Step 5. Place a pre-saturated Cleaning Card into the Card Feeder. The Cleaning Card will
automatically Ieed into the printer and the cleaning process will start (there is a
several second delay aIter the Cleaning Card Ieeds beIore the cleaning movement
starts). While the cleaning process is underway, the LCD Panel will display the
message CLEANING PRINTER.
Note This cleaning procedure uses two cleaning cards. One cleaning card is the size oI a
regular plastic card, and is reIerred to as the 'cleaning card. The other is elongated, with a
wider section at one end; it is reIerred to as the 'long cleaning card.
Cleaning the Printer
Step 6. At the conclusion oI this part oI the cleaning process, the Cleaning Card will be
ejected, and the LCD Panel will display the message PRESS BUTTON TO
CONTINUE.
Step 7. AIter the user presses the panel button, the LCD Panel will display the message
FEED LONG CLEANING CARD IN EXIT. Insert the long end oI the long cleaning
card into the card exit (directly above the Output Hopper). II the user inserts a
'regular cleaning card into the card exit, the LCD Panel will display the message
INVALID CARD, PRESS BUTTON until the user presses the panel button and
inserts the long cleaning card into the card exit.
Step 8. The long cleaning card will automatically Ieed into the printer and the printing
process will continue. The LCD Panel will again display the message CLEANING
PRINTER.
Step 9. When the cleaning process is completed, the long cleaning card will be ejected and
the LCD Panel will display the message READY, indicating that the printer is ready
to resume normal printing operations.
Step 10. Discard both cleaning cards aIter a single use.
Note II the user does nothing at this point (i.e., does not insert the long cleaning card), aIter
a timeout the LCD Panel display will change to CLEAN PRINTER. The printer will be able
to print, but the LCD Panel will continue to display CLEAN PRINTER.
This limited cleaning does not do a thorough cleaning, but may be perIormed iI no 'long
cleaning cards are available.
To restore the display to READY, you will need to perIorm a complete cleaning process,
using both short and long cleaning cards, Irom step 2 above through step 9 below.
Cleaning the Print Head
CIeaning the Print Head
A cleaning using the Cleaning Cards usually suIIices. However, a separate Print Head cleaning
can remove more stubborn deposits when print anomalies persist. To avoid deposits, only use
Ioam-tipped swabs.
Step 1. Place the printer power switch in the OFF ( O ) position.
Step 2. Open the Main Cover, release the Print Head Carriage, and remove the ribbon. Leave
the Print Head Carriage in its raised position. (For details, see Chapter 2.)
Step 3. Clean Print Head by moving an alcohol-moistened swab tip side-to-side across the
Print Head elements. Only use moderate Iorce. To re-order swabs, please reIer to the
Media List on the Windows Drivers and User Documentation CD supplied with this
printer.
Step 4. The swabs can also be used in a similar manner to clean the optional magnetic
encoding head.
Note Do not use previously used cleaning cards.
Caution Never use a sharp object or any abrasive to scrape deposits from the print
head. Permanent damage to the print head will result.
Card CIeaning Cartridge
Your P330! Printer includes a Card Cleaning Cartridge. This item cleans the cards entering the
printer through the card Ieeder. To ensure print quality, the cleaning roller requires periodic
replacement. New cleaning rollers are included with each ribbon or may be purchased
separately. (To reorder, please reIer to the Media List on the Windows Drivers and User
Documentation CD supplied with this printer.)
Installation oI the Card Cleaning Cartridge is described in Chapter 2 and is not repeated in
detail here.
When to RepIace the CIeaning RoIIer
Replace the Cleaning Roller each time you install a new ribbon.
How To RepIace the CIeaning RoIIer
Step 1. Open the main cover and locate the Card Cleaning Cartridge.
Step 2. Gently remove the Card Cleaning Cartridge. LiIt the 'handle end, and then pull it
away Irom the printer.
Hot Surface Do not touch the print head if the printer has been in service in the last
10 minutes. t could be very hot and cause a burn.
