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Zebra 105927G-235

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1. 9008 001 Rev A Zebra PA Ptr Service Manual Theory of Operation CPU PCBA Connections 3 6 CPU PCBA Connections Most circuitry in the printer is on the CPU PCBA Since the CPU PCBA is nota serviceable circuit analysis to the component level is pointless but a basie understanding of ow the CPU PCBA connect to the rest of the printer helps to beter understand the printer E Zebra PRA Card Printer Service Manual 950006001 Rev A Theory of Operation CPU PCBA Connections CPU PCBA Connections Connector Tabe ID Tag TE no ideni Contact Smart Gard Option d TIRE HERD agra Er OREO Tis TART Eoriac Sar Card Opin T Te m IB Key Security E TEE REET E TART Bardo Reader pT E LEAT ENCODER E TOPHTRTG Tp Healer BOTATRTC Hear E TF RFID Fler TEST Test conneairy E po ideni Option E PROG Test Conner Zebra PRA Gard Printer Service Manual 4 Troubleshooting 4 1 Introduction The objective of troubleshooting is to relate problem to
2. Specie Payout Spine Ensure that there is very itle end to end play detent in the Spindle adjust the take up spindle nut as required 9008 001 Rev A Zebra PE3Q amp PRA Cars Printer Service Manual 25 Replacement Procedures Ribbon Payout Spindle Instali the two Grooved Splined Cores Instali the one af the O ring in the font slots on the two cores Star 0 Select gt Rib Tasks gt Find Low Ribbon Torque h Observe the two cores rotate counterclockwise for approximately two minutes L When the motor stops tuming to the next step E Zebra Card Printer Service Manual Replacement Procedures Ribbon Payout Spindle Step 2 Find High Ribbon Torque Place the Clutch onto the Guide Saf Note that you may have to move the Printhead down to acces the Guide Shaft b Place one O ring around the Clutch in the res the rear slol slot and around the lef cone in Install the other O ring in the front slots on the two cores From the IDPrint sereen select Coni Ribbon Tasks Find High Ribbon Tonue e Observe the two cores rotate counterclockwise for approximately two minutes T When the motor stops tuming go to the next step 9008 001 Rev A Zebra PRA Card Printer Service Manual Replacement Procedures Ribbon Payout Spindle Step3 Run Ribbon Motor Clutch Burn In Remove the O
3. Rev A Zebra PRA Card Printer Service Manual Replacement Procedures Printhead Assembly Step Adjust the Printhead An a M not already done remove the Printhead Cover nd move the ground wire out of the way Loosen the inside mounting screw just enough to allow sliding movement of the printhead bracket inside Mounting pom Unlock the angle adjust screw tum it a quartum counterclockwise then e lock it This will have the effect of rotating the head counrercookwise faction ofa degree when you snug the button head against the printhead fame 4 Tighten the inside mounting sre e Print another Test Cand isa noticeable improvement try another quarter umm adjustment then print again 1 Ifthe print quality is seen to deteriorate rather than improve return to the previous senting or the 30 mi preset setting of the head angle screw then rotate it clockwise in quartertur increments This adjustment is complete when you are satisfied with the Test Card image Step 4 Install the Printhead Cover and ground wir The ground wire s secured with the Jonger ofthe two cover screws E amp PRA Card Printer Service Manual 2006 001 Rev A 06 001 Rew Replacement Procedures Printhead Assembly Adjust the Printhead Height Pressure Select Starr gt Printers and Faves right lick the Zebra Card Printer and select Properties from the
4. Step 2 Remove the RFID Antenna Cover Note that the cover snaps in place Step 3 With 4 TORX TIS driver remove the two screws that hold the Ribbon Encoder Sensor to the Frame 2m Zebra P840 Card Printer Service Manual sa0006 001 Rev A Replacement Procedures Ribbon Encoder Sensor Step 4 If not already donc remove the Rear Cover see Section 5 3 and the Main PCBA see Section 55 Spi From the rer of the printer locate the Ribbon Encoder Sensor Step 6 Cut any associated cable ties to the Ribbon Encoder Sensor Step 7 If not already disconnected remove the RIBBON ENCODER Connector iom J31 on the Main PCBA Step 8 Fron the rear of he printer slide the Ribbon Encoder Sensor out of its access hole Remove the Ribbon Encoder Sensor Rev A Zebra PE3Q amp PRA Gard Printer Service Manual Replacement Procedures Ribbon Payout Spindle 5 20 Ribbon Payout Spindle 5 20 1 Removal Step 1 Locate the Ribbon Payout Spindle Step 2 Remove the RFID Antenna Cover Note that the cover snaps in place Step 3 With a 7 64 hex driver loosen the two Screws that hold he Ribbon Encoder Sensor to the Frame Step 4 Slide the sensor down to clear the encoder wheel 22 Zebra PE3Q amp PRA Prater Service Manual 2006 001 Rev A Steps Sept Sip Sep Sep Replacement Procedures Ribbon Payout Spindle With 7 16 socket wr
5. Zebra PE3Q amp PRA Gard Pater Service Manual 930006001 Rev A Installation and Setup Instaling the Printer Driver Step 20 Wait while he an instalis the software Step 21 When software installation is complete the following window will display Click Finish campagne rauna new Step 22 This completes softwar driver installation To use the PEO or Posi Printer you would select it jast ike you would any obe printer connected a Windows system Installation and Setup Installing the Printer Driver 262 Installing the Ethernet Printer Di Note To install the USB driver see Section 26 1 Important The Erhemet Network must be configured correctly with the Printer and the host computer oa the same subnet mask If you are not sure how to verify this or change the configuration consult somcone knowledgeable on Ethernet Networks Important valid statie IP address must be assigned to the printer Important Sce Section 49 for system related troubleshooting issues Step 1 Connect the printer power see Section 2 4 and connect the Ethernet Port on the rear ofthe printer to an Ethernet Network Port see Section 2 5 Tom the Printer on and Teti initialize atl the READY LED on the front panel is lit Step 2 Insert the User Documentation Drivers and Training CD into the CD drive ofthe host computer The Select Language window will open Step 3 From the Select Language wi
6. Henter Temperatures Temperatures measured by thermocouples in the top and bonom laminator heater cores Laminate Sensors Reflective sensors that detect the presence of laminate on the transfer rollers The threshold numbers are Lam Present Threshold Below 124 laminate present Lam Absent Threshold Above 140 laminate absent The threshold numbers are not adjustable Accurate positioning of the laminate sensors is essential If they do not detect laminate reliably performance of the entire printer is compremisad 006 001 Rev A Zebra PRA Card Printer Service Manual zs Replacement Procedures Laminator Sensor PCBA Functional Test of the Sensors Nota The sensor board must be symmetrically positioned relative the transfer rollers n with tachment screws central in their slots Itis possible to get a false god reading if he sensors too close to the fed rollers Step 1 From cach af the laminators upper and lower remove the transfer guide and the laminas patch if any beneath The laminate sensor should read high around 250 Sep Replace the guide and the laminate sensor should read no lower than 180 Ir lower than 180 move the sensor board away from the transfer rollers 10 the lel see diagram below Step 3 Complete the test by running laminate onto the rollers press the LAMINATE burton The laminate sensor should read below 20 Adjust sensor board to correct Zeb
7. 10 sequently referred to as 30 mil cards Important Do not bend cards or touch the print surfaces as this can reduce print quality The surface of the cards must remain clean and dust Always store cards in an enclosed container Ideally use cards as soon as possible Step 1 Open the Card Feeder Cover and if present remove the Card Weight Sep Remove all wrapping from the card desk A Caution Do not touch print surfaces of the cards this can reduce print quality Step 3 Holding the cad deck by the sides hold it vertically against a flat surface such as a desktop Ifthe deck is too thick for your hand to hold it comfortably use about half a deck ata time Zebra PE3Q amp PRA Gard Pater Service Manual 980006001 Rav A Installation and Setup Seting up the Printer Step 4 Push he stuck back and forth to an angle of about 45 from vertical so as to separate all ofthe cards gt A Important Statie charges and edge burrs from the card die cuting process can render individual cards stuck together with significant adhesion force These cards must he physically separated fom each ther before inserting imo the Card Feeder if not separated feeding or printing problems may occur Step 5 Restore the cand stack to its original condition and place the cards in the input hopper The input hopper can hold up to 150 cards Note Cards with a Magnetic Sip should be loaded wit
8. 523 Nip Rollers Laminator 5231 Removal Step 1 If nt already donc remove the Rear Cover see Section 53 Its not necessary 10 remove the Main PCBA Step 2 Locate the Nip Rollers Step 3 Remove both Laminate Cassettes Step 4 Remove the Laminate Cassette Receivers and botom Use the 7 64 hex driver to remove both the top and bottom spring loaded cap Be careful aot lose the serews and springs 9008 001 Rev A Zebra PE3Q amp PAD Gard Printer Service Manual an Replacement Procedures Nip Rollers Laminator b Use the 7 64 hex driver to remove the skew adjust sees fom both the tap and bonom caet receivers 4 Remove the bottom Laminate Cassette Receiver Tum the cassette receiver clockwise until it ean be easily removed from the printer Zebra PRA Prater Service Manual Rev A Replacement Procedures io Rollers Laminator Sep With snaptng pliers remove the top snap ring that holds the nip roller shaft in place Step 6 With snaptag pliers remove the bottom snap ring that holds the nip roller shaft in place Step 7 Turn the printer around Step 8 With a TORX TIO driver loosen both motos remove two ofthe throe foreach moto and just loosen the third screw Step 9 Pivot the motors ofthe way o acces the Nip Rollers 9008 001 Rev A Zebra PSA Card Printer Service Manual
9. 980006001 Rev A Zebra P630 P640 Card Printer Service Manual CA Card TOS Solutions Copyright Notice o 2008 Z1H Corp This document contains information proprietary to Zebra Technologies Corporation This document and the information contained within is Copyrighted by Zebra Technologies Corporation and may not be duplicated in full or in part by any person without writen approval from Zebra While every effort has been made to keep the information contained within current and accurate as of the date of publication no guarantee i given that the document is error free or hat it is accurate with regard to any specification Zebra reserves the right to make changes Tor the purpose product improvement at any time Trademarks 630 and P640 are trademarks and Zebra is a registered trademark of Zebra Technologies Corporation Windows and MS DOS are registered trademarks of Microsoft Corp other trademarks or registered trademarks are marks of their respective holders Product Disposal x Product Disposal Information Do not dispose of is product in unsorted municipal waste This product s recyclable and should be recycled according to your Standards For more information please see our web site at Bii zebra comervirenment Contents 1 General Description 1 14 Description 1 12 Printer Features 2 13 Controls and Indicators 7 14 Specifications P630
10. P640 15 Declarations of Conformity 18 2 Installation and Setup 21 General Information m 22 Unpacking the Printer 12 23 Seting up the Printer 15 231 Attaching the Output Hopper 15 232 Instaling the Ribbon 16 233 Instaling the Cleaning Cassette 19 234 Loading Laminate 20 235 Loading Cards 30 24 Connecting Power 2 25 Connecting the Printer to your Computer 26 Instaling the Printer Driver 281 Insialing the USB Printer Driver as 282 Instaling the Ethernet Printer Driver m 005 001 Rev Zebra PRA Card Printer Service Manual a 27 Changing the Printer Driver Options Properties 28 29 3 Theory of Operation a2 35 36 4 Troubleshooting 42 43 44 45 46 47 231 General Tab 272 Sharing Tab 273 Ports Tab 27 4 Advanced Tab 215 Color Management Tab 276 Security Tab 217 Device Settings Tab 2113 Printer Adjustment 2772 Color Calibration 2773 Status 2774 Control Changing the Printing Preferences 231 Card Setup Tab 282 YMC Color Printing Tab 233 K Black Panel Tab 284 Image Adjustment Tab 285 Magnetic Encoding Tab 288 IDiLog Tab 237 Advanced Tab 288 About Tab Packing the Printer for Shipment Introduction Card Printing Basies 321 Printhead 322 Printing Technologies and Ribbons Sensors and Interlock Switches Card Movement During Printing Block Diagram CPU PCBA Connections introduction Error Messages Indicator Light St
11. driver and he IDPrint test and adjustment program The Clutch Bum In Tool Kit PIN 105927 430 consists of Clutch Pulley Assembly Grooved Spined Cores 2 Orias Step 1 Find Low Ribbon Torque a Remove the Ribbon Loosen the payout spindle mu the Payout Spindle rotates fi Takeup Spite Payout spinte 9008 001 Rev A Zebra PRA Cand Printer Service Manual 165 Replacement Procedures Main PCBA Ensure that there is very litle end to end play detent in the Take up Spindle adjust the take up spindle at as required Instali the two Grooved Splined Cores e Instali the one of the O ring in the font slots on the two 9 Select gt Rib Tasks gt Find Low Ribbon Toru h Observe the two cores rotate counterclockwise for approximately two minutes 1 When the motor stops tuming go to the next step E Zebra PRA Printer Service Manual sa0006 001 Rev A Replacement Procedures Main PCBA Step 2 Find High Ribbon Torque Place the Clutch onto the Guide Shaft Note that you may have to move the Printhead down to acces the Guide Shaft b Place one O ring around the Clutch in the res the rear slol slot and around the lef cone in Install other O ring in the front slots on the two cores From the IDPrint sereen select gt Ribbon Tasks Find High Ribbon Tongu
12. 0 serewadriver install the screw holding the Cam and Flip Am in place Step 29 the Azimuth Locate the azimuth adjustment screw Zebra Gard Prater Service Manual 2006 001 Rev A Replacement Procedures Filip Station Adjust she azimuth via the adjustment sere until the pin is aligned inthe middle ofthe ote e Lift and lower the carrier assembly to verify position Step 30 Adjust the a With a 1 4 socket adjust the back Flip Arm unti it just misses the Platen Zebra PE3Q amp PSA Card Printer Service Manual Replacement Procedures Fip Staton With a 1 4 box wrench adjust the front Flip Arm it just misses the Platen Step 31 Install the Drive Motor Drive Motor in place Wiha TORN T25 driver tighten the two serews holding the Drive Mator to the Frame b Ensure that the deive belt is aligned properly around the drive moto pulley e Manually rotate the drive motor to tighten the belt With TORX T25 driver fully tighten the two serews holding the Drive Motor to the Frame Replacement Procedures Flo Station 5123 Adjustments 5 10 4 11 Flip Station Calibration This routine determines the number of motor steps it takes for the carrier to descend from the upper limis position to the lower lini position that being the carrier s physical end stop This Stored number is used to drive the carrier
13. 222 224 225 231 236 236 238 241 241 246 249 251 254 950006001 Rav A 5 27 Magnetic Encoder 257 5271 Removal 257 5 27 2 Replacement 252 5273 Adjustment 260 6 Preventive Maintenance 263 61 Card Cleaning System 263 62 Pint Head Cleaning 264 63 Platen Care and Cleaning 265 Appendix Part Numbers 267 Appendix Magnetic Encoder Media Loading Orientation 269 Magnetic Card Stripe Encoding 270 Appendix Smart Card Contactless Encoder Introduction an Media Loading Orientation an Printing Contactless Smart Cards 272 Appendix D Smart Card Contact Station zn introduction 273 Media Loading Orientation 273 Laminating Contact Smart Cards 274 Appendix E Printer Security 275 Printer Parameters in the Driver 276 Appendix F Printer Pooling Seting Up the Printers Individually are Creating the Pool 280 Using the Printer Poot 281 Appendix G Spares List Appendix Worldwide Support 9008 001 Rev Zebra PE3Q amp P840 Card Printer Service Manual Zebra PSA Gard Prater Service Manual 1 General Description 1 1 Description The Zebra P630 and Card Printers provide highspeed full olor dual side card pining A miero positioning eard system provides enhanced color photos range interface encodertreader and security options allow ordering the specifie configuration Suitable for a particular applica
14. Name Your Prater sereen Step 17 Verify that the printer name is correct Specify if you want to use this printer as your printer this can always be changed in the Windows Printers or Printers and FAXes contol pane Then click Next gt Zebra PRA Card Prater Service Manual 950006001 Rav A Installation and Setup Instaling the Printer Driver Step 18 Specify whether or not you want to allow printer sharing then click Next gt Step 19 Specify if you wish to print a test page note that card printers consider each can bea page hen click Next gt 008 001 Rev Zebra amp PSADI Card Prater Service Manual Installation and Setup Instaling the Printer Driver Step 20 Click Finish Completing the Add printer eem Step 21 The following sereen will appear O pp Step 23 When the fl copying is complete your printer is ready to use Zebra PRA Gard Printer Service Manual sano06 001 Rev A installation and Setup Changing the Printer Driver Options Properties 27 Changing the Printer Driver Options Properties Noto The sereen shots shown in this section are for the printer using the USB interface I you are using the Ethemet interface the serens will refer to the Network Printer You can change the default settings for the printer driver Change the options as follows Step 1 From the Printers and Faxes list right click the C
15. Replacement Procedures Np Rollers Laminator Step 10 With a abad screwdriver remove the E rings from cach nip roller shaft Remove the top Ering b Remove the bottom E ring Step IL Bef cach one fr correct orientation when reinstalled ot bottom smoving the gear front top and F Replacement Procedures Nip Rollers Laminator Step 12 Slide the top and bottom gears off their respective shafts Step 13 Gently slide each shaft back up and out of the printer Step 14 Remove the Nip Rollers Note that the long end of the shaft goes to the back of the printer when installing the replacement Nip Rollers 9008 001 Rev A Zebra PE3Q amp Card Printer Service Manual Replacement Procedures Nip Rollers Laminator 5232 Adjustment Pocket Adjustment Skew and vertical offset are adjusted by screws in the cassette pocket 7 647 hex wrench fr skew blade screwdriver for vertical offset see diagram below Before adjusting for skew vertical offset remember that there is significant interaction between the ach and the adjusting screws in the pocket r3 AEN LEA ura axis Important Always adjust the latch afer adjusting cither of the screws in he pocket E Zebra PAD Card Pater Service Manual 280006 001 Rew A Replacement Procedures Nip Rollers Laminator Latch Adjustment cassette held in place by two ca
16. as assembled in production before adjustments in final tet Zebra PSA Pater Service Manual 950006001 Rev A Color Sensor Assembly 5 24 Color Sensor Assembly Step 1 Locate the Color Sensor Assembly Step 2 If not alreudy done remove the Rear Cover se Section 5 3 and the Main Gee Section 5 Step 3 With a TORX TIO driver remove the serow holding the Color Sensor Assembly in place 06 001 Rev A Zebra PRA Card Pater Service Manual 2 Replacement Procedures Calor Sensor Assembly Step 4 Turn the printer around view from back Step S Ct the associated cable ti Step 6 If not already disconnected remove the RIBBON SYNC Connector fom 35 oa the Main PCBA Step 7 Remove the Color Sensor Assembly n Note When replacing the Color Sensor Assembly ensure the round tab is inserted in the hole before tightening Zebra PE3Q amp PRA Card Prater Service Manual 980006001 Rev A Replacement Procedures Contact Smart Card Assembly 5 25 Contact Smart Card Assembly Step 1 Locate the Contact Smart Cand Assembly Step 2 If not already donc remove the Rear Cover se Seton 5 3 and the Main PCBA Gee Section 55 Step 3 Remove the Contuet Smurt Card With a Phillips 0 screwdriver remove the two stews holding the Contact Smart Cand Cover in lace 9008 001 Rev A Zebra PRA Card Printer Service Manual R
17. gt Printers and Fares Right click on the Zebra P630 or Zehra printer isting Select Properties gt Device Seins gt Control gt Advanced Unites gt Move Carriage Fom the drop down menu select Flip Poston Press he Move burton The cand should drive smoothly to rest almost touching the ight hand edge of the fip station must not rebound off the edge The can should land with a gap of between L0 mmn 102 5 mi The exact gap is not critical but it has to e visibly there anion meng To acess Flip Station Adjustment screen select Start gt Printers and Fates Right click on the Zehra Zehra POA primer listing Select Properties gt Device gt Printer gt Flip Satin To move the card further to the right increase make les negative the Card Position Adjust parameter and vice ver The ruck can depart leaving the card in the fip arms or it may drag the cand an inch or two Important This is a critical adjustment What can happen ifthe card position is incorrect toward the print station then jam Ree A Zebra PSA Gard Printer Service Manual E Replacement Procedures Printhead Assembly 5 13 Printhead Assembly A Electrostatic Discharge Caution The Printhead is extremely susceptible to Electrostatic Discharge ESD damage Do not touch the bottom surface of the Printhead The replacement must be performed at stat
18. push atthe back of the carrier near the guide shaft force Step2 Access the Advanced Utilities sereen select Sturt gt Printers and Fass Right lik on the Zehra ot Zebra P640 printer listing Select Properties gt Device Setings gt Conrol gt Advanced Uii remm pre Step 3 Click the Flip Station Calibration button This elevates the carrier to he upper position Which point the motor stops and the step count is saved ia lash memory The motor then drives the carrier back down to the lower init position Rev A Zebra PE3Q amp P840 Card Printer Service Manual hooting Adjustment Procedures 410 32 Max Height Adjust The card carrier needs to move high enough to actuate the flipping mechanism but should not oversavel excessively To acess the Flip Station Adjustment screen select Start gt Printers and Fans Right click on the Zehra or Zelva POA primer listing Select Properties gt Device gt Printer Adhsiment gt Flip Station Increase this parameter only if there s an occasional failure to flip Reduce this value if the carrier hits the upper bracket holding the guide shaft Ifthe fip station is not flipping reliably be sure i is a trave issue rather than anything else by opening the printer cover and moving the flip station up by hand to activate the flip IF it the mechanism itself is defectiv
19. repeat Flip Station Calibration on page 137 Another adjustment for this Sept Sep Step 3 Power the printer thea power up and ston for the station reset actio Access the Flip Staion Adjustment screen select Sturt gt Printers and Fares Rig ick the Zebra or Zebra Pod ite listing Select Properties gt Device Sttngs gt Printer gt Flip Satin Adjust m RR gt pum eet a meam FO Open the main cover then push gently down onthe carrier at the back close to the ade 1f there downward travel increase the parameter make i less negative but do not overdo it because this will increase the reset noise and potentially damage the carrier drive Zebra PSAL Card Printer Service Manual 950006001 Rev A Troubleshooting Adjustment Procedures 41035 Card Position Adjust This procedure adjusts how the ruck drives ito the Flip Station The adjustment should be sso that the cand s centered in the lip ams itis not centered the truck may have removing the card afier the flipping action move the cand into the Flip Station select Start gt Printers and Fares Right click on the Zehra P630 or Zehra P40 printer isting Select Properties gt Device gt Control gt Advanced Unites gt Move Carriage Fom the drop down menu select Flip Poston Press he Move
20. Card Printer Service Manual u Troubleshooting Adjustment Procedures 4 10 4 7 Vertical Offset Adjustment lower cassette Once the front surface consistently acceptable inspect the back surface patches of the last few cards to pass through the laminator Note the offset on the back surface When flipping the Tor inspection keep the mag stripe if present toward you I Fip me caras eft to right nat tront to back ram below correct for vertical offset in the lower laminator using the same e but note that the reel in aset adjust screw aust screw coche Zebra PE3Q amp PRA Card Prater Service Manual Rew A Troubleshooting Adjustment Procedures 410 48 Cassette Pocket Reset Skew is causo by misalignment of the laminate cassette relative to the left right axis of the Prints locking down on the printer from above The skew adjust crew causes the pocket to relative 1o the left right axis The vertical adjust serew controls the depth of the assets in he pocket Note that the car of the latch must be in close contact with the cassette without changing 15 position Reset the cassette pocket like this if the pocket has been replaced or if the laminate is grossly misaligned Sep Back of the vertical offset adjust screw skew adjust screw and cassette latch adjust screws Step 2 Using three CR 80 cards total thickness 0090
21. K on the same side ofa card a process called Black Extraction is enabled The K Black Panel screen displays available options for Blick Extraction To acess the K Black Panel sereen select Sart gt Printers and Fases Right click on the Zebra oc Zehra peinter ising Select Printing Preferences gt K Black Pane Sear er Black Extraction Black extraction has odo with the way the printer driver handles the lack panel The term applies to the surfaces of be cand on which Jorh YMC color nd K black are to be printed Equal amounts of Y and C dyes at maximum intensity deliver nearblack image but one Bats not machine readable A bar code printed from YMC will be visible to the eye but will sot be detectable by most bar code readers Tise remedy for this is to extract the black which means printing the same bar code using the K panel on top of the YMC bar code You can also choose print only in K omining YMC fom that region The K panel isnot a dye I is more of a containing carbon black which is highly visible to ifrard ype readers Zebra PE3Q amp PRA Card Printer Service Manual 950006001 Rev A installation and Setup Changing the Printing Preferences Elements Selection Depending on the program used to create the card layout elements of he design may be identified in different ways to the printer driver This printer driver recognizes five types of ele
22. Laminate 630 ana Peta Peta oni Hot Surface I the printer has boon in use the Healer Cores area of the Laminalor may be hot Important If either Latch Plate is opened even unintentionally the corresponding Cassette must be removed and the Laminate reeled in fut leaving one end attached to the core and the ether end under the cutter Keep UI EP DUE E ee 9008 001 Rev A Zebra PRA Card Printer Service Manual E Installation and Setup Setting up the Printer Step 2 If there isa suspicion a patch is blocked somewhere temporarily remove the omesponding Transfer Guide to be sure there are no scrap of laminate remaining I there any remove them Then slide the Transfer Guide back in unit is held in place by the Retaining Spring m Step 3 Open Cassette ike clam shell by separating its two halves Grasp the two halves fimi with your fingers then pull it apart Do NOT ool Upper Cassette shown Step 4 If there is an empty laminate core in the Cassette remove it Zebra PSA Gard Printer Service Manual 930006001 aA Installation and Setup Setting up the Printer 2342 Loading the Laminate Cassette s Important Ifyou are using laminate n the Lower Cassette of a Printer ead the following section Using Laminate before proceeding with this procedure Partial width laminates are frequently used o
23. Step amp will be displayed Then click OK on o FET 0006 001 Rev A Zebra PE3Q amp PRA Card Prater Service Manual a Installation and Setup Installing the Printer Driver Step 10 This brings up the Add Printer Wizard Click Next gt cope to the Ada Printer Step 11 The next sereen ets you specify the type of printer to set up Select Local printer atched othe computer Automatically tet and install my Plug and Play printer should be unchecked Then lick Next gt Installation and Setup Instaling the Printer Driver Step 12 The Add Printer Wand Select a Printer Port sereen will now appear p toate et mire Cae ue Step 13 Click on Use the following por scroll to ENETixx Zebra Ethemet intemal Where xxx is the number of the port any Zebra Ethernet number can be used Se ee aa tiene nm x ap gt Rev A Zebra P840 Card Pater Service Manual a Installation and Setup Installing the Printer Driver Step 14 Check that the printer is tumed on and the READY LED is then click Next gt This will being up the Add Printer Software Wizard screen Ea Step 15 Select the Manufacturer Zebra Technologies and the printer model number then lick Next gt Sep This brings up the
24. Step 4 With a Phillips 0 serewdriver remove the ten stews inside the front openings of the Clean Staton Housing see following view fom side Step S With a Phillips screwdriver onsen the sere holding the Clean Station Housing to the Frame see following view fom top am Zebra PRA Gard Ptr Service Manual Replacement Procedures Clean Roller Step 6 With small flat blade screwdriver lift the torsion spring out of the groove in the bushing that holds the clean roller shaft Do not remove the spring from the housing Step 7 Slide the Clean Staton Housing of the Frame Note the orientation of the torsion spring should it come loose om the housing 9008 001 Rev Zebra PE3Q amp P840 Card Printer Service Manual E Replacement Procedures Roller From the rear of the printer locate the Clean Station Sep Witha Phillips 4 screwdriver remove the nwo serews holding the Cleaning Encoder Sensor to the Frame Move the sensor out of the way Zebra PE3Q amp P840 Card Printer Service Manual 20006 001Raw A Replacement Procedures Clean Roller Step 10 Remove the Encoder Whos from the clean roller shaft by gently turning the wheel ck and forth while pulling outward Step 11 Locals the torsion spring holding the clean roller shaft in place Step 12 With small flat blade screwdriver lift the torsion spring out of the groove in the lean rol
25. Step 7 Turn the printer around view from back With a screwdriver remove he two screws shown below This will allow the backplane to move 006 001 Rev A Zebra PSA Card Prater Service Manual Replacement Procedures ject Arm Step 9 Turn the printer around view from front Step 10 Push and hold the backplate far enough to the rear ofthe printer to acces the sew atthe back af the Eject Step 11 With 916 hex driver remove the screws at he back and font of the Ejeet Am Step 12 Remove the Eject 25 Zebra P840 Cand Pater Service Manual 2006 001 Rev A Replacement Procedures Magnetic Encoder 5 27 Magnetic Encoder 527 1 Removal Step 1 Locate the Magnetic Encoder Step 2 If not already donc remove the Rear Cover see Section 5 3 and the Main PCBA Gee Sccion 55 Step 3 Wilh a 5 6 hex driver remove the shoulder screw nylon washer compression spring and flat washer ftom the right side of he Magnetic Encoder Step 4 With a 5 6 hex driver remove the shoulder screw aylon washer and compression spring frum the left side ofthe Magnetic Encoder Note that there is no flat washer On the leftside 9008 001 Rev Zebra PE3Q amp PRA Card Printer Service Manual Replacement Procedures Magnetic Encoder Step 5 Turn the printer around view from back Sep With a fla blade screwdriver disconnect the ground wi
26. Yalow ye Subimaton Fur Color Pring and Dye Sublimation Back Pring TT Dyesusman futCohrPming and Bye Sielmaton Beck Pring EI Fur ola Parting ana Dye Sublimation Beck Pring Bauen TT Rese Black Prning forie Blea Rema Tramal Transtar Rea Prin fore Sook athe cari Thermal Tansee Dye Subimaton Priming Process Ping Process Magia Vow Panem m Repeat De Dye Dye Ribbon Movement Fram Supply Spool Other ribbons are available for the 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 wwwacbricand com 9008 001 Rev Zebra PE3Q amp PRA Card Prater Service Manual E Theory of Operation Card Printing Basics The rition synchronizes to it s starting position whenever the Main Cover i opened and then closed Fora YMCKK ribbon the starting position is withthe leading edge of Black Panel atthe Printhead location The figure below shows how the ribbon and cad move relative to cach other 2 Cardis Fes to Ping Postion Under tna Primed e Cang and abn ove oer 4 4 Gars and Ribon siap at A ol Blao Panel e 5 Ribbons stationary Card ia Figged and Moved Back Printing Poston a 6 tton Move Together ES I addition the driver softwar
27. an if Back gf CARD FRONT caro f LA 1 Length Adjust il This is the length of the laminate patch F the patch is to long decrease this number and vice versa 2 Horizontal Offset mils Adjusts laminate placement oa the card Zebra PE3Q amp PAD Card Pater Service Manual 950006001 Rav A Installation and Setup Changing the Printer Driver Options Properties Heater Temperature This is the set point temperature Lethe For actuals se Sensor Dita on page 71 perature desired not the actual temperature Note Temperatures are monitored by thermocouples at the ofthe heated rollers Surface temperatures may differ significantly 4 Line Voltage ofthe heaters Running he printer at 10 in Auto mode may cause abnormal Jong heat up time and poor temperatur control Either wil a heater error massage in the printer status screen Caution Running the pintar at 220 in Aulo moda may causa premature fall Auto is select the printer guesses line voltage based on line frequen assuming that OV will be id GHz and 230V a IF this the ease in your Locality the printer Will guess wrong and you should set the voltage manually Rev A Zebra PRA Gard Pater Service Manual Installation and Setup Changing the Printer Driver Options Properties Flip Station Adjustment To acce
28. an associated assembly system function in order to most efficiently isolate and repair the problem This involves determining the failure symptom and then checking one or more possible causes of the failure Only a symptom chtd ist of possibilities appears In general for a given fur symptom or more possible causes are listed with suggested corrective action take These causes Should be checked ad corrective actions taken in the onder given they ane listed in onder of likelihood and complexity When the suggestions presented fail to lead to a repair CPU Boan replacement if not prescribed should nevertheless be tried A cheek fr Broken disconnected cables and any Toss of power should also take place along with checks for obvious mechanical damage Zebra Cand Printer Solutions offers Technical Support and factory repair as options 0008 001 Rev Zebra PRA Card Printer Service Manual E Troubleshooting _ Messages 4 2 Error Messages Mas emo byte prie are pred byte computer at error messages with corrective actions listed The following are examples of computer reported messages E Zebra amp PAO Card Ptr Service Manual IT Troubleshooting Indicator Light Status 4 3 Indicator Light Status READY MEDIA ALARM PRINTER STATUS Ready to print Primer busy Laminators in sleep made When not in use he hee cool at IF p
29. between Green Ready and Red Alarm the optimum condition would be Yellow Media on all the time 4 Adjust the payout spindle nut as required if Red tighten if Green loose e When the motor stops tuning and you are satisfied with the adjustment go to the next step Step S Remove the O ring and the two Grooved Splina Cores Step 6 the Ribbon Step 7 Power Cyel the Printer m Zebra PE3Q amp PRA Card Pater Service Manual sa0006 001 Rev A Replacement Procedures Main PCBA 5 5 2 3 Printhead Resistance Step 8 After changing the Main PCBA go into the Printer Driver and enter the Printhead resistance Select Starr gt Printers and Faves right click the Zehra Card Printer and select Properties rom the pop up men From the Card Printer Properties sereen se Adjustment gt Print Saton Adjust ect Device Setngs gt Printer Inthe Printhead Resistance Ohms enter the resistance of the Printhead This number is located on the label applied to each Printhead 3 The Printhead resistance i sach printer writen on the inspection report shipped with 0006 001 Rew A Zebra P840 Gard Prater Service Manual m Replacement Procedures Doors Main and Card Load 56 Doors Main and Card Load Sept Phillips 1 serewdriver remove the eight serews holding the Maia Door and Card Load Door in place Note that the orang
30. bunton The cand should drive smoothly to rest almost touching the right hand edge of the fip station must not rebound off the edge The cand should land with a gap of between L0 mmn 02 5 mi The exact gap is not critical but it has to e visibly there anion meng To acess Flip Station Adjustment screen select Start gt Printers and Fates Right click on the Zehra Zehra POA primer listing Select Properties gt Device gt Printer gt Flip Satin To move the card further to the right increase make les negative the Card Position Adjust parameter and vice versa The ruck can depart leaving the cardin the fip arms or it may drag the cand an inch ar two Important This is a critical adjustment What can happen ifthe card position is incorrect toward the print station then jam Rev A amp PRA Card Printer Service Manual Troubleshooting Adjustment Procedures 4 10 4 Laminator Adjustments Correctly positioned top front and bottom back laminate patches there is no magnetic on the underside a full width patch should be sd LA 4 Positioning of the patch is affected by three variables 1 Horizontal Leight 2 Stew S Fecal offi up down Horizon oft is sofware adjustment Skew and vertical offset are mechanical adjustments 4104 1 Latch A
31. down to the rest position before each and every flip Calibration is a one time setup routine but is also useful starting point when diagnosing fip sation problems Step 1 Power OFF lift the cover and push the carrier down to its physical end stop When pushing the carrier down push a the back of the carrier near the guide shaft force Step 2 Access the Advanced Utilities sereen select Sturt gt Printers and Fass Right lick on the Zehra Zera P640 printer listing Select Properties gt Device Settings gt Conrol gt Advanced TU CH remm pre Step 3 Click the Flip Station Calibration button This elevates the carrier to he upper Lir position Which point the motor stops and the step count is saved ia lash memory The motor then drives the carrier back down to the lower init position Rew A Zebra P840 Card Printer Service Manual LI Replaceme Fip Staton jent Procedures 5 10 4 12 Max Height Adjust The card carrier needs to move high enough to actuate the flipping mechanism but should not excessively To access the Flip Station Adjustment screen select Start gt Printers and Faxes Right click on he Zehra or Zelra POA primer listing Select Properties gt Device Seringe gt Printer gt Flip Station Increase this parameter only if there s an occasional failure t flip
32. end of the laminate is uneven or crinkled cut it as square as you can with scissors Step 7 Holding the cassette with the white roller up and pointing to your lef rotate the core counterclockwise to in the laminate Stop when the end of the laminate is even Wih the edge of the lips of the case Important Check for overhang any time the cassette latch i opened the cassette is removed Zebra PRA Pater Service Manual 980006001 Rev A installation and Setup Setting up the Printer 2343 Laminating Contact Smart Cards The laminating patch on he top surface of a smart card has rectangular aperture to expose card s electrical contacts In all other respects the laminating process for smart cards is he same as for ordinary cards Note that this procedure also applies registered laminates The special laminate fur the top cassette is punched with a repeated pattem Loading procedure for smart card laminate is exactly the same as for standard laminate n Note Chock ifthe patch roll is centered oa the cores if not gently tap the roll on a surface to re cemer The smaller hole is an index marker that tells the printer where to cut the laminate exactly splining the index hole the printer driver allows adjustment of the eut location After loading the Smart Card laminate in the upper cassette trim the laminate along the cut line as shown above Note When sing sma
33. followed by power eyeing the printer Poor color registration Minor mis tegistration of Y and C color passes may he due o printhead angle adjust serew not in firm contact with printhead frame Printhead Angle Adjustment on page 134 For gross mis egistration of M and suspect that the card not firmly positioned against left hand pick edge of Truck on one or more passes Spring at left end of Pisten may be missing or bound up To remove the Platen see Platen on page 177 Check printed card for damage on comers or edges Example the card may be seraping along the underside of the hopper base molding Printhead pressure too light se Printhead Position HeightProssur Adjustment on page 133 Printhead may be running hot Will occur if head resistance incorrectly entered in driver sofware see Printhead Adjustments on page 12 Toothod transport belt pulley may be sliping on drive shaft Check platen spring spring height should be the same as the pin height see Platen on page 177 Rev A Zebra Printer Service Manual E Poor color rendering Important Changes in contrast settings will not take until power is cycle Posible source issues poor quality photos graphics card layout application setings Tot the problem by printing known image To vary the brightness and contrast select Sturt gt Printers and Faxes Right click an the Zeh
34. he Old Password Enter a new password in the New Password field and enter the same password in the Confirmation field disable the 1DICode funcion leave the New Password and Confirmation fields blank When completed click the OK button Update Backup Config Most of the parameters affecting operation of the printer are set up using the printer driver and are then saved in the printer s fash memory as the curent configuration The original factory configuration also resides in a separate backup memory allowing you to recover the as Shipped senings Update Backup Config command instructs the printer to replace the factory configuration with the current configuration but do nat do this casually Onee the current configuration replaces the factory configuration you can no langer return the printer to the factory senings Restoring the Backup Configuration Settings Revert to Backup Config as follows Step 1 Tum power OFF Step 2 Remove the color ribbon Step 3 Press and hold the PRINT RIBBON and LAMINATE buttons at the same time as you switch on the power Step 4 Release the three buttons when you see activity in the printer amp PSAI Card Printer Manual 980006001 Rew A Printer Security Printer Parameters in the Driver Password Protection Password protection is not the same as 1D Code Password protection blocks acces to various low level printer adjustment
35. isin Appendis G Electric Shock Caution Bore performing any of tne procedures n this section sel the printer power to OFF and disconnect he power cord Electrostatic Discharge Caution A replacement procedures must be performed ala A atc work station an antistatic wrist strap must be wom and propery terminated or other appropriate protection must be used Caution Before beginning any ofthe procedures that folow read completely rough the procedure Ifyou da not have the specified tools or f any step s seem beyond your Skil ar experience level do not attempt the procedure You may cause additional damage tothe printer Note Some of the photographs in this section may show additional parts removed in addition to removals for the process being described 52 Replacement Procedures Required Tools Required Tools This section lists the tools required for the replacement procedures desciod ia this section Naturally not ool are required for particular procedures pectic tools are called out in sich step as appropriate Important When removing any of the nylon plastie pulleys or ears the use ofa gear Puller is strongly recommended 1 gear puller is not available use pliers andlor a at blade screwdriver 1o pey the gear or pulley of its shat either case remove any Loctite residue from the shaft and the gear pulls Inspect the old gear pulley very carefully fan
36. polenta laci shock suat Surface Warne you of a suntion where excessive haat could cause a bur Caution you that failure lake araved speci acion could result Tn Physical harm to you or result in physical damage t the hardware Zebra PE3Q amp PRA Gard Printer Service Manual 2 Installation and Setup 24 General Information section will guide you through the installation and setup of your printer This consists of the following procedures which should be performed in the order presented 22 Unpacking the Printer 23 Seting up the Printer 5 24 Connecting Power 25 Connecting the Printer to your Computer E 26 Installing the Printer Driver 27 Changing the Printer Driver Options Properties 28 Changing the Printing Preferences 29 Packing the Printer for Shipment w The procedure to be followed far Packing rhe Printer for Shipment is given at the end of this section Installation and Setup Unpacking Printer 22 Unpacking the Printer Remove the Printer from the Shipping Carton Step 1 Open and remove the plastic hande latches on either end of the shipping carton Step 2 Litt the upper part ofthe shipping carton off the lower part Step 3 Remove the items ftom the cutouts in the foam block atop the primer Verify that the following items are included Cleaning Carvidge Oupa Hoppe V Ribbon Take up Spo
37. pop up men b From the Card Printer Properties screen select Device Sins gt Printer Adjustment gt Print Station Adjust Inthe Printhead Position Adjust field decrease the value by 10 and print a card M your printed eard still looks good to you repeat Step c until you get an unacceptable printing Unacceptable printing would be light printing u the point that the image is almost not being transfered to the card Once you have unacceptable printing add 60 to your Printhead Position Adjust will set your optimal printhead Zebra PRA Card Printer Service Manual EI Replacement Power Supply rocedures 5 14 Power Supply 5141 Removal Electric Shock Caution Before performing Iis procedure set the printer power to and disconnect the power cord Step 1 Locate the Power Supply With a TORX TIS driver remove the four screws holding the Bottom Plate to the Frame Step 3 Carefully slide the Power Supply attached to the bottom plate of the priate Zebra P840 Card Printer Service Manual 950006001 Rev A Sep Steps Sep Steps 0006 001 Rew A Replacement Procedures Power Supply With a TORX TIO driver remove the four screws holding the power supply cover to he bortom plate Remove the power supply cover Disconnect the AC power connector Disconnect the DC power conn
38. ring Reinstall an O ring in the front slots the two cores From the IDPrint sereen select Contrat gt bon Tasks gt Run Ribbon Motor Chach Observe the two cores rotate counterclockwise 9008 001 Rev A Zebra PRA Cand Printer Service Manual Troubleshooting Adjustment Procedures Tighten the payout spindle nut the O ring bows then backoff slighty Listen to the hu of the motor aa Adjust the tightness of the payout spindle nut until the motor hum is constant ab This test takes approximately ten minutes When the motor stops tuming go to the next step Step 4 Adjust Payout Clutch n Note You need to repeat this until you are satisfied with the adjustment From the IDPrint sereen select Contr gt Ribbon Tasks gt Adjust Payout ad Observe the two cores rotate counterclockwise E Zebra PRA Pater Service Manual 2006 001 Rev A Troubleshooting Adjustment Procedures ao Observe the panel hts Note The panel lights should flash an equa amount of time between Green Ready and Red Alarm the optimum condition would be Yellow Media on all the ume at Adjust the payout spindle nut as required if Red tighten if Green loosen ag When the motor stops turning and you are satisfied with the adjustment go to the next sep Step Remove the O ring and the two Groove
39. select Sart gt Printers and Fares Right click on the Zebra PSO oc Zehra POU primer isting Select Properties gt Device Serting Printer Adjustment The following procedures can be performed via the Printer Adjustment screen 0006 001 Rev Print Station Adjustment e Laminate Station Adjustment Flip Station Adjustment Advanced Adjustments Card Hopper Pick Position Adjust Pixels Adjusts the position of the truck when picking a cad fom the hopper Cleaning Staion Clean Frequency Runs clean cycle wil be run after the specified umber af cards have been printed The clean frequency range is rom 1 1020 he default 10 Zebra PE3Q amp P840 Card Prater Service Manual Instat tion and Setup Changing the Printer Driver Options Properties Print Station Adjustment To access the Print Station Adjustment screen select Sturt gt Printers and Faves Right click on the Zebra PAHO or Zehra PBA printer listing Select Properties gt Device Settings gt Printer Adjustment gt Prin Starion Adjust Important Checking tne box cle in the figure teow w l enable me greyed out Print Station Adjustment settings be changed mm seat naman FS 3 Important Hold the cond in the orientation that it exits the printer 1o determine which adjustment to make left trailing edge right leading cipe Failure to do s0 will resu
40. the code and second reads it to check for accuracy and readability Any cand not passing this test s ejected through the laminator without printing Verification adds only 3 seconds to the processing ime per card and is recommended far all applications not calling for the highest possible throughput Bit by Bit Encoding This is used only in applications calling for a custom designed encoding format Call Zebra Tech Support for more infomation Enable EIN Readback Applicable only in applications using cans with pre encoded inventory numbers Zebra PSA Gard Printer Service Manual 980006001 Rev A Installation and Setup Changing the Printing Preferences ID Log Tab The ID Log is a driver utility that builds database of card transactions in the printer s host computer Important Make sure Status Polling Frequency is enabled by selecting Normal or Reduced To acess the Situs Polling Frequency option select gt Printers and Faxes Right lik onthe Zebra P630 or Zebra P 40 printer listing Selet Properties gt Derice Settings gt Control Advanced Ule Log rooms data encoded on the card s magnetic stripe together with dale tme and the printer s serial number The data set be uploaded at any time to a central achive s providing a means for security officers validate the eard by comparing it with tamper proof real data To access the IDYLog sereen select Start gt P
41. thus protecting critical with a tamperdetenent film Ir there is magnetic stipe on the underside a full widih laminate should be used 7 Front gf caro J emn 55 ZA aacr ofeano Gora 2 CIT E V Length Adjust mil This is the length ofthe laminate part f the patch is too long decrease this number and vice versa Horizont mils Adjusts laminate placement on the card Heater Temperature A Caution Do nol set the Healer Temperature above 18070 or below room temperature This is the set point temperature ke the temperature desird not the acta temperature For aciuals see Sensor Data Sensor Datu on page 71 NOTE Temperatures are monitored by thermocouples t The core of the heated rollers Surface temperatures may her significantly 4 Line Voltage ofthe heaters Running he printer at 110V in Auto mode may cause abnormal Jong heat up time and poor temperature control Caution Running te printer at 220V 80 in Auto mode may cause premature Ture A Auto is selected the printer guesses line voltage based on line frequency assuming that 110V will be t and 230V E I this is not the case in your locality the printer will guess wrong and you should set the voltage manually w Zebra PE3Q amp PRA Card Pri