Note BeIore replacing the Card Cleaning Cartridge or its cleaning roller, clean the Printer
using the Cleaning Cards as described earlier in this chapter.
Card Cleaning
Cartridge
Step 3. Remove the cleaning roller Irom the Card Cleaning Cartridge and discard.
Step 4. Install new cleaning roller into the Card Cleaning Cartridge. To avoid contamination,
always hold the cleaning roller by the ends. (For replacement cleaning rollers, please
reIer to the Media List on the Windows Drivers and User Documentation CD
supplied with this printer.)
Step 5. Peel protective wrapper Irom the cleaning roller by gently pulling on the tape.
Step 6. Replace the Card Cleaning Cartridge into the printer:
Step 7. Close the printer main cover.
Note DO NOT touch the adhesive roller surIace that contacts the cards.
Card Cleaning
Cartridge in final
position
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4"9)%,#$
Introduction
This section lists soItware commands to initiate, check, or adjust various system Iunctions,
parameters, and variables.
Detailed inIormation on the use oI these commands are given in the EPCL Programmer`s
Guide, Zebra document 980415-001, which can be downloaded Irom the Zebra Card Printer
Solutions website at http://www.zebracard.com.
Entering Software Commands
Step 1. From the Windows Start menu or Irom the Windows Control Panel, navigate to
Printer Properties. This will bring up a display like the one below
Software
Entering Software Commands
Step 2. Click on the Device Settings tab, then select Tools, then click on the Properties block
that will appear, as shown below.
Step 3. This brings up the Tools display. Type the desired command in the 'Command to
send to printer window, and click the Execute button.
Type the
command
here ...
... then
click the
Execute
button.
Software
Software Commands
Software Commands
The Iollowing listing includes the soItware commands that apply to the P330! Printer.
Complete inIormation about each command, including description, syntax, and parameters, is
presented in the EPCL Programmer`s Guide, Zebra document 980415-001, which can be
downloaded Irom the Zebra Card Printer Solutions website at http://www.zebracard.com.
A- - - - - - - - - - Print Test Card
ATM - - - - - - - Set Card Feeding Mode
&B- - - - - - - - - Load Magnetic Encoder Track Write BuIIer
BS - - - - - - - - Set Black Synchro
B/vB - - - - - - - Write Bar Code
&C- - - - - - - - - Set Coercivity
C - - - - - - - - - Adjusts Monochrome Intensity
$C - - - - - - - - Adjust Color Contrast
!CC - - - - - - - - Get Number oI Cards Printed
CDER - - - - - Get Magnetic Encoder Read Settings
&CDER - - - - - Set Magnetic Encoder Track Read Encode Parameters
&CDEW- - - - - Set Magnetic Encoder Track Write Encode Parameters
CDOTS - - - - Image Print Quality Compensation Factor
CH- - - - - - - - Adjust Hologram Intensity
CHECK - - - - - Return Checksum
CLEAN - - - - - Set Cleaning Card Sequence
CLN - - - - - - Check Due-Ior-Cleaning Parameters
CLNCARD- - - Set Cleaning Parameters
CV- - - - - - - - Adjust Clear Varnish Intensity
C/vC - - - - - - - Write Box (Monochrome)
!D - - - - - - - - - Move Print Head Down
&D - - - - - - - - Change Track Density
D/vD - - - - - - - Draw Diagonal Line (Monochrome/Overlay)