42. two cover screws Zebra PRA Card Printer Service Manual 2006 001 Rev A Troubleshooting Adjustment Procedures 41024 Image Skew Adjustment With a 3 32 hex driver loosen the Skew Adjust Screw Step 2 With a IKI hex driver loosen the Inside Mounting Sore 0005 001 Rev Zebra PE3Q amp P840 Cand Pater Service Manual E Troubleshooting Adjustment Procedures Step 3 With the nwo serews loosened Printhead can now pivot lef or right and the image skew can be corrected Step 4 Tighten the Inside Mounting Screw first and then the Skew Adjust Sere Step S Printa card to see if the image is centered If the image is stil skewed adjust the printhead again until the image skew is corrected Zebra PRA Gard Printer Service Manual sa0006 001 Rev A Troubleshooting Adjustment Procedures 4103 Station Adjustments 4 10 3 1 Flip Station Calibration This routine determines the number of motor steps it takes for the carrier to descend from the upper limis position to the lower lini position that being the carrier s physical end stop This Stored number is used to drive the carrier down to the rest position before each and every flip Calibration is a one time setup routine but is also useful starting point when diagnosing fip Station problems Step 1 Power OFF lift the cover and then push the carrier down to its physical end stop Whon pushing the carrier down
43. 06 001 Rev A Zebra PAO Card Printer Service Manual Troubleshooting Printhead Problems Image missing at top or bottom of card Ribbon folded over at edge Slacken ribbon by pulling more of supply roll unfold edge then press RIBBON button to resync Bottom edge and or right hand edge of image missing could be cad layout application sending wrong image size shouldbe 952 x 578 pixels Select appropriate mage size if available in Preferences or modify layout application Image skewed Printhead needs skew adjustment see Image Skew Adjustment on page 135 Consistent image defects card after card Debris on Platen or Platen surface not flat Clean Pte or replace if necessary Debris on Platen Chan Pisten Zebra PRA Card Prater Service Manual 930006001 Rev A Troubleshooting System Related Issues 4 9 System Related Issues Printer self ses takes more than a few minutes to complete gt READY indicator LED i ot lit on the panel A communications problem exists Invalid IP address A valid statie unique IP adress must be assigned to the printer The default sening has DHCP disabled IF you do not specify either the printer may incur an extended latency while being identified in your network Refer 10 your operating system networking configuration instractions set up a unique statie or DHCP selected IP address for your Ethemet nabled printer DHCP is enabled but
44. 10 Step 12 Step 13 Step 14 Goto Start gt Printers and Faxes gt Add a Printer tick Next on the Adi Printer Wizard welcome sereen Select Local Printer Make sure that Automatically Detect My Plug and Pay Printer K unchecked then click Next Select Use the following port and choose the port thut the first printer is In this illustration this will be ATLUSBODI In the printer list choose Zebra Technologies as the manufacturer then choose far this illustration Zebra P640 Click Next On the next sereen choose Keep Existing Driver then click Next Choose something meaningful for the printer name Poa for example Decide Whether or not this is 10 be the default printer then click Next Decide whether o not the pool is to be shared then click Next Shared means that other networked computers will be able to send jobs to the pool Choose no test page then click Next Click Finish In Printers and Faxes there should now be printer called Pool or whatever you named it Right click on Pool then click Properties Click he Ports tab Check the Enable Printer Pooling box the list of ports select the other ports that have printers connected them remember that only one port was selected on the initiat instal Foe this illustration hock the ATLUSBOO2 and ATLUSBODI ports then click OK The setup now is three printers Zebra P640 1 Zebea 2 and Zebra Pli 3 und o
45. 2 Advanced Tab lt About Tab EI 006 001 Rew A Zebra PE3Q amp P840 Prater Service Manual instal tion and Setup Changing the Printing Preferences 284 Card Setup Tab Cond Setup allows the user to adjust selected card parameters access the Cand Setup seven select Start gt Printers and Faxes Right lick on the Zebra 0 or Zebra P640 printer listing Select Printing Preferences gt Card Setup 1 Image Size Sets the image area for both front and back ofthe card 1 inet 300 pixel Cards Specifies the type of card loaded in the hopper Zebra Card is the only option Ribbon This isthe color ribbon installed in he printer This is not user selectable but is setup by the RFID For most applications two types available YMCK 3 color panels T I Black panel and YMCKK 3 color panels 2 panels For secure applications a thin type is available YMCUVE Uv isa panel of ultraviolet responsive resin When using a printer with RFID this option is not selectable 4 Front Back Allows you to apply color or black or both to either side of the card For example with a4 panel YMCK ribbon the usual arrangement is YMC Color on the font K Black oa the back If you check both YMC and K on one side this sets up 4 special condition known as black extraction S Laminate Allows you to choose whether laminate will be applied to the front side to both sides P640 P
46. 7 23 as fecler gauge in the between the pocket and back plate adjust for skew and vertical offset the ap is an even 0 90 across the width of the pocket Sep Wa a cassette in the pocket adjust the latch screw so that the front car is sug othe cassette but does not shift it out of position The pocket is now in its default position as assembled in prodction before adjustments in final tet 0006 001 Rev A Zebra PRA Gard Printer Service Manual Troubleshooting Adjustment Procedures 410 49 Laminator Parameters in the Driver access the Status sereen select gt Printers and Faxes Right click on the Zebra Zehra P640 printer listing Select Properties gt Device Senings gt Control gt advanced gt Show Sensor Data Henter Temperatures Temperatures measured by thermocouples in the op and bottom laminator hester cores 2 Laminate Sensors Reflective sensors that detect the presence of laminate on the transfer rollers The threshold numbers are Lam Present Threshold Below 124 laminate present Lam Absent Threshold Above 140 laminate absent The threshold numbers not adjustable Accurate positioning of the laminate sensors s essent reliably performance of the entire printer is compromised they do not detect laminate Zebra P840 Card Pater Service Manual 950006001 Rev A Troubleshooting
47. Adjustment Procedures 4 10 4 10 Functional Test of the Laminator Sensors Step 1 From cach of the laminators upper and lower remove the transfer guide and the laminate path beneath it The sensor should read high around 250 Step 2 Replace the guide and the sensor should read no lower than 180 If lower than 180 move the sensor board away fom the transfer rollers to the et diagram below Step 3 Complete the test by running laminate onto the rollers press the LAMINATE button The sensor should read below 20 Adjust sensor board to comeet Step 4 The sensor board must be symmetrical wih isan reading positioned relative to the transfer rollers Jument screws central in their slots Iis possible to get false good the sensor oo close 10 the feed rollers Rew A Zebra PE3Q amp P840 Card Printer Service Manual E Zebra PE3Q amp P840 Cand Pater Service Manual 5 Replacement Procedures 5 1 Introduction The following sections deseribe removing both major assemblies and where applicable subassemblies andor components that are considered replaceable In general only removal directions are presented unless otherwise noted replacement would be performed by reversing the removal steps Replacement instructions for some tems are not presented removal and replacement of these items considered obvious to warrant a description The Spares List
48. CUTTER BOTTON PROCESSOR TOF CUTTER TINENT CLEAN ENCODE CEDIAN EXON TANTCARDERIT TIE ENT RIBON ENCODER TAT TONE CARRIAGE STA SEN TUIFSTATION TEAD IT SEN MERD TIET RIBBON SYNC SYNC TED HOP EX SEV TRIED TTF EXIT SENSO DOOR OPER TOPDOORSW TOF OPEN CARNEARTIO TRENER TOF AT Top Hester BOTETE Coto Heater T TOFTITETC Top Hear T EOTHTETC TE RED REID FI CST TORTACST Conor Satin ACN ACOUT TEST TTE Cn FROG les Connector Replacement Procedures Main PCBA 5 5 2 Tests and Adjustments 5521 Reload The Configuration Information After changing the Main PCBA reload the configuration infomation save in at the beginning of this procedure into the printer Step 1 Run the IDPrint exe program Step 2 From the IDPrint Main Menu select Configure gt Load Config File Step 3 Tis saved configuration information will update your replacement Main PCBA E Zebra P840 Card Prater Service Manual 950006001 Rav A Replacement Procedures Main PCBA 5 5 2 2 Adjust Ribbon Torque The Main PCBA neds lea the amount of voltage required to run the ribbon drive motor do this you need to perform the Ribbon Torque Adjustment Procedure perform the procedure ensure you have Clutch Burn In Tool 7 16
49. DE MEDIALOWER Zebra P840 Card Pater Service Manual Miscellaneous Spares List Ki Description T0570 WITIUBRIPLTGRERSELAM SUSAN RITASSY CLUTCH BURNIN TOOL 10592763205 TITFICTER AC INPUT MODULE Zebra PE3Q amp PRA Cand Printer Service Manual Spares List Description 10892763205 CABLE To PWR SUPPLY 10592763437 FT EIA CABLE TO WAN PCBA KIT RFID ANTENNA ES Zebra PRA Card Pater Service Manual Shipping Carton Spares List KIT PACKAGING FETE 0006 001 Rew A Zebra PE3Q amp PRA Card Printer Service Manual Zebra PE3Q amp PRA Card Printer Service Manual Appendix H Worldwide Support For Technical Support or Repair Services contaet the appropriate facility isted below North America Technical Support Zebra Technologies Card Printer Solutions 1001 Flynn Road Camarillo CA 93012 8706 USA Phone 1 800 511 9909 North America Repair Services Before renaming any equipment 1o Zebra Technologies Corporation for in warramy or out of warranty repair contact Repair Services far a Return Materials Authorization RMA number Repack the equipment in the original packing material and mark the RMA number clearly on outside Ship the equipment Height prepaid to the address listed below Zebra Technologies Card Print
50. G 0006 001 Rew A Zebra PE3Q amp P840 Card Prater Service Manual Spares List Transport Description TOSO Z7 RIV BELT TING MALIN SS OT CON 199276278 WIBELTTWINGMXLSEW MUT T0570 A0 CARRIAGE HONE OBIT RTF CRD 195927698 RIV SWITCH NEAR HOPPER Spares List NUSEGZN RIT MOTOR WIPULLEY TRNSPRT 1059276394 RIV SPRING PLATEN RETURN RITPNPLATEN 105927635 RIT MAG ENCODER COMPLETE Zebra P840 Cars Printer Service Manual Spares List Cleaning Station KEF Description 1059276388 RIT SENSOR CLEANING ENCODER TOSGETE 250 RIT BEARING SLEEVE WIGROOVE SET OF S RIF ROLLER CLEAN POA Spares List Description 1959276349 RIP MOTOR HERD TOS A1 RIT MOTOR PRINT RIBBON PRU NESEGGU WIORING OE OBIT ATOA SENSOR REN ENCODER Spares List Description 10592763388 WILCOLOR SENSOR ASSY 105927658 FIT ARBOR REN SPINDLE PORK Flip Station Spares List Description 1059276303 KIT VERTICAL SUPPRT FUP STATN c TT TREE FUP ETAT 1059276330 TATUR GUDE REAR FUP STATH RES GUIDE F
51. RNT FLIP STAN 1059276 257 KTFF CARRIER Zebra PE3Q amp PRA Card Printer Service Manual Spares List Description TREAT TIT SPRING FLIP GUIDE FOI SET OF S RATERS RIT MOTORFLP STATION REE WILPCBASENSRFUP STATN Laminator Spares List 10592763775 RIT MOTOR BOTTOM LAW ROLLER 1059276 276 MOTOR TOP LAM ROLLER 10592763225 TIT HEATER ELEMENT TBST KIT COVERING HEATED TERE RIT MOTORTAM CARD Spares List Description TO 3 RITE SENSOR CARD LAM EXIT 1059276254 WILAN CASSETTE UPPER 1059276385 RIV LAW CASSETTE LOWER aem 1055276305 BELT TNING LAMINATOR Zebra Printer Service Manual 2006 001 Rev A Spares List 105927635 10592763306 SHAFT SINGLE 1059276307 TNF SHAFT DOUBLE RET FINE SHAFT LAMINATE 1059276 19 TRNSFR MLDED PEZURAD 0008 001 Ret Zebra P840 Gard Printer Service Manual EI Spares List KEF Description 89276 342 _ GUIDE EDGE TR 108827699 RIFGUDE FIEXPLASTIOSOSAN on NITGUDEMEDIKUPPER 7055276 250 KIT GU
52. Reduce this value if the carrier hits the upper bracket holding the guide shaft Ifthe fip station is not flipping reliably be sure i is a trave issue rather than anything else by opening the printer cover and moving the flip station up by hand to activate the flip IF it the mechanism itself is defective adjusting the height parameter will have 1f you overdo the height adjustment 1 sending the carrier too high the U shape azimuth just molding may be driven off the end ofits track This causes the carrier to wobble as the U re engages on the way down Zebra PRA Card Printer Service Manual 950006001 Rav A Replacement Procedures Fip Station 510 413 Insertion Height Adjust Insertion height is the intermediate non Ripping elevation which the card is driven for insertion into the laminator To acess the Flip Station Adjustment screen select Sart gt Printers and Fans Right click on he Zehra P630 Zeya P640 primer listing Select Properties gt Device gt Printer gt Flip Station E Adjust the parameter if the ejector arm misses the cand Raise the insertion height by increasing the parameter making it less negative and Laminator infeed roters 6 9 8 Rew A Zebra PSA Printer Service Manual EI Replacement Procedures Fip Staton 5 10 4 14 Rest Position Adjust This procedure adjusts how far d
53. Transport Knob hand erank the Tuck to push the card into one of two areas for easy removal under the hopper or under the fip station ift the carrier for access hen push it down again pepe Zebra PRA Card Printer Service Manual LI Troubleshooting Unusual Noises Unreported Events Unusual events In any ofthe following cases and ober unusual events ry power cycling first then investigate specifie issues Printhead descends before card arrives Contact Zebra Customer Service Printhead stays down after eard has gone away Contact Zebra Customer Service Laminate cuter fails to operate Unusual modia light indications Laminator spot check Note Remeniber the P640 Printer includes upper and lower laminates the Printer has the upper laminator only Make sure the Transfer Toggle 5 in the RUN horizontal position Upper or lower laminate feed problems remove then replace transfer guides discarding laminate patches on transfer rollers Check for laminate where it shoul be Remove boh laminate cassetes If out or nearly load fresh laminate Wind laminate back in to eliminate overhang Relastall cases latching securely Visually cheek path from cast trough feed roller cuter and taster guide Check for mis feeding of laminate due to poor engagement of white paste idler oa cassette with drive roller Mark the upper core 1o check that it rotates no need to mark h
54. a the bottom surface of cards that ave a signature panel or magnetic stipe Important The Upper and Lower Laminate Cassettes the lower one only used on the P640 Printer the upper used on both priaters are loaded differently even though the Cassettes appear virtually the same Note Handle the laminate by the ends of the spools to avoid contaminating the laminate Step 1 Remove the new roll of laminate from is pack Step 2 Carefully following the guidelines in the following figure place the laminate in the Casse Upper Cassette Used on Both P630 and P640 Notched End ot Spool to Lat a Under Spock Laminate Uri Over Spool EW id Norned End of Spee Right Rotor Down Lower Cassette Used on 640 Only Rew A Zebra PE3Q amp PRA Card Printer Service Manual Installation and Setup Setting up the Printer Step 3 Pull out an inch or two of laminate past the lip of the cast Step 4 Close the cassette by firmly pressing the clamshell together You will hear a click and fesl a detent when the halves of the cassette seat together Step 5 Pull out a ite more laminate between the lips of the cassette IF it suddenly stops resisting further pulling a spring detent on the cassette has probably snagged a notch on the end ofthe core This means that the core was installed the wrong way Open the cassette and re install the aia Step 6 Ifthe exposed
55. able on printhead may be disconnected Printhead elements may be scratched or burt Solution Call Service for printhead repair or replacement information Rew A Zebra P840 Card Printer Service Manual s Use a different supply or cards Posible Cause Diny printhead ando print path Solution Clan the printhead Clean the print puth Possible Caus Soli Replace the platen roller Zebra PRA Card Prater Service Manual 950006001 Rev A Troubleshooting Print Quality Problems Faint non uniform image Printhead pressure too low Adjust downward Printhead Position Height Pressure Adjustment on page 135 Printhead not pivoting freely Gaps in Imago at edges and corners Possible de aminaton vear of rubber surface Try cleaning Paten If unsuccessful replace Platen se Plate page 177 Posible non uniformity of card thickness or card surface defects Continuous white or black stripes on card longer dimension Before doing anything else clean the printing edge of the printhead se Section 62 White stripe means blown pixel non functioning heating element One or two blown pixeis in isolation may he acceptable some Others replace printhead see Printhead Assembly on page 192 Buck stripe means non functioning circu on printhead Io replace printhead but first check that i is not the result of an image size change not
56. agnete Magnetic Encoder Magnetic Card Stipa Encoding Card Stripe Encoding This section contains information on the additional operations of the P630 P640 Printer with Magnetic Card Stripe Encoder The magnetic encoder uses high coercivity 150 Standard Encoding Field Track Valid Tack separator Density Characters characters T ORF TF IASC 20 984 B ELS Numeric ASCII A Hem Nui ASCII isa T Except character Including throe characters Start Stop and LRC Note that these hes characters are automatically managed by the magnetic encoder cording 1o he ISO Standard Norms n Nota Refer to the Card Printer Programmer s Manual for complete programming information AAMVA Standard Encoding Tek wem Demy 7 SILLS LS S ELS LII Including three characters Star Stop and LRC Note that these three characters are automatically managed by the magne encoder according 10 the ISO Standard Norms Appendix C Smart Card Contactless Encoder Introduction printer operations remain the same as the standard model This section ec equipped with formation an the additional operations of a P630 or P64 Printer nal Smart Card Contactless Station Media Loading Orientation For contactless smart cards orientation s not con
57. all Printers and Drivers in the Printer Setup Window to remove any previous driver versions reboot and then restart the install process again Intl the new driver files Reboot your computer Zebra PRA Card Printer Service Manual 950006001 Rev A 261 Installation and Setup Instaling the Printer Driver Installing the USB Printer Driver Nota install he Ethemet driver sce Section 26 2 Step 1 Connect the printer power see Section 2 4 and connect the USB port on the rear of the printer 1o the computer s USB port see Section 2 5 Turn the Printer on and let it initialize until the READY LED on the front panel is it Step The Windows Found New Hardware sereen will appear Click Cancel Step 3 Insert the User Documentation Drivers and Training CD into the CD drive of te host computer The Select Language window will open Step 4 From the Select Language window choose the appropriate language for Zebra PE3Q amp PSAL Gard Pater Service Manual Installing the Printer Driver Step 5 The Main Menu will open in the selected language English shown below Security Line Step 6 From the Main Menu click Install Printer Driver The Printer Setup window will open Zebra PRA Gard Prater Service Manual 930006001 Rev A 06 001 Rew Installation and Setup Instaling the Printer Driver Han older or P640 Printer and Driver is inst
58. alled on your computer lick on Uninstall Printers and Drivers 1o remove it Follow the sereen prompts At the end of the uninstall process you will be asked to re boot your computer Before re booting exit from the Driver Installation program and remove the CD Then oot your computer und start over with Step 1 Ifthe computer enters the Found New Hardware Wizard at this tme this wizard rite ohn rea ETE gem ponemm Zebra Gard Pater Service Manual Installation and Setup Installing the Printer Driver Step 9 This will bring up the End User License Agreement To proceed with the installation lick Accept man E Step 10 This will bring up the Add Zebra Printer Port window Select the USB and then click Next gt Emm EC ec Zebra PSAL Card Printer Service Manual 950006001 Rev A Installation and Setup Instaling the Printer Driver Step 1 This brings up the Browse Printers window shown below If your P630 Printer sisted select highligh and click OK your printer not listed make sure the printer is powered on and check the USB cable connections then click Resean When it appears select highligh it and isk OK iE Step 12 This brings up the USB Port window If your printer Printer info area click Browse s
59. ander the printer can additionally have 10 L00T Ethernet port for connection to an Ethernet Network Only one interface at a time will be connected usa Connector Connector Son _ Rew A Zebra PE3Q amp P840 Pater Service Manual Instat tion and Setup Installing the Printer Driver 2 6 Installi g the Printer Driver Each computer that will use the Printer must have the Printer Driver installed A common Printer Driver serves both and Printers To instal the Printer Driver insert the User Documentation Drivers and Training CD included with your printer into the host computer and the InstallShield Wizard will walk you rough the required installation steps The InstallShield Wizard will Automatically install the User Interface when the driver CD is inserted Autorun must be enabled for your CD 1f Autorun is disabled Insert the Driver CD into the CD ROM drive Select Sort Ri Enter the leter that indicates the CD ROM drive followed by a colon a backslash and senp For example setup Start the installation process when the Insta from the Main Men Printer Driver menu item is selected Allow you to instal ether Local printer and driver ora networked printer and driver Detect previous versions af the driver and elean up any unnecessary Windows registry You must select Uninst
60. aning roller 1 printing one cardat the printer time replace the cleaning roller located at the front of 0006 001 Rew A Zebra PE3Q amp Card Pater Service Manual E Posible Cause Troubleshooting Print Quality Problems Cars may not meet specifications Posible Cans Troubleshooting Print Quality Problems Exam Printing shows blurry printed image Posible Cause Ribbon cartridge may not be correctly positioned Solution Chock that the ribbon is properly rolled anto the ribbon cores af the card with no winkles Replace ribbon cartridge making sure it locks in place and print again Posible Cause Ribbon may not be synchronized on the correer colar panel position Solution Open hen close lid to synchronize ribbon Posible Cause Cars may not meet specifications Solution Use a different supply of cards Posible Cause Dust ar embedded contamination inside the printer andar dirty cleaning roller Solution Clean the printhead Replace the cleaning roller m Zebra PRA Card Printer Service Manual 980006001 Rev A Troubleshooting Print Quality Problems Exam No printing onthe cand Posible Cause Ribbon cartridge may not be installed in the printer Solution Check for ribbon arid in the printer Posible Cause Cards not meet specifications Solution Use a different supply or cards Posible Cause C
61. ard Printer and select Properties from the pop up men Step 2 Te Printer Properties window will pen 008 001 Rev A Se General Displays printer name tab selection for Printing Preferences and Print Test Page ie the standard Windows lest page Sharing OS feature whore printer can be shared to other clients an a network feature displays available communication ports Advanced OS feature to select printer availability and spooling options Color Management Allows user to define color profili with color printers Security OS feature where permissions to printers can be defined Device Settings Allows user to make basie printer adjustments and access advanced printer controls Zebra PRA Gard Prater Service Manual Installation and Setup Changing the Printer Driver Options Properties 2 7 1 General Tab The General tab shows the printer model and tists the features of the printer To acess the General tab select Starr gt Printers and Faxes Right click on the Zelva P630 or Zebra printer isting Select Properties gt General 3 Printing Preferences Changes the cand settings se Changing the Printing Preferences on page 77 2 Print Test Page Prints the standard Windows test page Zebra PRA Card Printer Service Manual 980006001 Rev A installation and Setup Changing the Printer Driver Options Properties 2 7 2 S
62. atus Preventive Maintenance Unusual Noises Unreported Events Print Quality Problems Laminate Problems Zebra PSA Cand Printer Service Manual 100 103 103 104 105 106 aor m 120 XI 5 Replacement Procedures 0006 001 Rew A 48 49 Printhead Probleme System Related Issues 4 10 Adjustment Procedures E 52 m 54 55 56 57 59 4 10 1 Ribbon Torque Adjustment 4 10 2 Printhead Adjustments 41021 Printhead Resistance Sating 41022 Printhead Postion HeightPressire Adjustment 41023 Printhead Angie Adjustment 41024 Image Skew Adjustment 4 10 3 Flip Station Adjustments 41031 Fip Station Calibration 41032 Max Height Adjust 41033 Insertion Height Adjust 41034 Rest Position Adjust 41035 Card Postion Adjust 4 10 4 Laminator Adjustments 4104 1 Lateh Adjustment 41042 Pocket Adjustment 41043 Horizontal Offset Adjust 41044 Skew Adjustment Procedure upper cassette 41045 Skew Adjustment Procedure lower cassette 41048 Vertical Offset Adjustment upper cassetto 41047 Vertical Offset Adjustment lower cassette 41048 Cassette Pocket Reset 41049 Laminator Parameters in the Driver 4104 10 Functional Test of the Laminator Sensors Introduction Required Tools Rear Cover amp Cooling Fan Ethemet PCBA Main PCBA 551 Removal 552 Tests and Adjustments 5521 Reload The Configuration information 5522 Adjust Ribbon Torque 5523 Printhead Resistance Doors Main and Card Load Front Panel Swit
63. bon winking and Tad ovar can seriously affect pant qualiy Step 7 Re open the printer cover to inspect the ribbon path for wrinkles and fld Correct if necessary then close the cover If you do not then hear The motor advancing the ribbon press the RIBBON burton E Zebra P840 Card Printer Service Manual 2006 001 Rev A Installation and Setup Setting up the Printer 233 Installing the Cleaning Cassette Before being printed cach surface of the card is cleaned by a soft tacky roller that is itself cleaned periodically by adhesive tape in the Cleaning Casse By default the roller is cleaned every 10 cards The printer driver software allows the card count o be modified By cleaning the roller every 10 cars the Cleaning Cassette contains suficient tape Tor 3 00 Step 1 Open the main cover af the priate Step 2 If present remove the used Cleaning Cassette Step 3 Remove the Cleaning Cassette from its packaging Step 4 Remove the protective foil from the Cleaning Cassette Avoid touching the exposed tacky surface j P A Step 5 Install the Cleaning Cassette on the printer by locating the rectangular pin on the cleaning mechanism in the receptacle on the cassette Push the cassette gently homme ensuring that the internal grooves on the upper spool engage the teeth on the take up drive you will hear a lick when itis fully engaged Note that you may neod to move be take up side of the clea
64. cable ties as required to free the Cooling Fan cable and connector Step 7 Remove the Cooling Fan E Zebra P840 Card Printer Service Manual 950006001 Rev A Replacement Procedures Ethernet PCBA 54 Ethernet PCBA n Note The Ethernet PCB is only installed if you have the Ethernet option Seplo Locale the Ethemet PCBA Step 2 With a TORX TIS driver remove the serew from the bottom right hand comer of the Ethernet PCBA 0006 001 Ree A Zebra PE3Q amp PRA Card Printer Service Manual EI Replacement Procedures Ethemet PCBA Step 3 Pop the throe pins on the Ethernet PCBA of the mounting holes on the Main PCBA Spi Pull the Ethernet PCBA away Gom the Main PCBA to access the Ethernet connection Note that the PCBA is connected tothe Ethernet able Sp Remove the Ethemet PCBA E Zebra PRA Card Printer Service Manual 950006001 Rev A Replacement Procedures Main PCBA 55 Main PCBA Important Save the Printer s Configuration to do that you nce and follow the steps below Run the IDPrin exe program b From the IDPrnt Main Menu select Configure gt Save Config to File This saved configuration information will be used to update your replacement Main PCBA 008 001 Rev Zebra PSADI Card Prater Service Manual Replacement Procedures Main PCBA 5 5 1 Removal Step 1 With the Rear Cover and the Ethemet PCBA removed the Ma
65. cceptable printing Unacceptable printing would be light printing to the point thut the image is almost not being transferred to the anl Once you have unacceptable printing add 60 ta your Printhead Position Adjust This will set your optimal printhead heigl Zebra PE3Q amp PRA Printer Service Manual EI Troubi hooting Adjustment Procedures 4 10 2 3 Printhead Angle Adjustment Seep 1 Step 2 Stepa Stepa Sept Sep Sep aot already done the way remove the Printhead Cover and move ground wire out of Loosen the inside mounting screw just enough 10 allow sliding movement of the printhead bracket Iraide Adast Unlock the angle adjust sore turn it a quarter tum counterclockwise then rook it This will have the effect of rotating the head faction of a degree when you snug the buton head against the printhead frame jnen the inside mounting screw Print another Test Carl If there is a noticeable improvement try another quam turn adjustment then print again he print quality seen to deteriorate rather than improve reum to the previous setting or the 30 preset senting of the head angle serew then rotate it clack ise in quantum increments This adjustment is complete when you are satisfied with the Test Cand image quality Install the Printhead Cover and ground vie The ground wire s secured with the Jonger ofthe
66. ch Assembly Lower Front Panel End Panel Right Side 510 RFID Antenna Assembly 5 11 Platen Zebra PE3Q amp P840 Card Printer Service Manual 122 125 126 128 132 132 133 14 135 137 138 139 140 141 2 142 145 149 150 151 153 m 155 157 159 160 165 m am 173 174 175 176 am 512 Flip Station 5121 Removal 5 122 Replacement 5123 Adjustments 5 10 4 11 Flip Station Calibration 5 10 4 12Max Height Adjust 5 10 4 13insertion Height Adjust 5104 14 Rest Position Adjust 5104 15 Card Position Adjust 5 13 Printhead Assembly 5131 Removal 5132 Replacement 5133 Tests and Adjustments 5 14 Power Supply 5141 Removal 5 14 2 Tests and Adjustments 515 Clean Roller 5151 Removal 5 15 2 Replacement 516 Cleaning Encoder Sensor 517 Laminator Sensor PCBA 5474 Removal 5 17 2 Tests and Adjustments 5 18 Laminator Transfer Rollers 5 19 Ribbon Encoder Sensor 520 Ribbon Payout Spindle 5201 Removal 5 20 2 Replacement 5203 Adjustment 521 Laminator Heater Cartridge and Heated Roller 522 Heater Elements 5221 Removal 5222 Replacement 523 Nip Rollers Laminator 5231 Removal 5232 Adjustment 524 Color Sensor Assembly 525 Contact Smart Card Assembly 526 Eject Arm Zebra PRA Card Prater Service Manual a78 183 187 187 188 189 190 192 192 195 197 200 200 202 203 203 208 210 212 212 216 217 220 222
67. ck on the Zebra or Zelva POO printer isting Select Properties gt Device Settings gt Color Calibration Color rendering in the printer can described in terms of a curve which determines how much power is put into the printhead given shade The Y Mand color curves can be separately modified by the Gain and Offset parameters Click Restore Defaults if you are not satisfied with adjustments made The following procedures can be performed from the Color Cal Nota The values shown above are the default values recommended stings different fom the default values are shown oa he next page tea PE3Q amp PSA Cars Printer Service Manual 950006001 Rev A Installation and Setup Changing the Printer Driver Options Properties Note The values shown on the previous page are the default values recommended settings different from the default values are given in the following descriptions 1 Gain Adjusts steepness of the curve Lighter shades will remain unchanged but darker shades will get darker ar lighter as the number is increased or decreased Recommended sting 95 2 Offset Shifts the color curve up darker and down lighter Recommended sening 95 Preheat Adjusts how much the head is preheated before each print ine every three hundredths of an inch A larger value darkens sharpens the leading edges of colored aris A lower value may result in feathering starting li
68. d Printer Service Manual APPENDIX A Part Numbers Part Numbers This chart shows the coni uations that are available FART NUMBER DESCRIPTION Prater P630 Dual Sided Color Card Printer with Single Lines Laminar Dual Side Color Cand Printer with Single Lines Laminator and Advanced ID Key Security Feature asc Prater P640 Dual Sided Color Card Printer with Dual Lineas Laminar Du Sid Color Cand Printer with Dual Linerless Laminator and Advanced ID Key Security Feature Card Options None Contact Encoder Contact Encoder amp MIFARE contacto Coni Station MIFARE contacts Magnetic Encoder Stripe Up HiCo Barcode Reader None Linear Memory Expansion KES USB Standard Configuration USB and Bula Ethernet 104007 Power Corde 102V AC US and 230V AC Europe U K and Widow Drivers and Documentation Training Windows Driver CD Win 2K and XP an User Documentation amp Training CD Tons Appendix B Magnetic Encoder Media Loading Orientation magnetic stripe cards The magnetic stripe must be flush to the surface of the card Caution ONLY USE cards that comply wth ISO 7810 amp 7811 standards or A io work propery Naver use cards which have magnetic stripes When loading cards with stripe is face up facing the ont es into the card feeder please ensure that the magnete M
69. d Splined Cores Step 6 Load the Ribbon Sep Power Cycle the Printer 005 001 Rev Zebra PRA Cand Printer Service Manual Trouble hooting Adjustment Procedures 4 10 2 41021 Printhead Adjustments Printhead Resistance Setting After changing the Printhead go into the Printer Driver and enter the Printhead resistance Spo Select Start gt Printers and right click the Zehra Cond Printer and select Properties rom the pop up mens Step 2 From the Card Printer Properties sereen select Device Settings gt Printer Adjusment gt Print Station Step 3 nthe Printhend Resistance Ohms field enter the resistance of the replacement Printhead noted in the previous section 3 RES e emm FS mem mcmama Zebra P840 Cand Prater Service Manual 980006001 Rev A Troubleshooting Adjustment Procedures 410 22 Printhead Position Height Pressure Adjustment Sept Step 2 Stepa step 4 Seps Sep 006 001 Rew A Select Start gt Printers and Faves right click the Zebra Cond Printer and select Properties rom the pop up ment From the Card Printer Properties sereen select Device Senings gt Printer Adjusment gt Print Staton ust the Printhead Position Adjust field decrease the value by 10 Print cad your printed card still looks to you repeat Step 3 and Step 4 until you get an una
70. d is now set Tochonge the password click the Use Passwort checkbox Enter the old password into the Password and enter the new password into the New Password and Confirmation fields Click The pussword is now changed To disate the password click the Use Password checkbox Enter the ld password into the Old Password and leave the New Password and Confirmation fields blank Click OK The password is mow disabled Rev A Zebra P840 Printer Service Manual LI Installation and Setup Changing the Printer Driver Options Properties WD Code 1D Code is a security feature that restricts the use of the printer to PC s which have had password entered Once entered the PC will send this password the printer ae printer docs not receive the password it will not priat To enable the password click Set ID Code Leave the Password field blank and eater the mew password into the New Password and Confirmation fields Click OK The password is now set To change the password click Set Enter the old password into the Old Password field and enter the new password into the New Password and Confirmation fields Click The password is now changed To disable the password click Se ID Code Enter the old password ino the Old Password field and leave the New Password and Confirmation fields blank lik OK The password is now d
71. d wil resul Sept Sep Stepa Sep Steps Sept Place the printer power switch in the ON positon the printer Main Cover The Printhead will raise for easy access Remove the Ribbon Clean the Printhead by moving un alobol molsten swab tip side to side across the Printhead elements Only use moderate Frc Allow two to three minutes for the Printhead to dry Reinstall the Ribbon Close the printer Main Cover To reorder swabs reference the Printer Media List Zebra PRA Card Printer Service Manual sa0006 001 Rev A Preventive Maintenance Pisten Care and Cleaning 6 3 Platen Care and Cleaning Important Regular cleaning of the Platen helps maintain performance The Platen plays an important part in the printing process providing a rigid supporting surface for the cand as it passes under the print head Because lamess is important the Platen is surface ground to close tolerances Any irregularities in the surface due to abrasion dings or even seemingly unimportant particles of debris can noticeably degrade printing performance Step 1 Remove the Platen Step 2 Clean is surface with soapy water Step 3 Dry the Platen witha lint free cloth then return it to the truck Step 4 Hold the Platen s left end slightly downhill until it drops ito place taking care not to dislodge the spring 06 001 Rew A Zebra PE3Q amp PSAL Card Prater Service Manual EI Zebra PRA Gar
72. dicator on the printer lighis Step 2 If present remove the usod Supply and Take Up Spools Step 3 Remove the ribbon rom its packaging Remove the tpe that holds the end af the ribbon save this tape i wil be used shortly Step 4 Install the Ribbon on the e supply spindle wili the free end of the ribbon coming om the roll pointing dowa to your ght Note Note that the lange end of the ribbon spool is toward the rear of the printer and ake sure the internal grooves oa the core engage the teeth on the supply spindle Rew A Zebra PE3Q amp P840 Gard Pater Service Manual Installation and Setup Setting up the Printer Step 5 Route the Ribbon as shown in the figure below The Ribbon Supply Spindle is free wheeling pull ribbon oft as needed If the tape removed fom the mew ribbon in Step 3 undamaged us itt attach the end of the ribbon to the Take Up Spool otherwise use other backed tape Important When the end of the ribbon is attached the Take Up Spool slack in the ribbon be taken up by rotating the Ribbon Supply Spool not ry tum the Take Up Spool ravon up erg Ensue he 2 Rebongoes Brough he rabon goss Step 6 Close the printer Main Cover Press the RIBBON button on the Control Panel to synchronize the color ribbon If the MEDIA light fails to go out cheek the Ribbon Sensor A Caution Color ra
73. djustment ste is held in place by two ears on the cassette atch Using a piece of 1 mil laminate gage set the rom car close to but not touching the csset hex head screw arrowed sels font hock position of the atch Adjust the lich position using a 7 6 hex wrench w Zebra Gard Printer Service Manual Troubleshooting Adjustment Procedures 41042 Pocket Adjustment Skew and vertical offset are adjusted by screws in be cassette pocket 71647 hex wrench for Skew blade screwdriver for vertical offset see diagram below p Before adjusting for skew or vertical oe remember that there is significant interaction between the ateh and the adjusting screws in the pocket om 1 we erreur ans LL ssa ltt cassette pocket Important Aways adjust the latch after adjusting citer of the screws in the pocket 9008 001 Rev A Zebra P840 Cand Printer Service Manual Troubleshooting Adjustment Procedures 41043 Horizontal Offset Adjust To access the Laminate Station Adjustment sereen select Sart gt Printers and Faxes Right click onthe Zera Zebra P640 printer isting Select Properties gt Device Stings Printer Adjustment gt Laminate Sarton Accurate positioning of the laminate is important for practical and aesthetic reasons The laminate must cover the entire image as printed at the time of issuance
74. driver remove the inside mounting screw Step 9 Remove the Printhead Assembly E Zebra PRA Card Prater Service Manual sa0006 001 Rev A Replacement Procedures Printhead Assembly 513 2 Replacement Caution Do not auch the balam edge ofthe print head Grease or other contaminant from tha hands can attract particles that may in ime damage the head Step 1 Note the resistance e g R 2597 listed on the replacement Printhead Assembly Also change the value on the printhead cover to reflect the new resistance value Step 2 the angle adjust screw to approximately 30 mils the thickness ofa ca Rev A Zebra P840 Card Pater Service Manual 15 Replacement Procedures Printhead Assembly hat the head wil Ikely be destroyed if power is reapplied while you are in process of Caution Maka sure power disconnected before working the print head nate reconnecting the cable or ifthe plug s not seated propery Step 3 Connect the cable to the replacement printhead making sure it is seated properly Step 4 Ins the back mounting screw Note that the back serew is the shorter of the two mounting screws Sep Inst the front mounting screw Step 6 Ensure the front and back mounting screws are fully tightened Iraide Mounting Access Hole tor Angie Adast Back mounting From Mounting Step 7 Loosely tighten the inside mounting sere St
75. e e Observe the two cores rotate counterclockwise for approximately two minutes T When the motor stops tuming go to the next 9008 001 Rev A Zebra PAO Card Printer Service Manual Replacement Procedures Main PCBA Step3 Run Ribbon Motor Cluteh Burn In Remove the O ring in the font slots on the cores b Remove the Clutch and associated O ring Reinstall an O ring in the ont slots onthe two cores 4 From the IDPrint screen select Canto gt on Tasks gt Run Rian Motor Chach e Observe the two cores rotate counterclockwise E Zebra PRA Card Printer Service Manual Rev A Replacement Procedures Main PCBA 1 Tighten the payout spindle nut the O ring bows then back of slighty Listen to the hun ofthe motor h Adjust the tightness of the payout spindle nut until the motor hum is constant This test takes approximately en minutes When the motor stops tuming go to the next sep Step 4 Adjust Payout Clutch n Note You need to repeat this step you are satisfied with the adjustment a From the IDPrncseren select Como gt Ribbon Tasks gt Adjust Payout 0005 001 Rev Zebra Gard Printer Service Manual Replacement Procedures Main PCBA b Observe the two cores rotate counterclockwise Observe the panel hts Note The pon lights should flash an equal amount of time
76. e adjusting the height parameter will have 1f you overdo the height adjustment 1 sending the carrier too high the U shape azimuth just molding may be driven off the end ofits track This causes the carrier to wobble as the U re engages on the way down Zebra PE3Q amp PRA Card Printer Service Manual 950006001 Rav A Troubleshooting Adjustment Procedures 4 10 3 3 Insertion Height Adjust Insertion height is the intermediate non Ripping elevation to which the card is driven for insertion into the laminator To acess the Flip Station Adjustment screen select Sart gt Printers and Fans Right click on the Zehra or Zehra P640 rite listing Select Properties gt Device Setings gt Printer Aliisinent Flip Sation Adjust E one ae ay Adjust the parameter if the ejector arm misses the card Raise the insertion height by increasing the parameter making it less negative and Laminator infeed roters 6 8 Rew A Zebra Printer Service Manual hooting Adjustment Procedures 41034 Rest Position Adjust This procedure adjusts how far down the carrier drives Ifthe truck fills to pull the card oF the ip station afler the Ripping action chances are 1 The position is wrong see Card Position Adjust oa page 141 2 The carrier is not coming down the way
77. e allows the user to specify which ribbon panels are printed on either side ofthe cand Theory of Operation Card Printing Basics Dye Sublimation Printing Dye Sublimation Printing cach Printhead heating clement is appli voltage at one of a numberof pulse wid wider pulse results in the clement getting hotter which converts more of the dye that pixel locaton to a gas and diffuses into the surface of the ear a wider pulse gives more color at that pixel is repeated for each ofthe dye panels Le Yellow Magenta and Cyan to result in full lor images Ribbon Carer Layer ink Layer Gaseous Dye is Absorbed by Cara Thermal Transfer Pri In Thermal Transfer Printing voltage s either applied or not applied to cach Printhead printing clement If voltage is applied the ink at that location s transferred to the surface of the card Each pixel is either printed e the ink transferred to the card of not there are no intermediate levels Thermal Transfer printing with a resin ribbon is used for printing bar codes since contrast between the light and dark areas is the highest and the edges are the sharpest Layer Ink Layer ka Tansee lo Surface of Cari 0006 001 Rew A Zebra PE3Q amp PRA Card Pater Service Manual Theory of Operation Sensors and Interlock Switches 3 3 Sensors and Interlock Switches types of sensocs and interlock switches but they
78. e arrows point out the eight screw Step 2 Remove the wo Door m Zebra PE3Q amp PAD Cand Printer Service Manual Rev A Replacement Procedures Front Panel Switch Assembly 57 Front Panel Switch Assembly Wath a Philips 1 serewdriver remove the no left side screws and two front Front Panel Switch Assembly in place Note that the i arrows point out the four screws Step 2 If not already disconnected remove the DISPLAY Connector from 19 onthe Main PCBA Spi Remove the Front Panel Switch Assembly 0005 001 Rev Zebra PE3Q amp P840 Card Printer Service Manual m Replacement Procedures Lower Front Panel 5 8 Lower Front Panel n Note The Front Panel Switch Assembly must be removed to access the left side screw Step 1 WIth a Phillips 1 screwdriver remove the ten screws holding the Lower Front Panel in place Note that the orange arrows point the two screws Step 2 Remove the Lower Panel E Zebra P840 Gard Prater Service Manual Replacement Procedures End Panel RightSide 59 Panel Right Step 1 With a Phillips 1 serewdriver remove the wo ouisid serews holding the End Panel in place Note that the orange arrows point out the two screws Step 2 With a Phillips 1 screwdriver remove the three inside screws holding the End Panel in place Note that the orange point out the three Screws S
79. e lower core watch the notches on the laminate core Feed laminate by pressing the LAMINATE button Laminate patch may be wrapped around the heated voller causing card feed problems andlor poor lamination Tura priater OFF remove the laminate patch immediately Donor use melal knife or any to that might damage the heated rollers Check upper and lower laminate sensor readings with and without laminate present 20 if present gt 180 if absent numbers valid only if transfer guides installed Zebra PE3Q amp P840 Card Printer Service Manual 950006001 Rav A Troubleshooting Print Quality Problems 4 6 Print Quality Problems Important The use of Zebra cans and True Colours ribbons vill give the best print section will help you resolve print quality problems The print quality is dependent on several factors The two mom important factors that will increase your print quality are cleanliness and can stock To diagnose and fix print quality problems follow the troubleshooting procedures below Exam Yj Posible Cause Contamination on the card surface Solution Check that cards are stored in a dust free environment Use a different supply of cards Possible Cause Cleaning roller not installed Dust inside the printer andlor dirty cleaning roller Solution Perform a cleaning of the printer Check that the protective cover was removed from the ribbon cartridge cle
80. ector With a TORX TIO driver remove the four screws holding the power supply to the bonom plate Remove the Power Supply Zebra PE3Q amp Gard Printer Service Manual mm Replacement Procedures Power Supply 5 142 Tests and Adjustments Step 1 Mount the replacement Power Supply o bottom plate Step 1 Anach the AC and DC connectors to the Power Suppl Step 2 Plug in and power up the printer A Electric Shock Caution Do nol touch the Power Supply Board or he Main PCBA Step 3 With a Volt Meter inthe VDC mode attach the black probe to a black wire in the 24V DC Power connector and tach the red probe to a red wire in the 24V DC Power connector 24V DC Power Vonage Pot Spi With a small at hlade screwdriver adjust the pot screw until the voltage reads 2400 VDC on the Volt Meter Note that tuning the pot screw clockwise increases he voltage and vice versa Steps Turn the printer of Step 6 Inst the replacement Power supply Zebra PAD Pater Service Manual 950006001 Rev A Replacement Procedures Clean Roller 5 15 Clean Roller 5 15 1 Removal Step 1 Locate the Clean Station Step 2 If not already donc remove the Rear Cover sce Section 53 andthe Main Gee Section 55 Step 3 Remove the Cleaning Tape Cartridge 9008 001 Rev A Zebra PRA Card Pater Service Manual am Replacement Procedures Roller
81. ench remove the ack nut from the Ribbon Payout Spindle Slide the spindle otf he shalt Carefully slide the clutch parts of the spindle Remove the three screws holding the Encoder Wheel to the Spindle and set the Encoder Wheel aside Set the Spindle aside tea PE3Q amp PRA Cand Printer Service Manual Replacement Procedures Ribbon Payout Spindle 5 20 2 Replacement Step 1 Attach the Encoder Wheel to the replacement Spindle Step 1 Instali the euch part in the order indicated Step 2 Slide the spindle with the clutch parts installed onto the spindle shaf Step 3 Loosely tighten the lock nut Step 4 Sle the Ribbon Encoder Sensor up and into its original position Step S With a 7 6 hex driver tighten the two screws that hold the Ribbon Encoder Sensor tothe Frame Step 6 Install he RFID Antenna Cover Note that the cover snaps in place Step 7 Set the true ofthe clutch se Section 5203 Zebra PE3Q amp P840 Card Prater Service Manual 980006001 Rav A Replacement Procedures Ribbon Payout Spindle 5 20 3 Adjustment Ta perform the procedure ensure you have a Chich Bum In Tool Kik 7 16 driver and he IDPrnt test and adjustment program The Clutch Bur I Too Kit PIN 105027 430 consists of Clutch Pulley Step 1 Find Low Ribbon Torque Plugin and power up the printer Ensure the Payout Spindle rotates freely
82. ense Pursuant to Part 1521 ofthe FCC Rules any changes or modifications to this equipment not expressly approved by Zebra may cause harmful interference and void the FCC authorization o operate this equipment FCC Radiation Exposure Statement applicable to 15 247 device only equipment complies with FCC radiation exposure limits set forth fran uncontrolled envionment This equipment should be installed and operated with minimum 20 em between the radiator and your This transmitter must not be collocated or operating in conjunction with any other amenna or ransmiter unless authorized to do so by the FCC Industry Canada Notice This device complies with Industry Canada ICES 003 class requirements quipement est conforme I ICES 003 classe de la Norme Industrielle Canadienne Zebra PE3Q amp PRA Card Printer Service Manual sa0006 001 Rev A General Description Toons 1 6 Icons shout this manual diferent icons highlight important information as follows Note Indicates information that emphasizes or supplements important points ofthe Important Advises you of information that is essential to complete a task or paints out the importance of specific information in the text Provides an example or scenario to demonstrate or clarify a section of text Electrostatic Discharge Caution Warns you of the potential for electrostatic discharge iirc Shock Caution Warns you of a