E - - - - - - - - - - Retransmit Last Response
&E- - - - - - - - - Write Single Track
&E* - - - - - - - - Write Track BuIIers
EC - - - - - - - - End oI Print
$F - - - - - - - - - Clear Color Image BuIIers
!FF- - - - - - - - - Set Ribbon Color Sequence
$FP - - - - - - - - Clear SpeciIied Bit-Maps
FS - - - - - - - - - Control Use oI Card Feed Sensor
F/vF - - - - - - - - Clear Monochrome Image BuIIers
GS - - - - - - - - - Download Color Graphic
G/vG - - - - - - - Initialize Monochrome Graphic (B/W)
HEAD- - - - - Get Print Head Serial Number
I - - - - - - - - - - Print Monochrome Panel
Software
Software Commands
IH - - - - - - - - - Print Hologram Overlay
IM - - - - - - - - - Print Color Test Card
IMB- - - - - - - - Print Gray Test Card
IS- - - - - - - - - - Print Card Panel
ISC - - - - - - - Set Smart Card Serial Port Data Rate
ISC2- - - - - - - Set Smart Card Serial Port Data Rate (Advanced)
ISERIES- - - - - i-Series Printer Test
IV - - - - - - - - - Print Clear Varnish
J - - - - - - - - - - Print Multiple Monochrome Cards
!L - - - - - - - - - Check Status oI Printer Sensors
$L - - - - - - - - - Draw a Horizontal Line/Rectangle in a Color BuIIer
&L- - - - - - - - - Read Single Track
$L - - - - - - - - Adjust SpeciIied Color Intensity
$LD - - - - - - - - Initialize a Color BuIIer to a SpeciIied Intensity Level
L/vL- - - - - - - - Draw Horizontal Line (Monochrome/Overlay)
!M - - - - - - - - - Move Print Head Up
MB - - - - - - - - Return Card To Card Feeder
MC - - - - - - - - Clear Media Path
MCL - - - - - - - Move Contactless
ME - - - - - - - - Exit Card To Output Hopper
MI - - - - - - - - - Move Card Into Print Ready Position
MIB- - - - - - - - Move Card Back To Print Ready Position
MM - - - - - - - - Move Card Through Printer
M/m- - - - - - - - Multiple Command
MO - - - - - - - - Move Card To Output Hopper
MR - - - - - - - - Check Ior Card Presence
MS- - - - - - - - - Move Card To Smart Card Programmer
&N - - - - - - - - Select Magnetic Encoding Standard
!NL - - - - - - - - Get Printer Impression and Error Counters
O- - - - - - - - - Print OIIset X-Axis
OCL- - - - - - - OIIset Contactless
OS - - - - - - - - Smart Card X-axis OIIset
O/vO - - - - - - - Load Single Line Bit-map (Monochrome)
OY- - - - - - - - Print OIIset Y-axis
!P- - - - - - - - - - Move Card Forward 8 cm
PRF - - - - - - - Pre-Feed a Card Close to the Print Area
PS - - - - - - - - - Download Color Image BuIIer
P/vP - - - - - - - - Draw Single Dot (Monochrome/Overlay)
R - - - - - - - - - - Reset
!R - - - - - - - - - Print Head Resistance
&R- - - - - - - - - Reset Magnetic Encoder
~R - - - - - - - - - Read Data From Smart Card Serial InterIace
Software
Software Commands
~RB- - - - - - - - Read Data From Smart Card Serial InterIace in ASCII hex Form
~RG- - - - - - - - Contact Internal Gemplus Smart Card Read Command
!RIBBON - - - - Get ribbon type installed
!RIBPN - - - - - Get ribbon part number
!RIBLEN - - - - Get number oI remaining panels on ribbon
RO- - - - - - - - X-Axis OIIset, Relative
ROY - - - - - - Y-Axis OIIet, Relative
!SA - - - - - - - - SelI Adjust
!SAN - - - - - - - PerIorm pre-calibration baseline testing
SDATA- - - - - - Force immediate save oI parameters
SERIE - - - - - Get Printer Serial Number