83. ep 8 Pivot the head assembly forward to bring the angle adjust serew in contact with the head Trame then tighten inside mounting screw Step 9 Make sure the cable is not inhibiting free rotation of the Printhead about its pivot Step 10 Adjust the Printhead sce Seton 5 133 Zebra PRA Card Printer Service Manual Replacement Procedures Printhead Assembly 5 13 3 Tests and Adjustments Sep Enter the Printhead Resistance Select Starr gt Printers and Faves right click the Zebra Card Printer and select Properties from the pop up menu From the Card Printer Properties sereen select Device Seng gt Printer Adjustment gt Print Station Adjust In the Printhead Resistance Ohms field enter the resistance ofthe replacement Printhead need in Step lof the Printhead Replacement section E memes E FS cnr 3 Step 2 Test Card Press the PRINT button on the Control print the image stored in the printer s memory When the printer is powered up the memory is loaded with a checkerboard test utem The following igure shows tood test print b Mf you are satisfied with the overall appearance and uniformity of the image then his procedure has been completed If you feel some improvement could he achieved proceed to Step 3 otherwise Step 4
84. eplacement Procedures Contact Smart Card Assembly b With a 2mm hex driver remove the screw holding the Contact Smart Card PCBA to the shaft e If not already disconnected remove the connector fom J16 on the Main PCBA 4 Remove the Contact Card PCBA and shs a E Zebra PRA Card Printer Service Manual 2006 001 Rev A Replacement Procedures Contact Smart Card Assembly Step 4 Remove the Smart Card Solenoid a Locate the Contact Smart Card Solenoid b With a Phillips 2 serewdriver remove the two stews holding the solenoid in the bracket If not already disconnected remove the connector fom 16 on the Main PCBA 4 Remove the Contact Smart Card Solenoid 06 001 Rev A Zebra PE3Q amp PRA Card Printer Service Manual m Replacement Procedures ject Arm 526 Eject Arm Seplo Locate the Eject Am Step 2 If not already done remove the Rear Cover see Section 5 3 and the Main PCBA see Section 55 Spi Ifthe Contact Start Card Option s installed remove the Contact Smart Card PCBA sce Section 525 Step 4 With a TORX T10 driver remove the screw holding the Color Sensor in place Zebra PE3Q amp PRA Gard Printer Service Manual sa0006 001 Rev A Replacement Procedures Eject Arm Steps Move the Color Sensor out ofthe way Step 6 With a 5 22 ball end hex driver loan the two serewsshown blow This wil allow he backplate to move
85. er Service Manual sa0006 001 Rev A Troubleshooting Adjustment Procedures 9 Ensure that there is very litle end to end play detent in the Take up Spindle adjust the take up spindle at as required Instali the two Grooved Splined Cores 1 Instali the one ofthe O ring in the font slots on the two cores J Select gt Ribbon Tasks gt Find Low Ribbon Toru 1 Observe the two cores rotate counterclockwise for approximately two minutes m When the motor stops tuming go to the next step 9108 001 Rev A Zebra PE3Q amp PSA Card Printer Service Manual E Troubleshooting Adjustment Procedures Step 2 Find High Ribbon Torque Place the Clutch onto the Guide Shaft Note that you may have to move the Printhead down 1o acces the Guide Shaft omg o Place one O ring around the Clutch in the res the rear slol slot and around the lef cone in Instali the other O ring in the front slots on the two cores 4 From the IDPrint screen select Conima gt Riihon Tasks Find High ibbon Tongue t Observe the two cores rotate counterclockwise for approximately two minutes When the motor stops tuming go to the next step Step 3 Run Ribbon Motor Clutch Burn in Zebra PAO Card Printer Service Manual Troubleshooting Adjustment Procedures Remove the O ring in the frant slots on the cores Remove the Clutch and associated O
86. er Solutions 1001 Flynn Road Camarillo CA 93012 8706 USA Phone s 800452 4034 1805 S78 1201 repaireuczehracom wide Support Europe Middle East and Africa Technical Support Zebra Technologies Card Printer Solutions Zebra House Unit 14 The Valley Road High Wycombe Buckinghamshire 6EQ UK Phone 44 0 8702 411527 emaii Europe Middle East and Africa Repair Services Before renaming any equipment to Zebra Technologies Corporation for in warrunty or out of warranty repair contact Repair Services for a Return Materials Authorization RMA number Repack the equipment in the original packing material and mark the RMA number clearly on he outside Ship he equipment right prepaid to the address listed below Zebra Technologies Card Printer Solutions Piman Way Fulwood Preston Lincishie PR29ZD UK Phone 4400 177269309 FAX 44 0 1772603046 com Latin America Technical Support Zebra Technologies Card Printer Solutions 9800 NW 41st Street Suite 220 Doral FL 33178 Phone 1 305 558 3100 extension 2821 omal edisupponiasbra com Latin America Repair Services Please contact Noth America Repair Services Zebra PRA Card Printer Service Manual 950006001 Rev A Worldwide Support Asia Pacific Technical Support and Repair Services Website Before rtuming any equipment to Zebra Technologies Corporatio
87. er minute Laminators beating up bul not yet at operating temperatur Normal hopper colo rhon out cleaning ape cu laminator case out Mag encoding wit ir Numa Serious error conditions including Main Cover open Laminator to hot Card Transport stalled card not seated lg properly mag encoding verification error head lift failure ton jam card jam any location cad missing any location no gap between laminator patches Printhead temperature crror or intemal firmware problem ET Troubleshooting Preventive Maintenance 44 Preventive Maintenance is almost no preventive maintenance to be performed Dust and debris should be vacuumed out every 12 months or more frequently in adverse environments Mast ofthe problems described in the following pages are correctable by the user but please note there is the potential for unexpected results ifthe procedures are not followed carefully If in doubt Zebra Technical Support Before calling for technical support do the following Check all cable connect is including power Chock that the power swich is ON Unless you heur noises suggesting cand jam condition power cycling switch OFF 15 seconds then switch ON Open the Main Cover then look fr obvious problems e a card where it should not be media outages mie fees color ribban
88. ev A Installation and Setup Seting up the Printer 2 3 Setting up the Printer 2 3 1 Attaching the Output Hopper The Output Hopper is positioned on the right side of the printer to receive the printed sands Step 1 Install the Output Hopper by inserting the tab oa the left side of the Output Hopper into the slot on the ight side of the printer Step 2 Ensure the on the Output Hopper locks securely in the slot in the Printer 06 001 Rev A Zebra P840 Gard Pater Service Manual ss Installation and Setup Sating up the Printer 2 3 2 Installing the Ribbon Ribbon Take Up Spool by sliding it onto the Ribbon Taks Lp Spindle and Step 1 Auch sigh back until in clicks into place Important Make sure that the Ribhon Take Up Spool is attached with its woth end toward the rear of the printer The two figures below show the right and wrong ways 1o insert the printing ribbon on either spindle Weng way core nol pushed against ho back ide reslin in a Y border an he ante cards Right way the clo OVER e co s Zebra PRA Gard Printer Service Manual sa0006 001 Rev A Installation and Setup Seting up the Printer 2 3 2 2 Install the Ribbon Note tna on the monit Step 1 Open the printer Main Cove The printhead will raise for easy ribbon loading val printer operation when the ribbon is exhausted a warming message appears andthe MEDIA in
89. ght hen darkening over the following few pixels as the head heats up Recommended sening 90 4 Back Black Panel Density This controls the amount of heat energy applied to any pis required to be black higher value gives darker printing ut can cause undesirable blooming indefinite edges Recommended sening 100 S Black Panel Preheat Temperature offset applied across the entire head specifically for K panel printing A higher value results in beter resin transfer on the leading edge of rapes and text than you would get with a cold start but it may lead to undesirable blooming indefinite edges overall Recommended sening 15 6 Front Black Panel Density This controls the amount of heat energy applied to any pixel required to be Back A higher value gives darker printing but can cause undesirable blooming indefinite edges Recommended sening 100 Contrast Adjust subile color printing control allows the user to shape the printer s lightness curve This means the ability control how the printer resolves or the lighter and darker shades Between contrast settings of 100 the lightness curve transitions ftom linear 1o sinusoidal Linear 0 tends to resultin a low contrast muddy looking image Sinusoidal 100 gives mostly good results but tends to sacrifice the lightest and darkest shades Recommended sening n Important The printer must be power cycled for an
90. h the stripe up and toward the front ofthe printer as shown in the figure below Sept Step 7 Close the Card Feeder Cover 906 001 Rev Zebra PE3Q amp P840 Gard Ptr Service Manual Installation and Setup Connecting Power 24 Connecting Power The AC Power is connected and turned on so tht in the next procedure Rion Installation when the printer s main cover is opened the Print Head will raise automatically Siepl Verify tha the printer s Power Switch i set to OFF O Step2 Select the proper power cori for the local ae power source fom the accessories that are shipped with the printer Caution Ifyou do not have the proper power cord for your local power source ori the power cord appears frayed damaged any way or ithe power cord wil not securely plug into the printers power connection or the source outlet STOP Use of a damaged or incorrect power cord could cause equipment damage resul in electrical ire or Possibly cause Step 3 Flog the power con ito the printer s power connection and a grounded AC power Step 4 the priate on by setting the Power Swich to ON h Zebra PE3Q amp PAD Card Pater Service Manual 950006001 Rav A Installation and Setup Connecting the Printer to your Computer 2 5 Connecting the Printer to your Computer The PO and P6401 Printers have a USB interface as standant As options must be specified at time of
91. haring Tab On the Sharing ah Sharing Property Page you can choose to share the printer over the nctwork and install additional drivers o accommodate different operating systems To acces the Sharing tab select Start gt Printers and Faxes Right click on the Zebra Zebra pite listing Select Properties gt Shaving Share names can also be assigned The Sharing Property Page is only displayed if the computer is set up on nctwork for sharing 0006 001 Rew A Zebra PE3Q amp P840 Card Pater Service Manual E Instat tion and Setup Changing the Printer Driver Options Properties 273 Ports Tab Use the Ports tab to specify the compute ort to which the P630 or P640 is connected This will ave been established at the inital installation of the printer and will not normaly require attention To access the Ports tab select Start gt Printers and Fares Right click on the Zebra P6301 or Zebra printer listing Select Properties gt Poras An exception this is if you wish to use printer pooling the ability to distribute print jobs to multiple printers enable printer pooling check the Enable Printer Pooling box then chock multiple parts Each port should have a single Zebra printer installed on it All the pooled printers must be identical models with the same configuration for example all ith YMC tront K back Now when you print to the main printer that is w
92. have one hing in common they tell he printers control logic what s happening and where enabling i to continue with the process or if a malfunction occurs to light the appropriata indicator light and report specific error condition on the host computer screen The figure below shows the relative locations ofthe sensors that track card and ribbon position and movement Cover Cover Monon Melon iT Cariaga Sg 1 E 7 vee i Sensor Po pe Bn Zebra PE3Q amp PRA Cand Pater Service Manual sa0006 001 Rev A Theory of Operation Card Movement During Printing 34 Card Movement During Printing The printer moves card though a specifie sequence of movements asit encodes and prints the card This example describes dua sided printing with YMCKK ribbon Options 9 Magnete Spe Smar Cara Upper Laminate Gassene cara The card is fed onto the Truck fom the botom of the stack in the Card Input Hoppe Note It is not possible to install both a Barcode Reader and a Magnetic Stripe Encoder n because the two devices occupy overlapping physical spaces and us similar Windows diver functions Ue printer includes an optional Barcode Reader Station tbe can is moved to the Staton and the code s read Ie printer includes an optional Magnetic Stripe Encoder Station the cand is moved 10 the Stat
93. hichever printer you right clicked in Printers and Faxes to get to this sereen this printer will get print jobs until it has buffered as many jobs as it can take Remaining jobs will then spill over 1o other printers until all printers in the pool are busy Soe Appendix F for details Zebra PE3Q amp PRA Cand Pater Service Manual 950006001 Rev A Installation and Setup Changing the Printer Driver Options Properties 2 7 4 Advanced Tab Determines the spooling queuing of priat jobs and how spooled jobs are handled relative to he most recen job Printing Defaults allows the system administrator to establish selected default settings To access the Advanced tab select Sturt gt Printers and Fases Right click on the Zebra Zehra P6401 printer listing Select Properties gt Advanced 0006 001 Rev A Zebra PE3Q amp P840 Gard Pater Service Manual Instat tion and Setup Changing the Printer Driver Options Properties 275 Color Management Tab Color Management settings allow you to associate color profiles on the printer based on the ype of media being used and printer configuration The Add button allows the operator to add additional profiles to the color profile ist To access the Color Management b select Start gt Printers and Faxes Right click on the Zebra PAO Zebra P640 printer isting Select Properties gt Color Management a See 1 Automatie Allows Windows to selec
94. his format MMDD YYYY Log File Contents selections include Time Logs the time a which the card was sent to the printer in the HH MM SS format The 24 hour clock s usod so 13 00 1 00 pa and 0S 00 500 am Date Logs the dale on which the card was sent to the printer in the MMIDDIYYYY forman Printer Serial Number Logs the serial number of the printer which printed the card Statie Text Adds to the recond text in the box at right Enter no mone than 16 characters IP Address Logs the IP address ofthe PC which sent the card to the printer Magnetic Track 1 2 3 Data Logs the dats sent to the printer o be encoded on the cards magnetic stripe EIN Data from Mag Track 2 Logs the Embedded Inventory Number pee encoded on Track 2 Note that EIN Readback must be enabled for this action Application wili send data with Lx TextOut Allows third applications to be logged in much the same way as they would send magnetic data Spoiler Job Number Logs the number whieh the cand priat job was assigned in the Windows print spooler User Name Logs the usemame of the person submitting the card print job Zebra PRA Card Printer Service Manual 950006001 Rav A installation and Setup Changing the Printing Preferences 287 Advanced Tab The Advanced secon allows the user to Disable support foc multiple cas pe job Enable Turbo Mode and Enable Enhanced Barcode Prin
95. hut FCC Clam A ULAEC TN 6950 4 i 33C encoding Stage sta ISSF 20 19 TC Sta SN 159g net Sipping weht 19 5 06 001 Rev A Zebra PAD Printer Service Manual General Description Declarations of Conformity 15 Declarations of Conformity For a formal certificate please contact the Compliance Office at Zebra s Camarillo f ili EUROPE Norway Only This product is also designed for power system with phase to phase voltage 230V Earth grounding is via the polarized power cord Laite on ittis sucjamaadoitus koskettimilla varustettuun pistorasiaan SE Apparaten skall anslutas til jordat ug NO Apparatet tilkoples jordet stikkontakt FCC Regulations Model P630 P6401 has been tested and found to comply with the limits for a Class A digital device pursuant 10 Part 15 of the FCC Rules These limits are designed t provide reasonable protection against harmful interference when the equipment is operated ia a commercial environment This equipment generates uses and can radiate radio frequency energy and if ot installed and operated in accordunee wit the User s Manual may caus harmful interference to radio communications Operation of this equipment in residential area is likely to cause harmful interference in which case the user wil be required to correct the interference at his own exp
96. ic trae work stan an anti static wrist strap must ba worn and properly terminated or other appropriate protection must be used Important This procedure describes replacing the Piahead Assembly The Printhead Assembly is supplied with components in correct alignment with each other These alignments are critical to proper operation of he printer Important Do not deviate fom the procedure given here do not loosen or tighten any screws except those specifically noted in this procedure and do not attempt adjust any part ofthe Printhead Assembly Note The Printhead Assembly can be replaced without removing any other paris of the printer Removal Step 1 Locate the Printhead Assembly Zebra PAD Card Pater Service Manual sa0006 001 Rev A Replacement Procedures Prithead Assembly Step 2 With a S164 hex driver remove the fion mounting screw LONG SHOULDER Back Mounteg DONGTLOOSENor Front Mounting Step 3 With a 5 647 hex driver remove the back mounting serew SHORT SHOULDER Step 4 With 3 32 hex driver remove the two serews holding the Printhead Cover in place Note that the ground wire is tached via the longer ea screw Step 5 Remove the Printhead Covet Step 6 Move the ground wire of the way 0005 001 Rev Zebra PE3Q amp PRA Gard Pater Service Manual E Replacement Procedures Printhead Assembly Step7 Disconnect the Printhead Cable With TORX TIO
97. ide giving a print resolution of 300 dts per inch There are a total of 672 heating elements Since the with of the plastic card is 2 125 inches 4 mm 638 elements provide full width coverage Zebra PE3Q amp Card Pater Service Manual sa0006 001 Rev A Theory of Operation Card Printing Basics 3 22 Printing Technologies and Ribbons There two types of printing technology used in the printer Dye Sublimation and Thermal Transfer The technology to use is determined by the type of dye or ink on the ribbon Monochrome Ribbons havea single colar ink on the length of the ribbon The printer is programmed to use Thermal Transfer printing for monochrome ribbons Multi Panel Ribbons have a repeating sequence of panels different dye RFID Muli PanelRibhoas have an RFID on the supply spool the RFID code identifies the ribbon type and panel count Note that the lack of an REID tug will be interpreted by the printer as being Monochrome Ribbon Printing with a Multi Panel Ribbon requires multiple passes of the card under the Pri Head once per panel For dual sided printing typical situation would be to print a full color grap such as person s picture along with black text andlor ar coding on the front and Black text undo barcoding on the rear In this case a YMCKK Muki Panel Ribbon would be used A YMICKK bon has successive panels as follows Color Technology Function Usage
98. imilar to the buttons om the front of the printer acces the Control sereen select Star gt Printers and Faxes Right click on the Zetra PASO or Zehra P640 primer listing Select Properties gt Device Sening gt Control following procedures can be performed from the Control screen note that 1 2 and 6 perform the same functions as the front panel buttons 1 Advance Ribbon Advances the print ribbon to the next set of panets Use this afier a bon jam or when you load a new ribbon 2 Advance Laminate Advances the Laminate onto the rollers under the flex guides Ifthe laminate chips are already loaded this wil have no effect Run Clean Cycle Activates the clean cycle to clean the sticky roller Print Test Card This will print a test card containing driver configuration information Clear Error Clears some error conditions within the printer to allow printing to resume Papp Print Contra Reprint Last Card and Copies Activate a reprint of a card You can also set he number of copies to print Zero Buffer Count Receive Iran error oceurrod there may be a card image stack in the receive buffer This clears the receive buffer if you do not want to print iL Print Ifan eror occurred there may be a card image stuck in the print buffer This eats the print buffer if you do not want to print it 3 Advanced Utilities See Advanced Uti is oa page 73 Zebra PRA Gard Printer Service Man
99. in PCBA is visible and accessibile fully disconnect the various wires and connectors that anach to the Main PCBA Stepa With a TORX TIS drive place Note that the orange arrows point out the cleven PCBA mounting seres E Zebra PRA Card Pater Service Manual 980006001 Rav A Replacement Procedures Main PCBA Step 4 With the Main PCBA removed the view from the hack of the printer looks like the following picture Step Set the Main PCBA aside Step 6 The following figure and table show the connections to the Main PCBA 06 001 Rew A Zebra PE3Q amp Card Printer Service Manual E Replacement Procedures Main PCBA Main PCBA Connections Zebra PE3Q amp PRA Card Printer Service Manual 980006001 Rev A Replacement Procedures Main PCBA Main PCBA Connections Tonner FERD Cae T VIN TAN T FAN FAN En CLEAN SET CLEAN MOTOR TE Tae Contr Saar CT ORT T TAM TRANSPORT TAM CARD TRANSFER T TOP TAM XFER TOPTAN HEAD LIFT MIK HEAD XER RIGO ME RENT TRE MAG HEAD Magnetic Encider ria T PRINTER PRINT HERT TART Tos Sa CATO CARRIRGE DENTE CARD TRANS CARRIAGE NTI TBUT TID Ray Opin DISPLAY CONTROL PAD USE TART rcd Kester TRG les Conse OT
100. ing in the font slots on the cores b Remove the Clutch and associated O ring Reinstall an O ring in the ont slots onthe two cores 4 From the IDPrint sereen select Canto gt Ro Tasks gt Run Rian Motor Chach e Observe the two cores rotate counterclockwise 2m Zebra PRA Gard Pater Service Manual sa0006 001 Rev A Replacement Procedures Ribbon Payout Spindle 1 Tighten the payout spindle nut unti the O ring bows then back off slighty Listen to the hun ofthe motor h Adjust the tightness of the payout spindle nut until the motor hum is constant This test takes approximately en minutes When the motor stops tuming go to the next sep Step 4 Adjust Payout Clutch n Note You need to repeat this step you are satisfied with the adjustment a From the IDPrncseren select Como gt Ribbon Tasks gt Adjust Payout 9008 001 Rev A Zebra Printer Service Manual Replacement Procedures Ribbon Payout Spindle b Observe the two cores rotate counterclockwise Observe the panel hts Note The pane lights should flash an equal amount of time between Green Ready and Red Alarm the optimum condition would be Yellow Media on all the time 4 Adjust the payout spindle nut as required if Red tighten if Green loose e When the motar stops tuning and you are satisfied with the adjustment go t
101. ion and he stripe is encoded The card is then backed up and run through the Magnetic Encoder again on this pass Be card is read to verify that the magnete stripe was properly encoded encoding fils the card is moved directly to the Card Exit and into the Card Output Hopper This is done to avoid wasting time und ribbon panels on defective can Thecard is moved along with it s back side in contact with the exposed sticky area of the Clean Roller this cleans dust or dirt particles fom the upper card surface The card is moved to just before the Printhead 0006 001 Ree A Zebra amp P840 Printer Service Manual o Theory of Operation Card Movement During Printing The last time the Main Cover was opened and closed ribbon was automatica synchronized thereby bringing the leading of the Black K ribbon panel under the Printhead The leading edge of the card moved under the Printhead be Printhead is lowered and printing begins After this Black pass completed the Printhead is ase and the card moved to the Card Flipper The card is tumed over and is moved hack through the priater so the other ofthe can be cleaned Ihe printer includes an optional Smart Card Encoder Station the ans moved the Sion and encoded As the cand is encoded it is checked to verify that it was encoded properly encoding fils the card is moved past the Printhead directly to the Cand Exit a
102. ipped use the original printer packing and shipping material for shipping the primer only It is important to use the original packing and shipping material to prevent damage to the printer Important Do not ship the printer wih the Hopper Weight the Ribbon or the Cards in prn Scams epi ner cn pina sina eon iat M the original material is lost or damaged a replacement Shipping Kit canbe ordered from Zebra please refer 10 the Media List oa the Windows Drivers and User Documentation CD supplied with this printer Security Line Support locutions listed in Appendix H 0006 001 Rev A Zebra PE3Q amp Pater Service Manual Zebra PRA Printer Service Manual 3 Theory of Operation 31 Introduction This section includes five major topics Cand Printing Basies Sensors and Interlock Switches 96 Card Movement During Printing Block Diagram CPU PCBA Connections 100 Theory of Operation Cord Printing Basics 3 2 Card Printing Basics 324 This section provides an overview descriptio of how images are printed on plastic cards Printhead The Printhead Assembly mounts in the Printhead Bracket which holds the Printhead at a right angle to the card s long surface The Printhead is a thin film device that consists of a row of individually addressable heating ements Each heating element is approximately 0 0033 inch 0 08 mm w
103. isabled 3 Disable Printer s Print Button Enable or disable the front pane Print button to prevent cant reprinting 40 Disable Printer s Other Buttons Enable or disable the front panel Ribbon and Laminate butions Status Polling Frequency n Note For EIN to work correctly the None option neds to be selected Normal This isthe default for directly connected printers Reduced This is the default for a printer connects via Ethemet This cli problems cased by timeout because the driver polls the printer less often None Selecting this option stops the driver from checking the printer foreros The driver just sends print jobs and assume everything is well with the printer Ifthe printer stops printing the reason must determined via the front panel Condition lights 42 Number of Times to Retry This number indicates the number f times the driver should attempt to communicate with the printer ifi gets a failure The default is 3 Zebra PRA Card Prater Service Manual 950006001 Rev A Installation and Setup Changing the Printing Preferences 2 8 Changing the Printing Preferences To access the Printing Preferences serens select Sart gt Printers and Fase then right lick Zebra Zehra P64 printer and select Printing Preferences an EN ses Card Setup Tab LI O YMC Color Printing Tab o Kick Pane Tab EI Image Adjustment Tab 2 Magnetic Encoding Tab 17 s
104. it corectly under the print head Ifyou hold the RIBBON button down and power up the printer toggles on fF the Ribbon Synchronization feature when the doors closed In standard applications the ribbon type is YMCK and the back of the card is printed sch cases pressing the RIBBON button will advance the color ribbon to bring the leading edge of the next black panel under the print head LAMINATE button n Note The LAMINATE button can be disabled via the printer driver see Advances Utilities on pase 75 Forth P640 Printer this applies to the Upper and Lower Laminator the P630 Printer has only the Upper Laminator 1 either or both of the laminate transfer rollers is not loaded with laminate patch then pressing the LAMINATE bunion will correct the condition provided the cassette is not out of laminate and ifthe cassette latch is closed locked both transfer rollers are already loaded the LAMINATE burton has no effect I you bold the LAMINATE button down and power up the printer it toggles ont the Ribbon Synchronization feature when the printer is powered up A standard use of the LAMINATE burton is in reloading a transfer roller after removing the first panch of laminate following installation of a fresh roll 06 001 Rew A Zebra PESO A P840 Cand Printer Service Manual General Description Controis and Indicators Control Panel Indicators Depending on the condition they are reporti
105. ithms to work properly Important 1f ou replace the Printhead change this value to matel the resistance of the This number is located on sticker on the printhead cover and on the label applied to cach printhead The printhead resistance is also written onthe inspection report Shipped with each printer Printhead Position Adjust This setting controls printhead pressure also see Printhead Position Height Pressure Adjustment on page 133 Rev A Zebra P840 Card Pater Service Manual Installation and Setup Changing the Printer Driver Options Properties Laminate Station Adjustment To acess the Laminate Station Adjustment select Sart gt Printers und Faxes Right lick on the Zebra Zebra PGA printer isting Select Properties gt Device Stings Printer Adjustment gt Laminate Sion Adjust The standard laminate patch length is 325 82 55mm Accurate positioning of the laminate is important for practical and aesthetic reasons The laminate must cover the entire image at the time of issuance thus protecting critical data with a tamperdetemont fi is no magnetic stripe on the underside full width laminate should be used When using smart card or registered laminates and the length is too Jong or too short use the Length Adjust mils option to make length adjustments as required CE werten TT E
106. laminate cleaning cast Note In onder to see what is happening in the printer during test eg check Flip Station operation while the Feder and Main Covers are open override the interlocks by inserting into the corresponding interlock slots 106 Zebra PSA Pater Service Manual Troubleshooting Unusual NoiseslUnreported Events 4 5 Unusual Noises Unreported Events Color ribbon runs for longer than 2 or 3 seconds when cover is closed MEDIA light stays on Color ribbon notin Color Sensor Both ribbon cores not fully engaged on Spindles Ribbon not secured to Take up Core ALARM light stays ON after error condition is cleared n Nota There is a delay after closing the cover before the ALARM light goes Some alarms require reeyeling power in onder to clear Main Cover interlock switch may not have actuated when cover closed Alarm condition not cormectod color panels stick to card Printhead running too bot Can happen after head replacement if head resistance incorrectly entered through printer driver see Printhead Adjustments on page 132 Color gain and offset too high Contact Zebra Customer Service Check ribbon take up and supply torques see Ribbon Torque Adjustment on page 126 Rattling noise every 10 cards Cleaning cassette not firmly engaged Cleaning cassete broken or cassette halves separated Cleaning casse
107. laneous T Shipping Carton m Spares List Assemblies Description RTRSY FOF STATION COMPLETE RITASSY CARD EJECT ARM 062276 286 RITASSY CLEAN STATION 1059276339 KT POWER SUPPLVERAT ET Zebra PRA Card Pater Service Manual Rev A Spares List 1059276498 TORE KIICTTRWVZRUN CE 1059276 233__ 10592763295 KTOR PRINTHEAD Spares List Description NUSEGGH RIT WEIGHT HOPPER T0527 A0 REPLACEMENT KEY 062276 446 KITASSY DONGLE 1050276 27 RIT MANUAL DRIVE Zebra Pater Service Manual 2006 001 Rev A Enclosures Spares List Description 10592762273 RIT SWITCH DOOR OPEN BITE RIT SWITCH HOPPER SEEN 70592763 TIT FRONT PANEL SWITCHILEDICEL KERE KIT HOPPER OUTPUT Spares List Description 105927294 KIT PANEL END ENCLOSURE BITE RT COVER REAR ENCLOSURE 1050276 227 BOORLOAD CARD 1059276329 _ RITASSY DOOR MAIN ACCESS Zebra P840 Card Pater Service Manual Spares List Description TOBE KITPANELFRONTIOWER WIFANCOOUN
108. ler shaft Do not remove the spring Replacement Procedures Roller Step 13 From the front of the printer slide the Clean Roller out of the Frame Step 14 Remove the Clean Roller Zebra P840 Card Printer Service Manual Replacement Procedures Clean Roller 5152 Replacement Step 1 Install the rear torsion spring encoder whee and sensor first hen install replacement Clean Roller Step 2 The Pivot Screw left side screw must not be too tigh of 1 2 tum tighen then back Step 3 After installing the replacement Clean Roller run a clean cycle Step 4 Ifthe cleaning tape seizes adjust the Pivot Screw 1 2 turn counterclockwise Repeat until the clean cycle becomes operational see figure above 908 001 Rev A Zebra PE3Q amp PRA Card Printer Service Manual 200 Replacement Procedures Cleaning Encoder Sensor 5 16 Cleaning Encoder Sensor Step 1 If not already donc remove the Rear Cover se Section 5 3 and the Main Gee Section 55 Step 2 From the rear of the printer locate the Cleaning Encoder Sensor Step 3 With a Phillips 0 serewdriver remove the two serews holding the Cleaning Encoder Sensor to the Frame Step Cut any associated cable es of Cleaning Encoder Sensor Step S 1f not already disconnected remove the CLEAN ENCODER Connectar from 129 on the Main PCBA Zebra PRA Card Printe
109. lt in the adjustments made being opposite of the desired result Horizontal X Offset pixels This is the number of pixels to shift the image to align iron the media Increasing these values move the image left while decreasing them moves the image right This parameter be used to center the image onthe card orto align it with an edge Vertical Y Offset pixels This is the number of pixels to shift the image to align it on the media Increasing these values moves the image down while decreasing them moves the image up This parameter can be to center the image on the ead orto align it with an edge 2 Ribbon Changing Ribbon values is not recommended Ribbon Position mm The sensor position adjust determines the distance from the printhead dot line to the center of the gap interrupt sensor used to sense the ribbon syne mark or resin black pane The sensor adjustment cn be used to control the from the start of a color panel to where the printing begins To increase this make the sensor adjustment larger The default value 32 Ribbon Torque Adjust 6 This seting controls the toque of the ribbon take up motor This value should always be set 10 100 Zebra PSA Card Printer Service Manual 930006001 Rav A Installation and Setup Changing the Printer Driver Options Properties 3 Black Panel Changing Black Panel values is not recommended Black Panel Speed mm These para
110. ments is text which is sent explicitly as such to the printer driver Lines and pixels are ines and dots pixels sent as such to the printer driver fils are color filled geometrie shapes Monochrome bitmaps are l bir bitmaps every pixel itor black o white Color bitmaps black portions aay are full color ur compresed pixel maps The above elements may not always be sent to the driver as expected For example a bar code may be sent as text a series of area ills monochrome bitmap Results will vary by application used create the card design Any ofthe above five elements may be selected far black extraction when the ribbon is set up to apply YMC color and K black to the same surface af the cand In this condition he driver generates an extracted K image by looking for tne Mack features in the selected element types that is instances where three YMC values are at the maximum ful intensity Each such true black instance generates a corresponding cluster of black pixels in the extracted image which will be printed with the K black panel either on top of the YMC image or replacing it entirely your choice 006 001 Rev A Zebra PE3Q amp PRA Card Printer Service Manual Installation and Setup Changing the Printing Preferences 284 Image Adjustment Tab From the Image Adjustment sereen the operator can adjust the brightness and contrast of the images printed on the cards To acce
111. meters determine the speed of the receptor movement during printing for black printing and overlay printing This value should aways be sett Black Panel Compensation If line of black dts is printed along the cand motion axis the beating clement pixel in question does nat cool down completely between adjacent dots Without compensation he steadily increasing residual heat would cause the printed dot to increase noticeably in size bloom below left Properly compensated the dot size is reasonably constant below righi Card direction gt Card direction 4 Overlay Panel Changing Overlay Panel values is not recommended Note The term Overlay Panel refers to the second Black Panel ar the first Uv Panel Overlay Panel Speed mm s These parameters determine the speed of the receptor movement during printing for black printing and overlay printing This value should always beset to Overlay Panel Compensation 4 Ifa line or black dots is printed along the cand motion axis the heating element pixel in question does not cool down completely betwee adjacent dots Without compensation he steadily increasing residual heat would cause the printed dot to increase noticeably ia size Bloom above left Properly compensated the dot size is reasonably constant above right 5 Printhead Printhead Resistance Ohms replacement printhead The numbers must be the same for the algor
112. n for in warranty or out of warranty repair contact Repair Services for a Return Materials Authorization RMA number Repack the equipment in the original packing material and mark the RMA number clearly on he outside Ship the equipment eight prepaid to the address listed blow Zebra Technologies Printer Solutions 120 Robinson Road 500 01 Parakon Building Singapore 068913 Phone 65 email esohyezebra com 006 001 Rew A Zebra PRA Gard Printer Service Manual sor Zebra PRA Gard Printer Service Manual
113. nd into the Card Output Hopper As for a failed Magnetic Stripe Encoding this is done to avoid wasting time and ribbon panels on defective card The Tending edge of the card moved under the Printhead and the Printhead is lowered Printing continues with the Yellow Y ribbon panel the Magenta M panel the Cyan C panel and the Black K panel When printing is completed the card is moved to the Card Flipper raised and pushed by the Eject Arm into the Laminator As the card passes through the Laminator the upper and lower Transfer Rollers apply patch of laminating film othe card At the sume time laminating film ix measured ct and rolled onto the Transfer Rollers for the next card The cand with the panch of laminating film then passes between a pair of heated rollers Which seals the laminating film to the card The cand is moved from the Laminator to the Card Exit where it falls into the Cand Output Hopper Zebra PE3Q amp PSA Printer Service Manual 950006001 Rav A Theory of Operation lock Diagram 3 5 Block Diagram Most af the citer in the printer is on the CPU PCBA Since the CPU PCBA is nota serviceable circuit analysis to the component level is pointless Below block diagram ofthe functional circuits ofthe printer the block diagram also shows how signals are passed to and from the CPU PCBA to the rest of the printer PRIOd CPU PCBA a
114. ndow click on the appropriate language fr your system Zebra PSA Cand Printer Service Manual Installation and Setup Instaling the Printer Driver Step 4 The Main Menu will open in the selected language English shown below Security Line Step amp From the Main Menu click Install Printer Driver The Printer Setup window will open Click Install an Ethernet Printer and Driver sti Pain i ede aed enn Pp FF ohn pene Rev Zebra PE3Q amp PRA Card Pater Service Manual Installation and Setup Installing the Printer Driver Step 6 This will bring up the End User License Agreement To proceed with the installation lick Accept rentem You man ee Step 7 This brings up the Configure Ethernet Port screen Click the Browse bution r Zebra P840 Pater Service Manual 930006001 Rev A Installation and Setup Instaling the Printer Driver Step 8 Any Zebra printers will be located Select highlight the desired printer for this procedure is a P640 but the steps would be the same for a P630 and click the OK bution Note Ifthe Printer is not found check make sure the Printer is powered on and the Ethernet connector is engaged an EE rT br ha h Cs am a Step 9 The Configure Ethernet Por sereen will reappear but now the information for the 640 printer selected in
115. ne pool which is all of them Zebra PE3Q amp Gard Printer Service Manual 950006001 Rev A Printer Pooling Using the Printer Pool Using the Printer Pool Send print jobs o the poo not to an Individual printer When the first printer has taken as many jobs as it can handle that being two jobs one o printed immediately the other waiting the following jobs spill over to the second printer fd hen 1o the third Note that if you are only printing two jobs they would both go to the first printer Pooling isa spillover methodology I does not balance printer usage Once the pool has been set up maintenance and configuration changes should be done through he menus for each individual printer e Zebra 1 nor through the pool which can produce undesirable results Important The effect of any maintenance or changes can and should be tested by sending print jobs separately to cach printer not to the pool 06 001 Rew A Zebra PE3Q amp PSAL Card Prater Service Manual am Zebra P840 Gard Pater Service Manual APPENDIX G Spares List Introduction Spare Parts Kits available for amp PAO Card sure to check the Partner Zone on www zebeacand com for the The Spares List is arranged in the following categories Assemblies Enclosures Transport Cleaning Station Printing Station Flip Station Laminator Miscel
116. ng the three indicator lights READY MEDIA and ALARM can be in one of three states On steady or Flashing Note The READY indicator is bicolore Its two color channels green and yellow function independently READY indicator Ready o ri Flashing Printer busy Steady Laminators mode Flashing Laminatn s not at operating temperature MEDIA indicator O Normal steady Any media outage Flashing Magnetic encoding failure ALARM Indicator o Nonna Steady Error condition requiring intervention Flashing Printhead temperature er ar major intemal consol problem requiring power eyeing of c printer OFF pause then ON Zebra PRA Card Pater Service Manual sa0006 001 Rev A 14 Specifications Prot ters cde epi Windows deer See eure een General Description Specifications P630i P640i Sige pnts with ip sation ra bck ining Dye bina or YMC cn nd eal mo for ead Uv pee page ac PS2 pale X600 pixel Ove Cope Hinek ISO and AAMVA copie aca he lle Rll redd art y reser ape selectable ed erase 20 carde eae ear fo ree Wate dein wih in caters 1 0425 mm hick Prt bon dene Laminate scs Realy to print VS 107100 Mp le eon Key otim D Code and printere PC paar
117. ning tape assembly to allow for full engagement 06 001 Rev A Zebra PE3Q amp P840 Card Pater Service Manual E Installation and Setup Setting up the Printer 2 3 4 Loading Laminate Note In this description of loading laminate references 1o the lower Laminate Cassette apply only to the P640 Printer The P6AD Primer can apply laminate to both surfaces of the the P630 Printer only 1o the upper surface The Laminate laminating film is loaded into cassettes to protect i from dirt or other Soe the figure below The Upper Laminate Cassete used on both the P630 and P640 Printers has a label with the word UPPER and another label of a dot The Lower Laminate Cassete used only on the Printer has a labe with the word LOWER and another label of yellow do Upper Lower Laminate Laminate pun Cassete Peso and Pea oniy Psa Zebra PRA Card Pater Service Manual 950006001 Rav A installation and Setup Setting up the Printer 2341 Removing the Laminate Cassette s Step 1 The Laminate Casset s Upper only for the P630 Printer Upper and Lower fr the P64 are held in position by latch plates The Upper Cassette is froed by turning its Latch Plate counter clockwise 1o a full vertical position the Lower Cassette nly present on the P640 Printer is freed by tuming is Latch Plate clockwise Then pull the cassette straight out fom its holder Upper
118. not listed in the Leave the two timeout values alone Click OK Step 13 This will bring up the Printer Installation window Note the value shown on the first Tine ATLUSBOO fo the sereen shown here then click OK Rev Zebra PSA Cand Pater Service Manual 3 Installation and Setup Installing the Printer Driver Step 14 This opens the Ada Printer Wizard welcome window Click Next gt welcome to the Add Printer Step 15 This brings up the Add Printer Wizard Local Network Printer window standard USB installation select Local Printer attached to this computer and check the box to detect a Plug and Play printer Then click Next gt Installation and Setup Instaling the Printer Driver Step 16 This brings up the Found New Hardware Wizard welcome window In general select Yes his time only and then click Next gt Welcome to tho Found Now Trovare wead Step 17 The next window helps install the software driver Select Install he software automatically Recommended and ten click Next gt ped Lue pue Dum Installation and Setup Installing the Printer Driver Step 18 The Wizard will search for the Printer The sereen that appears while searching appears on the next page Step 19 When the Wizard finds the Printer it may display a window referring to compatibility as shown below If so click Continue Anyws
119. ns on the cassette Latch Using a piece of 1 mil laminate asa feeler gauge set Ihe fon car close to but not touching the cassette A hex head screw arrowed sels font hock position of the Latch Adjust the latch position using a 7 64 hex wrench E 006 001 Rew Zebra PE3Q amp PRA Cand Printer Service Manual a Replacement Procedures Nip Rollers Laminator Cassette Pocket Reset Skew is caused by misalignment of the laminate cassette relative 1o the left right axis ofthe printer looking down on the printer fom above The skew adjust crew causes the pocket 10 mote relative 10 the left right axis The vertical adjust serew controls the depth of the assets in the pocket Note that the frant car of the latch must be in close contact withthe cawene without changing position Reset the cassette pocket like this i he pocket has been replaced orif the laminate is grossly misaligned Step 1 Back off the vertical offset adjust seen skew adjust screw and cassette latch adjust Step 2 Using three CR 80 cars total thickness 00907 23 mam asa fecler gauge in the between pocket and back plate adjust for skew and vertical oft until the qup is an even 0090 across the width of the pocket Step 3 With a cassem in the pocket adjust the latch screw so that the lath s front ear is snug to the cassene but does not shift it out of position The pocket is now in its default position
120. nter Service Manual sa0006 001 Rev A Troubleshooting Adjustment Procedures 410 44 Skew Adjustment Procedure upper cassette corrected as described in the previous section n Note The following procedure assumes that the horizontal offset has been software Seb oft casts ay ae a poston dut aol cago cache meng ec Sel Pitan lamina et cari sal wey stg he dco se Dont nary shure fuera sagem a onchange Ai lice pce era ot amen pres Supi and rene the upper ast fom i pocket Rott teint cae ttn tng heater ig e pears ae VERY IMPORTANTI seca kao he wpe ute car ni E ure yu dnd dc ph ob dirti he stewie Uning a tsp pea mak the sewed rtf Sten 6 Ung 764 bex wench mth sce nu at ede teton One in o eec d deve lanae yeni cua 0 0 us my meted Feri ara 7 ig CARD FRONTS CARD A TEED Reinstall he caste Ser so remove and disear the ait pateh on the tr tl sete pn cove te ps e LAMINATE bon to ous eh ton Sep zat cada stew Step Rape Se deo Sep 10 unt mi sat Rew A Zebra PE3Q amp P840 Card Printer Service Manual us Troubleshooting Adjustment Procedures 41045 Skew Adjustment Procedure lower cassette Once the front surface ske
121. o the next step Step5 Remove the O ring and the two Grooved Splina Cores Step 6 Loud the Ribbon Sep Power Cycle the Printer 2m Zebra PRA Card Pater Service Manual 2006 001 Rev A Replacement Procedures Laminator Heater Cartridge and Heated Roler 5 21 Laminator Heater Cartridge and Heated Roller Hot Surface Wal 10 20 minutes for the printer 1o coal down Step 1 Locate the Heated Rollers Sep 908 001 Rev Zebra PRA Card Pater Service Manual Replacement Procedures Laminator Heater Cartridge and Heated Roller Step 3 Remove the Laminator Heater Cari Step 4 With a 1 16 hex driver the set screws that hold the two brass gears to their spective shafts Note that cach pear has wo set screws Step S Remove the two bras ET Zebra P840 Gard Printer Service Manual sa0006 001 Rev A Replacement Procedures Laminator Heater Cartridge and Heated Roller With a TORX TIO driver remove the three serews that hold the front bracket in place Step7 Remove the front bracket Step With a TORX TIS driver remove the four screws that hold the rear bracket in place Rev Zebra PE3Q amp PSA Card Printer Service Manual m Replacement Procedures Laminator Hester Cartridge and Heated Roller Sep With small screwdriver remove the two gt Step 10 Remove the rear racket Note that
122. ol Tuo Power Coris Q 2 Zebra P840 Printer Service Manual Rev A Installation and Setup Unpacking the Printer Card Weight Documentation amp Driver CD USB Interface Cable Step 4 Remove the foam block fom the top of the shipping carton Step 5 Lif the printer from the shipping carton A Caution The printer weighs approximately 159 kg 35 bs Step 6 Remove the protective plastic bag from the printer Important Save all the packing material and the shipping carton n case the printer needs to be moved or shipped If the original material is lost or damaged replacement Shipping Kit san be ordered from Zebra Flat surface at east 699 mm 27 5 in 246 9 7 in that can support the weight of the printer additional space preferred Vertical clearance at least 450 mm 17 7 in Clearance between the back panel and any wall at least 100 mm 3 9 in There should be easy access to all sides of the printer Temperature within the range of 10 o 35C 50 to 95 F Relative Humidity 20 80 non condensing AC power accessible 0006 001 Rev A Zebra PRA Cand Pater Service Manual EI Installation and Setup Unpacking Printer Step amp Open the printer Main Cove Locate and remove blue tpe that secures the flip ston in position Zebra PE3Q amp PAD Gard Printer Service Manual 950006001 R
123. ontact Station Laminating Contact Smart Cards Laminating Contact Smart Cards The Laminating patch on the top surface of a smart card has rectangular aperture to expose the card s electrical contacts in all other respects the laminating proces for smart cards is he same as for ordinary eats The special laminate for the top cassette is punched with a repeated pattem Loading procedure for smart card laminate is exactly the same as for standard laminate as shown in Chapter 2 The smaller hole is an index marker that tells the printer where to cut the laminate exactly spliting the index hole the printer driver allows adjustment ofthe eut location After loading he Smart Cand laminate in the upper cassette trm the laminate along the cut line as shown Note When using smart card or registered laminates the laminate length value in the driver need to be adjusted see Laminate Station Adjustment on page 64 m amp PRA Card Printer Manual 980006001 Rev A Appendix E Printer Security ID Key The optional ID Key isa physical security key that is programmed for each specific or P640 rez eis tended prevent unauthorized use of hat printer The IDiKey has a non alterable memory containing unique 64 bit serial number tht is compared prior to cach print job with a serial umber stored in the printer s Non Volatile Random Access Memory NVRAM Ifthe serial n