&SVM - - - - - - Disable/Enable Magnetic Encoding VeriIications
&T- - - - - - - - - Magnetic Encoder Card Eject
T/vT- - - - - - - - Draw Text (Monochrome/Overlay)
V- - - - - - - - - - Check Printer Type/Version
!V - - - - - - - - - Return Operational Parameter
V- - - - - - - - - Black Print Speed
!W- - - - - - - - - Move Card Backward 8 cm
&W - - - - - - - - Change Encoding Direction
~W - - - - - - - - Write Data To Smart Card Serial Port
~WB - - - - - - - Write Data Formatted in ASCII HEX To Smart Card Serial Port
~WG - - - - - - - Contact Internal Gemplus Smart Card Write Command
!X - - - - - - - - - Check Command Initiator
X- - - - - - - - - Change Command Initiation Character
!Z - - - - - - - - - Re-Synchronize Card
Z/vZ- - - - - - - - Load Bit-map (Monochrome)
.- - - - - - - - - - - Clear Error Status Lines
Software
Software Commands
'(()*+,- /
?BBC0 A"&$- D5>;$#*
SpeciIic model numbers include identiIiers that speciIy options using the Iollowing lettering
conventions:
Part Number Description
P 3 3 0 i - _ _ _ _ _ - _ _ _
Base Printer
P330! Color Card Printer
_ _ _ _ _ - 0 _ _ _ _ - _ _ _
_ _ _ _ _ - B _ _ _ _ - _ _ _
_ _ _ _ _ - C _ _ _ _ - _ _ _
_ _ _ _ _ - D _ _ _ _ - _ _ _
_ _ _ _ _ - E _ _ _ _ - _ _ _
_ _ _ _ _ - F _ _ _ _ - _ _ _
_ _ _ _ _ - H _ _ _ _ - _ _ _
Smart Card Options
None
Contact Encoder
Contact encoder & HD !CLASS contactless
Contact encoder & MFARE contactless
Contact station
HD !CLASS contactless
MFARE contactless
_ _ _ _ _ - _ 0 _ _ _ - _ _ _
_ _ _ _ _ - _ M _ _ _ - _ _ _
Magnetic Encoder
None
Yes (select defaults below)
_ _ _ _ _ - _ _ 0 _ _ - _ _ _
_ _ _ _ _ - _ _ 1_ _ _ - _ _ _
_ _ _ _ _ - _ _ 3 _ _ - _ _ _
Magnetic Encoder DefauIts
None
Stripe Down, HiCo
Stripe Up, HiCo
_ _ _ _ _ - _ _ _ 0 _ - _ _ _
Memory Expansion
None
_ _ _ _ _ - _ _ _ _ A - _ _ _
_ _ _ _ _ - _ _ _ _ C - _ _ _
Interface
USB Only
USB and Ethernet
P330i ModeI Numbers
_ _ _ _ _ - _ _ _ _ _ - I _ _
_ _ _ _ _ - _ _ _ _ _ - U _ _
Power Cords
U. S. and Europe
U. K. and Australia
_ _ _ _ _ - _ _ _ _ _ - _ D 0
Windows Drivers and User Documentation / Training CD
Windows Drivers and User Documentation / Training
included on one CD (Software & Documentation Package)
which contains Multi-language documentation.
'(()*+,- 1
E"#-&%1&$ 4$#@10$ F
4522"#)
Service and Support Locations
North America Region
Zebra Technologies
Card Printer Solutions
1001 Flynn Road
Camarillo, CA 93012-8706 USA
Phone: 800-511-9909
e-mail: techsupportzebra.com
Europe, MiddIe Ease, and Africa Region
Zebra Technologies
Card Printer Solutions, Europe, Middle East, AIrica
The Valley Centre, Gordon Road, High Wycombe
Buckinghamshire HP13 6EQ, England
Phone: 44 (0) 870 241 1527 (Irom outside U.K.)
Phone: 0870 241 1527 (Irom isside U.K.)
e-mail: cardtszebra.com
WorIdwide Service & Support
Website
Latin America Region
Zebra Technologies
Card Printer Solutions, Latin America
9800 NW 41st Street, Suite 220
Doral, FL 33178 USA
Phone: 1 (305) 558 3100
e-mail: techsupportzebra.com
Asia Pacific Region
Zebra Technologies Asia PaciIic, LLC
16 New Industrial Road
#05-03 Hudson TechnoCentre
Singapore 536204
Phone: 65 6885 0833
Fax: 65 6885 0836
e-mail: esohzebra.com
Website
www.zebracard.com

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