124. orizontal X decreasing vert Do Imago loss at top of card on either edge Almost cerni due to ribbon fld aver Could be head non pivoting problem Contact Zebra Customer Service Could be image size problem resize image Zebra PRA Card Printer Service Manual 930006001 Rav A Troubleshooting Printhead Problems Random colored patterns on image Ribbon wrinkling Reduce take up torque sce Ribbon Tongue Adjustment on page 126 Check printhead pressure eight see Printhead Position Height Pressure Adjustment on page 133 Too much heat being applied YMC panels Try reducing gain offe and preheat seporatly far cach color in the driver Select Start gt Printers and Faxes Right click on the Zebra P630 or Zehra printer listing Select Properties gt Device Color Calivaton namey po ore fre Printhead running too hot happen after head replacement ifthe head resistance is incorrectly entered via the printer driver see Priathead Adjustments on page 132 Random colored lines Probably resulting from excessive take up torque see Ribbon Tongue Adjustment on page 126 Seratches dings on long edges of card Look for a naow band of abrasion up to about 0 1 2 5 mmn in from either or both ofthe ong edges Contact Zebra Customer Service Coni hopper base set too low Contact Zebra Customer Service
125. ough coating that is extremely heat resistant while protecting against rust and oxidation at high temperatures a Loosen the thumb sew that holds the Laminator Hester Cartridge ia place b Remove the Laminator Hester Cartridge E Zebra PRA Cars Pater Service Manual sa0006 001 Rev A Replacement Procedures Hester Elements Turn the Laminator Henter Cartridge around and brush Triflunox 72 food surfaces and inside both pears all around 4 Reinstall the Laminator Heater Cartridge into the Laminator Ensure that the sears mesh property Zebra PSA Gard Printer Service Manual Replacement Procedures Heater Elements Step 2 Slide the Heater Elements into place Ensure the top ad bottom heaters in their spective positions Note In the next step use the replacement serews that came in the Spare Parts Kit they havea dry to the ouch im applied to the threads which lock and seal the screws in place Spi With a TORX TIO driver secure the three screws that hold each heater to the Frame The screws must not be too tight tighten thea backoff 1 2 turn Step 4 Connect the Hester Elements to the Main PCBA Sep Turn the printer around and wipe away any Tiunox 722 that may have seeped out of the front of the Laminator Heater Cartridge Zebra Card Printer Service Manual 280006 00 Rew A Replacement Procedures Nip Rollers Laminator
126. own the carrier drives Ifthe truck is pull the card of the station afler the Ripping action chances are 1 The card position is wrong see Cand Position Adjust page 191 2 The carrier is not coming dowa all the way repeat page 187 Another adjustment for this ip Station Calibration on Step 1 Power down the riter then power up and listen for the ip station reset action Sep 2 Access the Fip Station Adjustment screen select Sr gt Printers and Fares Right lick va the Zehra or Zehra POU printer listing Slot Properties gt Deuce Seine gt Printer Adjustment gt lp Son Adjust gt alate 8 eet ase 3 93 Open the main cover then ey down on the carrier a the back close to the If there is any downwand travel increase the parameter make it less negative but do not overdo i because this will increase the reset noise and potentially damage the carrier drive Zebra PRA Card Printer Service Manual 980006001 Rev A Replacement Procedures Station 5 10 4 15 Card Position Adjust This procedure adjusts how the ruck drives into the Flip Station The adjustment should be set so that the card s centered inthe lip arms itis not centered the truck may have removing the card afier the flipping action move the cand into the Flip Station select Start
127. p men b From the Cond Printer Properties screen select Device Songs gt Contml gt Advanced Load a few magnetic cards 4 Click the Mag Position Adjust burton e Observe the printer load encode and eject the card Note that this is a one time setup when the starting position is stored in the firmware Itis not necessary repeat this step unless the Magnetic Encoder is mechanically adjusted am Zebra PRA Card Printer Service Manual 980006001 Rev A Replacement Procedures Magnetic Encoder Important Do not perf Step 2 if the encoder sucessfully writes to the magnetic stripe and al three racks oa the stripe read properly Step 2 If there is a magnetic encoder error go into the Printer Driv Magnetic Encoder Amplitude Adjustment Select Starr gt Printers and Faves right click the Zehra Card Printer and select Properties from the pop up men b Fron the Card Printer Properties sereen select Device Serting gt Contrai gt Advanced Cites Londa few magnetic stripe cards 4 Click the Mag Amplitude Adjust bution Observe the printer loud a card and run the card back and orth under the Magnete Encoder 0006 001 Rew A Zebra PRA Card Printer Service Manual EI Replacement Procedures Magnetic Encoder amp Observe the Mag Data Monitor window which shows the amplitude values of all tres tracks All three tracks should clo
128. pen and close main cover then press RIBBON to re syne ribbon Reprint last job Color ribban panels out of syne see previous action Color ribbon not advancing consistently Color ribbon supply andr take up not engaging properly on spindles Front eolo side of card printed with black Open and close main cover then press RIBBON to re syne ribbon Inconsistent color very faint printing Printhead not pressing on ribbon see Printhead Position Height Pressure Adjustment on page 133 Color ribbon torn or jamming intermittently Clear jm Pull from supply roll and reattach take up roll Also chock Printhead Position Height Pressure Adjustment on page 133 K Black panel sticks to card Printhead running too hot Can happen after head replacement if head resistance incorrectly entered through printer driver see Printhead Adjustments on page 132 Black panel density andar prehet set too high Contact Zehri Customer Service Check ribbon take up and supply torques see Ribbon Torque Adjustment on page 126 Color image printing with K Pack panel Cheek selections ade in Printing Preference Loud rattling screeching from card transport 006 001 Rew A Card has fallen Truck drive belt and is jammed at some poit the cover and remove all the cards from the hopper Remove the jammed card if accessible Look for the card in the transport bod Using the Card
129. r Service Manual sa0006 001 Rev A Replacement Procedures Cleaning Encoder Sensor Step 6 Remove the Cleaning Encoder Sensor 906 001 Rew Zebra P840 Cand Printer Service Manual m Replacement Procedures Laminator Sensor PCBA 5 17 Laminator Sensor PCBA 5 17 1 Removal Step 1 Locate the Lam Sensor PCBA These Step 2 22 Zebra PE3Q amp PRA Cand Prater Service Manual 2006 001 Rev A Replacement Procedures aminator Sensor PCBA Step 3 With a TORX TIS driver remove the screw holding the upper Retaining Spring to the Frame Step 4 With a TORX TIS driver remove the two screws holding the Lam Sensor PCBA to the Frame 9008 001 Rev A Zebra PRA Gard Printer Service Manual Replacement Procedures Laminator Sensor PCBA Steps Unplug the Lam Sensor Step 6 Remove the Lam Sensor PCBA Note When installing the replacement Lam Sensor PCBA align the serews to the center ofthe opening This will help in achieving the optimal sensor reading ES Zebra PRA Card Prater Service Manual sa0006 001 Rev A Replacement Procedures Laminator Sensor PCBA 5 17 2 Tests and Adjustments Laminator Parameters in the Driver To access the Status sereen select Sur gt Printers and Faxes Right click on the Zebra PAJO Zehra P640 printer listing Select Properties gt Device Senings gt Control gt advanced Unities gt Show Sensor Data
130. r hole and slat 1331 Laminate or Magnate Stipe Cards 06 001 Rew A Zebra PE3Q amp P840 Card Pater Service Manual Installation and Setup Setting up the Printer 2345 Installing the Laminator Cassette s Step 1 Insert the cassette into it black molded pocket then close the cassette latch clockwise for the UPPER counterclockwise forthe LOWER Upper Laminate Cesar Laten Plale ana Peta Step 2 Close the main cover If there was a laminate errar before you replaced the cassette laminate will automatically fed iom the just loade cassette followed by cutting action to free patch of laminate onto the transfer roller If laminate does no feed automaticaly press the LAMINATE button on the printer control panel Zebra PRA Card Printer Service Manual 980006001 Rev A Installation and Setup Seting up the Printer 2 3 4 6 Clearing the Laminate Channels M your scissor cus were neat enough to pss for machine made cuts continue with printing cats Ifo do not waste a priat eyele Instead remove the hand cut pate from the Transfer Rollers as follows Nota Clearing procedures for the upper and lower laminate channels similar The upper channel is shown here Removal of e Transfer Guide gives acess to the Transfer Rolle Retaining Transtar Taage Springs Shown a pei Step 1 Push the Reining Spring to the left pull the Transfer Guide st
131. r two screws holding the Backplate tothe Font e do Step 17 Zebra PRA Cand Ptr Service Manual sa0006 001 Reva Replacement Procedures Flo Station 5122 Replacement Step 19 From the rear of the printer install the Backplate by lifting it up and into the piter Ensure the two tabs t the tp of he Backplate are on the outside of the support beam on the rot Step 20 Install the two 5 16 screws that hold the Backplate to the Frame Step 21 With a Phillips 2 screwdriver install the two screws holding the Backplate to the Front Bezel Step 22 With a tighten the two 5 16 serews installed in Step 20 Note For case of handling insert cand between the Flip Arms when installing the carier assembly in the printer Step 23 From is highest point slide the entire carrier assembly into the printer Step 24 Slide the shaft into position Step 25 Side the carrier assembly down to the Platon Step 26 With a Phillips 0 screwdriver tighten the screw that olds the shaft in place The screw is tightened onto the notch at the op of the shaft do not over tighten 9008 001 Rev A Zebra PE3Q amp PSAL Cand Printer Service Manual EI Replacement Procedures Fip Staton Step 27 Position the Cam and Flip Arm Note that the large side lobe of the Cam is on the same side as the extend Flip Stop Fip Sop Step 28 With a Phillips
132. ra P840 Cand Prater Service Manual 980006001 Rav A Replacement Procedures Laminator Transfer Rollers 5 18 Laminator Transfer Rollers Note This procedure applies to the removal and replacement of the upper Lam Transfer n Roller which si bth the and card printers The wer Lam Transfer Roller Which is only in the card printer is removed similarly Step 1 Locate the Lam Transfer Rollers Step 2 Remove the upper Flex Guide 9008 001 Rev A Zebra PSAL Card Printer Service Manual 27 Replacement Procedures Laminator Transfer Rollers With a TORX TIS driver remove the sere holding the upper Retaining Spring to the Frame Step 4 From the rear of the printer locate the Transfer Roller Gear Zebra PE3Q amp P840 Cand Printer Service Manual 2006 001 Rev A Sept Sip Sep Replacement Procedures Laminator Transfer Rollers With snap ing pliers remove the snap retaining ring and roller gear from the transfer roller shaft Wit a TORX TIS driver remove the two screws holding the Laminator Transfer Roller to the shaft see figure above Remove the Laminator Transfer Roller ftom the shaft by pulling the shalt oul toward the fivat of the printer Zebra PSA Printer Service Manual 29 Replacement Procedures Ribbon Encoder Sensor 5 19 Ribbon Encoder Sensor Step 1 Locate the Ribbon Encoder Sensor
133. ra P840 Card Pater Service Manual m Replacement Procedures Fip Staton 5 12 Flip Station 5121 Removal Seplo Locate the Flip Sitio Sep If not already done remove the Rear Cover see Section 53 and the Main PCBA Gee Section 55 Step 3 From the rer of the printer locu the drive moto Zebra PE3Q amp PSAL Card Prater Service Manual sa0006 001 Rev A Sep Sep Sep Sep Sep Sep Replacement Procedures Station With a TORX T25 driver remove the two screws holding the Drive Motor to the Frame Cut the associated cable Disconnect the ground wire Remove the drive Mave the drive belt to Le of he way With a Phillips 0 screwdriver the serew that holds the shaft in place Zebra PSAL Card Printer Service Manual Replacement Procedures Fip Staton Step 10 Remove the shaft by pulling it up and of the Flip Station Step 12 Remove the Cam and screw E Zebra PRA Card Printer Service Manual Replacement Procedures Flo Station Step 13 Slide the entire carrier assembly up o ts highest point and out ofthe printer Step 14 Remove the carrier assembly 9008 001 Rev Zebra P840 Gard Printer Service Manual Replacement Procedures Fip Staton Step 15 With sre ower two 5 16 serews that hold the Step 16 With a Phi pewdriver remove the uppe
134. ra P630 oc Zebra 6 printer listing Select Printing Preferences gt mage Adjustment E Zebra amp PSADI Card Prater Service Manual Rev A Troubleshooting Print Quality Problems To adjust the contrast select gt Printers and Faves Right click on the Zebra P630 or Zehra primer listing Select Properties gt Device Soins gt Color Calibration 008 001 Rev A Zebra amp PSADI Card Prater Service Manual 4 7 Laminate Problems Laminate not centered on card Vertical adjust mechanical adjustment for tbe upper cassette see Vertical Ort Adjustment upper asset on page 147 for the lower caselle see Vertical Ori Adjustment lower cassette on page 148 Horizontal oft adjust printer properties adjustment see Horizontal Offer Adjust on page 14 Laminato not parallel with card edges Skew adjust mechanical adjustment for the upper cassette se Skew Adjustment Procedure upper casei on page 145 for the lower cassette see Skew Adjustment Procedure lower easet on page 146 Musing partial width laminate edge guide no properly installed one of positions Transfer guide not properly installed Laminate patch wrapped around heated roller Laminate wrinkling Canoceurat end of ol Remove case If nearly discard Ins fresh roll If notend oF ol problem suspect obstructions in laminate fed path Laminate bunches up o
135. raight out toward you Step 2 Remove and discard the laminate patch on the Transfer Roller Never re use Step 3 If nceded turn he Transfer Toggle to the OPEN vertical position Step 4 Remove any laminate between the Transfer Rollers Step 5 Retur the Transfer Toggle to the RUN horizontal position Note that the laminate will not fed and place correctly if transfer toggle is not in RUN position Step 6 Reinstall the Transfer Guide with its top edge above the laminate cutter guide Pull hack the Retaining Spring while re inserting the Transfer Guide then release the spring when the guide is pushed into place Step 7 Press the LAMINATE bunan to load the Transfer Rolle Important Improper replacement of the Transfer Guide can cause laminate skewing and mis feeding Be sure the Transfer Toggle is set to RUN horizontal Take care to avoid damaging the Transfer Roller ribs when replacing he Transfer Guide Observe the orientation o the Transfer Guides If they ae upside down you risk breaking the rims on the rollers 08 001 Rev A Zebra A P840 Printer Service Manual Installation and Setup Setting up the Printer 2 3 5 Loading Cards The POO and 640 Printers use standard ISO CR 80 PVC Composite cards Do not use paper adhesive backing Size Six 86 mm 2 125 x 3375 in nominal refer to SO Specification for exact dimensions and tolerances Thickness 75 mm 08 n
136. ration Use these o adjust the mag head and printer sensors 4 Mag Position Adjust e Mag Amplitude Adjust 3 Flip Station Calibration This routine determines the number of motor steps it takes for the carrier o descend fim the upper position to the lower position Le he carrier s physical end stop This step count is save in flash memory and s used to Mise the carrier down to the rest position before each and every flip station acti Be Smart Card Calibration L Set Ribbon OEM not used Jo PH Pressure Calibration n Zebra PRA Card Printer Service Manual 980006001 Rev A Installation and Setup Changing the Printer Driver Options Properties 4 Update Backup Config Causes the printer o updat printer s current senings its backup configuration with the 5 Upgrade Firmware Caution This should anly be done won you have downloaded an upgrade firmware e A from Zebra Sends a new version of fia to the printer 6 Send Features File Send a Features File to the printer A Features File is sent for the Purposes of enabling Uv printing resting a dongle or resetting the pine password T Password Protection Enable or disable password protection o prevent someone fom changing the Printer Properties When the Use Password checkbox is checked the following pop up appears Enter the new password into the New Password and Confirmation fields Click The passwor
137. re attached 1o the Frame Step 7 1f not already disconnected remove the Magnetic Encoder Connector from 114 on is Main PCBA Step 8 Turn the printer around view from front Step 9 Carefully pull the cable and connector through the opening behind the Hopper Step 10 Remove the Ms 2m Zebra PRA Card Printer Service Manual 2006 001 Rev A Replacement Procedures Magnetic Encoder 527 2 Replacement Step 1 Set the replacement Magnetic Encoder in place Important Use the 30 thousandths shim while installing the shoulder screws and associated hardware then remove it once the screws are tightened Adusoscen Non AAZ hes washer caro Step 2 Install the shoulder screws nylon washers compression springs and flat washer Note that there is o lat washer on the let side Step 3 Remove the shim Step 4 Carefully pull the ground wire and cable amp connector though the opening behind the Hopper Step 5 Connect the Magnetic Encoder Connector to 114 on the Main PCBA Step 6 Connect the ground wire to the Frame Rev A Zebra PE3Q amp PRA Card Printer Service Manual Replacement Procedures Magnetic Encoder 5273 Adjustment Step 1 After replacing the Magnetic Encoder go into the Printer Driver and perform the Magnetic Encoder Position Adjustment Select Starr gt Printers and Faves right lick the Zebra Card Printer and select Properties rom the pop u
138. rinter only or to neither side This option will automatically tum on the heaters 6 Orientation Allows you to set up the font and back images independently fr landscape or orientation checking the tae bx you can also flip either image upside down The following combination is not available Front landscape and Back Zebra PRA Card Printer Service Manual 980006001 Rev A Installation and Setup Changing the Printing Preferences 282 YMC Color Printing Tab YMC Color Printing allows the user to adjust seleted color printing parameters To access the YMC Color Printing screen select Start gt Printers and Faves Right click on he Zehra or Zehra PED primer listing Select Preferences gt YMC Color Printing The printer accepts 24 bit color images meaning that each af the colos Y M and C is by bits per pixel In High Quality the default senting all 24 bits are processed In Low Quali the printer driver transmits a smaller amount 16 bits of color information the effect being a slight degradation of the printed image With a USB Connection standard interface configuration there will be no noticeable difference 06 001 Rev A Zebra PE3Q amp PRA Gard Prater Service Manual Instat tion and Setup Changing the Printing Preferences 283 Black Panel Tab When the Card Setup sereen is set fr YMC and
139. rinters and Faxes Right click on the Zebra P6301 Zehra P6401 printer isting Select Printing Preferences gt Log Caisan 1 1 imaw tapas ET T e Finn mM 7 pr Gated be enabled Enable EIN Readback can be found on the Mogneti Encoding tab sce Important In order to log iter Magnetic Stripe or Barcode EIN data EIN Readback must Section 285 0006 001 Rew A Zebra PE3Q amp PSA Prater Service Manual Installation and Setup Changing the Printing Preferences 3o Enable Logging If this box is checked the lo be feature is enable 2 Log File Definition Choose one of the following options Ifthe Create New Log File Each Day box is unchecked click Browse 10 navigate to a directory folder in which to save the log fie Ifthe box is checked File changes to Pali and the Browse button becomes inoperative requiring the directory to be entered manually The fle generated by is of the type MMDDYYVVJog In addition o the file or folder name you may wish to specify a field Separator Character than the default T Log File Contents The Log File Contents group selects the data to be logged in the file you specified as above The data will be logged in the order displayed on the sereen ach cla being separated by the character specified in the Log File Definition Dua files are named by date n t
140. rt card or registered laminates the laminate length value in the driver may neod to be adjusted see Laminate Station Adjustment on page 64 06 001 Rev A Zebra Gard Printer Service Manual Insta tion and Setup Setting up the Printer 23 44 Using Partial Width Laminate E Noto Since portal width lamin tes are only used for the back Les lower surface ofthe Sardis section only applies to the Printer Laminate come in three widths Full Width laminate is 2 in 51 mm wide Full width laminate is used on he front ie upper or back ie lowe surface of the cand laminate is available in two widths L6 in 42mm wide laminate is uted for cards with a writable signature panel 1 33 in 33 mm wide laminate is used for cards with a magnet stripe theres signature or magnete stripe on the back of the card full width laminate Would generally be used These are shown in the following figure T Front d CARD n 48 Step 1 Remove the Laminate Edge Guide from its storage location on the Laminator Frame it snaps Zebra PE3Q amp Gard Printer Service Manual XI Step 2 For 13 in 33 mm laminate for use with magnetic stripe cars snap the Laminate Edge Guide into the iner hole and slot in the lower cassette as shown in the following pictures For 1 66 in 42 mm laminate for use with signature stripe cards use the oute
141. s PRINT Button Note The PRINT burton can be disabled via the printer driver see Advanced Utilities T3 Pros the PRINT button to print image stored in the printer s memory When the printer s powered up the memory is loaded with a checkerboard test pattern In regular on line use the PRINT button reprints the last image downloaded fom the computer 1o the buffer memory Ifyou hold the PRINT button down and power up the printer the Ribbon Synchronization feature which normally forces ribbon synchronization Whenever the door is closed or the printer is powered up is disabled Ifyou press and hold the PRINT button for more than two seconds the piter will continuously reprint the image in the buffer Stop this action hy pressing the button momentarily while printing is in proce Note that pressing the PRINT buton will have no eft if any of the following applies An emor condition exists You have set up the print driver to print color an both sides af the card The optional hardware lockout key ID Key is missing but this does not disable the checkerboard printout available afier power up Zebra PRA Gard Printer Service Manual 980006001 Rav A General Description controls and Indicators RIBBON button Note The RIBBON button can be disabled via the printer diver see Advanced Utilities on page 73 This burton is used o synchronize the ribbon in other words to position
142. screens Ta enable password protection select Starr gt Printers or Printers and Fates Right click Zehr P630 or Zebra PSA then select Propert gt Device Seige gt gt Advanced Utes In the Password Protection section check Use Password and enter a password of your choice 9008 001 Rev A Zebra P01 Card Printer Senice Manual m amp Card Printer Manual APPENDIX F Printer Pooling Setting Up the Printers Individually For lactation we will establish a of three Note In the P60 many ofthe configuration variables are stored in the printer itself unlike the typical printer as defined by Mierosoft posed P640 printers must be set up similar Step 1 Install and setup the three printers The printers can have any names of your loosing here we will name them Zebra P640 I Zebra P6402 Zehra and we will assume they are attached to ports ATLUSB0O1 ATLUSBOO2 ATLUSBOD3 respectively Before proceeding to pool the printers estem individually and be sure they are configured similarly Specifically chock the following Ribbon panel configuration ribbon type and what prints on which side of the cad o Mag encoding configuration Black extraction configuration if applicable Printer Pooling Creating the Poot Creating the Pool Step 3 Steps Step 6 Stepo Step
143. se in value und be greater than 100 4 With a 332 hex wrench adjust the amplitude by tuning the adjusting screw 1 4 um clockwise GOZ wrench E h Continue turing the adjusting screw clockwise 1 4 tum any or all amplitudes drop off sharply then back off the adjustment 1 2 tum Allbree tracks should be close in value and be greater than 100 Encode and read another magne stripe card Repeat these adjustment steps if necessary Zebra PE3Q amp PSA Gard Printer Service Manual 950006001 Rev A 6 Preventive Maintenance There is almost no preventive maintenance 10 be performed Dust and debris should be vacuumed out every 12 months or more frequently in adverse environments 6 1 Card Cleaning System Your Printer includes a simple cleaning system using a Cleaning Cassette 10 cards the Cleaning Cassete contains sufficient tape for 3 000 908 001 Rev Zebra PRA Cand Printer Servos Manual Preventive Maintenance Print Head Clearing 6 2 Print Head Cleaning The cand cleaning system using the Cleaning Cassette will normaly do an adequate job of leaning the ends However a separate Printhead cleaning using swabs can remove more Stubborn deposits when print anomalies persist A Caution Only use foamlipped swabs Naver use sharp objec o scrape deponis from the print head Permanent damage to the print hea
144. sideration unless the car on see below il be printed smart Card Contactless Encoder Printing Contactless Smart Cards Prini g Contactless Smart Cards When designing material to be printed on Contactless Smart Cards be sure the printing will ot be on the smart chip area Le the printing on either side of the card must not beon top of underneath the smart chip area By looking at an un printed card very carefull itis possible 1o see the chip location as in the figure on the left below If you print in that area resus will be unsatisfactory in the figure on the right the star should have been a single solid color x Sar Chip Location ES Zebra P840 Card Printer Service Manual 950006001 Rev A Appendix D Smart Card Contact Station Introduction Smart Cards have a built in microcomputer andlor memory chip which is usd to store oc other types of data The printer ming Smart Cards ISO 7816 a at the contact station where the printer connects 10 the contacts on he Smart Card other printer operations remain the same asthe standard model formation an the additional operations oa P630 or P64 Printer Smart Cand Contact Station This section ct equipped wih Media Loading Orientation Orient the cars wit the gold plated Smart Cand contacts atthe bottom surface of the cand and acing to the right Sirace cl Cad smart Card C
145. ss the Flip Starion Adjustment sereen Start gt Printers and Funes Right click on the Zehra or Zebra PH primer listing Select Properties gt Device Sings Printer Adjustment gt Flip Adis a eo d mee um d curs mmy Flip Station Height Adjust This parameter modifies the position to which the lip station rises while ping a cad Increasing this parameter forces the flip station rise higher postin while decreasing this parameter forses it to rise to a lower position Setting this parameter too high will result in undue wear and tear on the machine Setting irtoo low will result in failure to flip cards 2 Insertion Height Adjust This parameter modifies the position to which the flip station rises while inserting a cad into the laminator Incresing this parameter forces the flip station insert at a higher position while decreasing this parameter forces itt insert at Tower position Seting this parameter ton high orto low wil result in failures to insert sands ino the laminator Rest Position Adjust This parameter modifies the position at which the flip station rests when not flipping Increasing this parameter forces the flip station to rest at a higher position while decreasing this parameter forces itt rest at a lower position Sening this Parameter too high or too Tow will result in poor fips and dropped cards 4 Card Position Adjust Pixels This parame
146. ss the Image Adjustment sereen select Sart gt Printers and Fixes Right lick on the Zebra PESO oc Zehra POU primer isting Select Printing Preferences gt Image Adjustment Brightness and Contrast Controls on the Image Adjustment sereen have same effect on the printed image as do similar controls on typical office color printers Move the slide bars to adjust the brightness and contrast of the cards being printed Zebra PE3Q amp PSA Card Printer Service Manual 980006001 Rev A Installation and Setup Changing the Printing Preferences Here some sample prints to illustrate the effects of changing the brightness and contrast senings Click the Reset burton to return to default Brightness 50 and Contrast 80 senings Rew Zebra PE3Q amp PRA Card Printer Service Manual Instat tion and Setup Changing the Printing Preferences 2 8 5 Magnetic Encoding Tab Important Ifyou have the Magnete Swipe Encoder installed ensure that the Mog Encoder On checkbox is checked The Magnetic Encoding sereen allows the user to set various magnetic encoding options To access the Magnete Encoding sereen select Sarr gt Printers and Faxes Right click on the Zebra PEO or Zebra P640 printer listing Select Printing Preferences gt Magneti Encoding Mag Encoder Verify Om If this box is checked every card is run twice under the rea write head The first pass writes
147. t Rotate the laminate core counterclockwise reeling in the laminate 10 bring it even with the lips of the Gasse Set the cassette aside Step 4 Remove the upper transfer guide then discard the laminate patch on the upper transfer roller 1f you don t do this the next patch to be applied will not reflect the vertical offset adjustment you are about to make Using feri pen mark the vertical offset adjust screw head for reference Step 6 Using a blade screwdriver tum the vertical offe adjust serew in tum increments as directed in diagrams below NOTE One full counterclockwise tum ofthe screw pushes out the cassete and therefore the laminate patch by approximately 003 ust under 1 mm 7 7 FRONT ZF CARD FRONTS CARD 4 4 corect tis condition tum the verical To hs cond on turm the vertical ast countereiockwae adjust screw ciockwise Step 7 Reinstall the casen Step Adjust the cassette ach screw in the same direction by the same amount Ifyou have not already done so remove and discard the laminate patch on the upper transfer roller close the printer cover then press the LAMINATE button 10 un out a fish patch from the upper east Step 10 Print test cand and inspect for vertical oft Step 11 Repeat Step 6 through Step 10 until the laminate is positioned 0006 001 Rew A Zebra PE3Q amp PRA
148. t computer sereen 1 Ribbon Panel Detect The curent reading ofthe Color Sensor 2 Panel Threshold The current value of the detection threshold for the colar ribbon Above this value is termed black below this value is termed not black 3 Laminate Sensors Reflective sensor that detect the presence of laminate on the transfer rollers below 124 laminate present above 140 laminate absent 4 Card Presence Sensor The reflective sensor to the right ofthe hopper High no card Low card present Printhead Voltage Should be about 24 AC Frequency 50 or 60 Hz 7 Assumed AC Vo assumed for 60 Hz 3 Printhead Temperature Temperature ceiling 70 C above that temperature stopped until he head cools e printing is 3 Controller Board Temperature Should be about 5 above ambient 40 Heater Temperature Temperatures at the top and bortom laminate heater cores Logie States Summarizes all two state interlocks and photo sensors a very useful diagnostic tol For example opening closing the doors will result in the logie states to commute from 1 to O and if not isa clear indication the sensor switch is faulty Rev Zebra Card Primier Service Manual n Installation and Setup Changing the Printer Driver Options Properties 277 4 Control The Control seren allows manual control over the printer Some of these functions are s
149. t the best color profile dea 2 Manual Profile Window Zebra PE3Q amp PSA Gard Prater Service Manual Allows the operator to select the desired profile from the list shown in the Color 950006001 Rev A Installation and Setup Changing the Printer Driver Options Properties 2 7 6 Security Tab This is the standard Windows securi screen showing user access to various printer contral options Both Print and Manage Printers must be checked for full functionality of the printer Ta access the Security tab select Sturt gt Printers and Faves Right click on the Zehra Or Zebra P6401 printer isting Select Properties gt Security x fcm Lo 06 001 Rev Zebra PE3Q amp PRA Card Pater Service Manual Installation and Setup Changing the Printer Driver Options Properties 2 7 7 Device Settings Tab The Device Settings sereen allows you to acess various adjustment and calibration To access the Device Stings tab select Sturt gt Printers and Faves Right lick on the Zehra or Zebra primer listing Select Properties gt Device Settings ete Tea H TATANA om Sea Zebra PE3Q amp PRA Card Prater Service Manual 950006001 Rav A Installation and Setup Changing the Printer Driver Options Properties 27 7 1 Printer Adjustment A Caution Modifying these values could cac undesirable results To access the Printe Adjustment sereen
150. tep 3 Remove the End Panel 0008 001 Rev Zebra PRA Card Printer Service Manual s Replacement Procedures REID Antenna Assembly 5 10 RFID Antenna Assembly Sept Sep Stepa Stepa Steps Sept Locate the REID Antenna Assembly Antenna Cover and Antenna Flex Cable RFID Antenna Remove the Antenna Cover from the Payout Spindle Note that the Antenna Cover snaps in place Separate the Antenna Flex Cable fom the Antenna Cover With a TORX T25 driver remove the rwo stews shown ia the figure above This Wil loosen the cover plate and provide enough clearance to slide the Antenna Flex Cable our ofthe Frame If not already disconnected remove the REID Connector from J45 on the Main PCBA From the rear of the printer slide the Antenna Flex Cable ofthe Frame Zebra PSA Card Printer Service Manual sa0006 001 Reva Replacement Procedures Piston 5 11 Platen Step 1 Using the Card Transport Knob move the Tack back to ts home position stopping when the right hand edge of the Platen is even with he right hand inner surface of the Card Input Hopper Step 2 Push the Platen to the ke against ts spring Step 3 Pry the Platen out using a CRA cand Important Do not lose the spring t holds the platen tight against the right of the truck and is essential for good print registration Step 4 Remove the Platen Seng 9008 001 Rev A Zeb
151. ter modifies the distance that the card carrier drives n to the flip station Increasing this parameter drives it further toward the laminator while decreasing this parameter doesn t drive it as far into the laminator Setting this parameter too high or too low will result in the cnl not being centered in the station leading to poor ips and dropped ards Zebra PRA Card Printer Service Manual 950006001 Rev A Installation and Setup Changing the Printer Driver Options Properties Advanced Adjustments 0006 001 Rev A To acces the Advanced Adjustments sereen select Sturt gt Printers and Faxes Right click on the Zehra or Zebra P640 primer listing Select Properties gt Device Sings Printer dajustment gt Advanced Adjust Note These adjustments should only be made if the normal auto ealibration procedures do not allow these functions to work properly eee Em eurn ced mares c Override Defaults Checking this box will enable the grayed settings to be change Magnetic Encoding Adjust the start position of mag dita on the mag stripe Smart Card Position Adjust Adjusts the position of the cand carrier under the smart ca probe Zebra PSA Gard Printer Service Manual Installation and Setup Changing the Printer Driver Options Properties 277 2 Color Calibration To access the Color Calibration screen slot Start gt Printers and Faves Right li
152. the printer is not connected to your network Verify that the Ethemet cable is properly connected to the printer and ta the Ethernet port your computer ar the network Valid host name has not been assigned to the printer your client uses Windows 2000 a valid host name must be assigned t the printer Failing to do so may cause DHCP to register the IP address as the printer name in DDNS for clients that do not support dynamic updates Color differences may be attributable to the Windows operating system installed a miliriner installation the colors printed on one unit do not match the colors from another even though the printer color senings are the same To ensure colar consistency it is recommended that the identical operating system and settings be used on all computers generating print jobs Rev A Zebra PSAL Gard Printer Service Manual Troubleshooting Adjustment Procedures 4 10 Adjustment Procedures 4 10 1 Ribbon Torque Adjustment perform the procedure ensure you have Clutch Too Kik 7167 driver and he IDPrint test and adjustment program The Clutch Bum In Tool Kit PIN 105927 430 consists of Clutch Pulley Assembly Grooved Spined Cores Step 1 Find Low Ribbon Torque Plugin and power up the printer V Ensure the Payout Spindle rotates f Takean Specie Payout spinte Zebra PE3Q amp Print
153. the two flanged bearings should remain nthe sear bracket Zebra PE3Q amp PAD Card Pater Service Manual 950006001 Rev A Replacement Procedures Laminator Heater Cartridge and Heated Rolar Step 11 From the front ofthe assembly remove the C ring that corresponds to the Heated Roller that neds replacing 008 001 Rev A Zebra PRA Gard Printer Service Manual zs Replacement Procedures Heater Elements 5 22 Heater Elements 5221 Removal A Hot Surface Wal 10 20 minutes forthe printer 1o cool down Step 1 Mootalrendy done remove the Rear Cover see Section 5 3 is not necessary 10 remove the Main PCBA Step 2 Locate the Heater Elements Spi Disconnect the Elements frm the Main PCBA Remove the top heater om MIA and and remove the bottom heater from and 14 Step 4 With a TORX TIO driver remove the three screws that hold cach heater to the Frame Zebra PAD Gard Pater Service Manual Replacement Procedures Hester Elements Sep Slide out the top Heater Element 5 2108 2 WAN Step 6 Slide the bottom Hester Element Step 7 Remove the Henter Elements 9008 001 Rev A Zebra PRA Card Printer Service Manual Replacement Procedures Heater Elements 5222 Replacement Step 1 Replace the T funox 722 lubricant Nota Note hr Tifuno 722 is a lubricant which provides a t
154. ting for 3 pixel or 2 ine eduction Other Functions include Enhanced Flipping Options and Magnetic encode only To access the Advanced sereen select Start gt Printers and Fares Right click on the Zebra PIU or Zehra P40 primer sing Select Prning Preferences gt Advanced Disable support for multiple cards per job Not used leave unchecked 2 Enable Turbo Mode Determines bow the printer buffers data leave unchecked Enhanced Barcode Printing Prints clearer barcode image by reducing blooming Important Only use this option if you are having trouble printing barcodes This change Will be applied to all K panel printing checked choose one of the following options Reduction Prints 3 out of 4 pixels Reduction Prints 2 out of3 pixels 4 sms ard Fliping Options Do not fip card before printing Color side up 5 Magnetic encode only 0006 001 Rew A Zebra P840 Pater Service Manual Installation and Setup Changing the Printing Preferences 2 88 About Tab The About displays copyright and version information about the printer driver access the About sereen select Sarr gt Printers and Faxes Right click on the Zehra PHO or Zehra P6401 printer sting Select Priming Preferences gt Abou Zebra PRA Card Printer Service Manual 950006001 Rev A 2 9 Packing the Printer for Shipment fhe printer is to be sh
155. tion The difference between the P630 and the POD is that the has a single sided laminator Ge it lays down and seals a laminating im on the top surface of the printed card while he dO has laminator Le it lays down and seals laminating im on either the top surface only or both surfaces of the printed card References in this document that refer to either or both of the models will be in the form of the printer or the P630 P640 Printer references that are specifie to one or the other will bela the form of the Printer or he Printer 1 2 Printer Features The following figure shows features of the P6SOUPGAO Printer Cleaning Cassete Riton RebonTakeUp Fip Staton Pint Laminat Salon P640 Reeder Encoder Encoder Head Optional Options Sion Power ACPower DBO Seral ierta Swich Connerior Connectar tarConiact Connector Cantor Contact Optonay Staton 2 Zebra PE3Q amp PRA Card Pater Service Manual XI General Description Controis and Indicators 1 3 Controls and Indicators A limitei amount of contol and status information s available at the Control Panel on the oat ofthe printer Additional control functions and satus information is available via the host or nctwork compute Gener Controis and Control Panel Button
156. tte cannot rotate upward to disengage fom the cleaning amm serew to tight or too loose roller Pivot Rev A Zebra P840 Pater Service Manual Troubi hooting Unusual Noises Unraported Events Card has both front and back images printed on same side Both pages print the same side with YMCK Check the ribbon settings Select Start gt Printers and Faxes Right click on the Zehra or Zehra printer listing Select Printing Preferences gt Card Senp Card does not flip Run the Flip Tests to check flip action To run the Flip Test select Start gt Printers and Faxes Right click on the Zebra or Zehra P640 printer listing Select Properties gt Device Seige gt Control gt Advanced Unites Se nea setas e pre F ee p p To comet refer to Flip Station Adjustments on page 137 MEDIA light ON steady but no obvious visual problem Color ribbon notin Color Sensor Colo ribban supply andor take up cores not engaging properly on Spindles Cleaning cassette not engaging properly on the take up drive End of path Laminate mist Zebra P840 Card Printer Service Manual 980006001 Rev A Troubleshooting Unusual NoiseslUnreported Events Completely unexpected print results Color ribbon or nearly Replace ribban Main cover opened during a print job O
157. ual 980006001 Rev A Rew A Installation and Setup Changing the Printer Driver Options Properties Udita I teste Tests Activate various flip tests used to troubleshoot station problems and activate a can eject eyele Flip Test 1 Picks up a card runs it to the flip station fips it raises it to the laminator infeed then ejects trough the laminator The sequence repeats until the PRINT button is pressed and released Flip Tes 2 Pieks up a card runs it to the station flips it returns it to the Platen then backs it to the cand sensor by the mag head The sequence repeats until the PRINT bunion is pressed and released FlpyPause Picks up a eard runs it to the flip station raises it to the laminator infeed then holds this position erme the Insertion Height in the station dialog until the user presses the PRINT button at which point the flip carrier descends and the tuck retur the card to the hopper Ejeet Card Picks up a cand runs it to the flip station raises it to the laminator infod then ejects it through the laminator Like Flip Test 1 but done onee only and without flipping Move Carriage Use this button to move the card carrier to the desired position This is useful when adjusting the mechanical settings on the printer Zebra PSA Card Pater Service Manual n Installation and Setup Changing the Printer Driver Options Properties 3 Calib
158. umbers frilto match or if no ID Key s detected the printer is disabled The ID Key is caved in a 27x 7 plac fob that plugs into a receptacle to he right of the card hopper Typically atthe end ofeach work session the is removed from the printer and stored in a secure location such as a key safe g a Lost ID Key Important Ifthe IDKey is removed during a card printing session the printer will cease 10 operate after the current batch of cans is printed The recovery procedure requires special computer ile obnal only from Zebra produet support This ile is downloaded to the printer following which the replacement ID Key is inserted The printer is then power cycled off then on at which point the keys serial number is recorded in Printer Security Printer Parameters in the Driver Printer Parameters ID Code the Driver The ID Code or password synchronizes the driver with the printer This prevents use ofthe printer with a PC not having the same ID Code c Doaa sre The initial ID Code i assigned at the factory during Str on nrc oft De aeree pm Printers and Faxes Right lik Zebra or cama Zebra P640 then select Properties gt Devie Sings Control gt Advanced Utes change this code select Start gt Printers or In the Change ID Code window enter the old password fom the underside of the IDKey in
159. utside the cutter assembly This can appen to either upper or lower laminates Failing o latch the cassette Unltch the cassette gently wiggle the cassette out o te pocket then latch the cassette scissor eut on the leading edge of the laminate You can make this casier by cuing the laminate above the latch Remove all laminate scraps Leading edge of laminate not esed in even with the lips of the cassette Cu the leading edge of the fesh laminate as square as you can with scissors then rel itin instal and latch the cassenie Note Any time you unlatch cassette you must chock that the laminate is even with the lps ofthe cassette before re latching E Zebra PRA Gard Printer Service Manual 980006001 Rev A Troubleshooting Laminate Problems jammed in laminator Dings or rough on the card depending on vendor cand quality can vary even from bach to batch Either of the cutters fails to so the card is stopped dead by a of laminate ow firmly held by the laminate eed roller which can nor be rotated by tugging on he lamina Note rollers in the main drive ain of the laminator not the cassette out feeds are n connected by toothed any of them fails to suspect loose set serews on the toothed pulleys Heated Rollers Ines Rollers Or Outfeed Rollers not rotating Corectiv Aetion Step 1 Tum off the primer allo
160. w is consistently acceptable inspect the back surface patches of the las few cards to pass through the laminator Note the direction of skew on the back surface Don t worry about vertical offset at this stage unless the laminate overhangs grossly in which case proceed to the fet adjustment procedure When flipping the cards for Inspection keep the mag stripe if presen toward you Fip me caras aft to ight nat tront to back Referring to diagrams below correct for skew in the lower laminator usi as in Step 1 through Step 11 for the upper cassette but nate that the ree Siep 3 will be claekwise for the lower cassette as isis in the printer s the same procedure in direction for st screw it screw clockwise Zebra PSA Cand Pater Service Manual Rev A Troubleshooting Adjustment Procedures 4 10 4 6 Vertical Offset Adjustment upper cassetto corrected and that skew has been corrected n Note The following procedure assumes that the horizontal offe has been software Seplo Check the action ofthe cassette lath If necessary adjust its fore aft position so that its ears smoothly engage the cassette without nudging the case Step 2 Printand laminate a few test cards in the usual way noting the vertical offset front to bock position of the laminate puteh on the front ofthe cand Step3 Unlateh and remove the upper cassette from its pocke
161. w itto cool for about 10 minutes 1t necessary tum he roter toggle separate te anster roters and pressure onthe ca Hot Surface Even afer allowing cooling ime the assembly wil ba HOT hold it by is outer cover Step 2 Unscrew the heater assembly fastener then partially withdraw the assembly with the cand Step 3 Pull the cand out of the heater inspect the rollers for laminate scraps and foreign matter then re install the assembly Do nar use metal tools o clean the rollers 9008 001 Rev A Zebra PE3Q amp PRA Card Printer Service Manual Troubleshooting Printhead Problems 4 8 Printhead Problems Whiteline across length of the card The white ine sa sign ofa blown pixel The adjacent back stripe is a printhead driver problem Le components oa the head sel These are independent problems not necessarily co located that may require replacement of the printhead Random occurrences of white un printed spots Possible card quality probem Run IDPein Lite with graston bmp cards from a dierent batch Check Platen surface for specks of debris Image not contered on card To adjust the horizontal vertical oft select Start gt Printers and Faves Right click on the Zehra PA30 or Zebra Pd printer sting Select Properties gt Device Stings gt Printer Adjustment gt Print Station Adjust Image offset on card Correct this by increasing h
162. y adjustments to take effect Rev A Zebra PE3Q amp PRA Card Pater Service Manual E Installation and Setup Changing the Printer Driver Options Properties 2113 Status The Status screen displays the current state of the printer and provides standard printer information and sensor data which is updated every few second To access the Status sereen select Sur gt Printers and Faxes Right lick on the Zehra Zehra P640 printer isting Select Properties gt Device Sening gt Suus Media Images Left The exact umber of YMCK sets remaining oa the color ribbon as reported by the color ribbon core 2 Enabled Features Uv Printing Uv Printing is enabled in manufacture or by field technician b ID Code the user password is enabled by the user IDIKey requires installation ofa physical key This displays Yes once the printer has ocko itself to the key not just because it has the key installed Zebra PSA Gard Printer Service Manual 950006001 Rav A Installation and Setup Changing the Printer Driver Options Properties Sensor Data These are of several different types of sensors and interlock switches but they have one thing in common they tell the printer s conto loge whut is happening and where enabling ito continue with the process or if a malfunction occurs to ight the appropriate indicator light and report specifie enor condition on the hos
163. y teeth hae burrs are missing or are damaged or if the center hole is distorted or enlarged the gear pulley must he replaced father than the old one re installed 27 532 amp 9 64 Regular and Ballpoint Hex Drivers 6 12 Channel Lock Pliers 332 5 16 amp 5 32 Slotted Screwdrivers 0 1 amp 2 Phillips Screwdrivers 3 pe File Set Surface Mount and Round Nose Cutters JA amp 516 Open End Wrenches TIO TIS T20 amp T25 Regular and Ballpoint Drivers Flashlight 23 Pice Inch Socket Set 1 4 3 8 Drive 005 007 amp 010 Gauges 6 14 Straight Hemost 614 Curved Hemostats amp 10 25mm Heavy Duty Straight Fixed Tip Sap Ring Pliers 5127 Long Nose Pliers 6 Vise Grip Looking Pliers Long Nose Zebra PRA Card Printer Service Manual 980006001 Rev A Replacement Procedures Rear Cover amp Cooling Fan 5 3 Rear Cover amp Cooling Fan Step 1 With a Phillips 2 serewdriver remove the seven screws holding he Rear Cover in place Noe that the range arrows point the seven Rew A Zebra P840 Printer Service Manual Replacement Procedures Rear Cover amp Cooling Fan Step 3 Disconnect the Cooling Fan plug from connector J2 the Main PCBA Step 4 Remove the Rear Cover Step S With Phillips 1 serewdriver remove the four screws holding the Cooling Fan in place Step 6 Cut the

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