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980569-001 Rev. A Service Manual Zebra ® P330i Card Printer

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Page 1: Zebra P330i Service Manual

980569-001 Rev. A

Service Manual

Zebra® P330iCard Printer

Page 2: Zebra P330i Service Manual
Page 3: Zebra P330i Service Manual

980569-001 Rev. A P330i Card Printer Service Manual i

Foreword

This manual contains service information for the Zebra P330i Card Printers manufactured by Zebra Technologies Corporation, Camarillo, California.

Copyright Notice© 2004, 2005 ZIH Corp.

This document contains information proprietary to Zebra Technologies Corporation. This document and the information contained within is Copyrighted by Zebra Technologies Corporation and may not be duplicated in full or in part by any person without written approval from Zebra. While every effort has been made to keep the information contained within current and accurate as of the date of publication, no guarantee is given that the document is error-free or that it is accurate with regard to any specification. Zebra reserves the right to make changes, for the purpose of product improvement, at any time.

TrademarksP330i is a trademark and Zebra is a registered trademark of Zebra Technologies Corporation. Windows and MS.DOS are registered trademarks of Microsoft Corp. All other trademarks or registered trademarks are marks of their respective holders.

Product Disposal

Product Disposal Information �• Do not dispose of this product in unsorted municipal waste. This product is recyclable, and should be recycled according to your local standards. For more information, please see our web site at:http://www.zebra.com/environment

Page 4: Zebra P330i Service Manual

ii P330i Card Printer Service Manual 980569-001 Rev. A

Foreword

Declarations of Conformity

For a formal certificate, please contact the Compliance Office at Zebra�’s Camarillo facility.

EUROPE: Norway Only: This product is also designed for IT power system with phase to phase voltage 230V. Earth grounding is via the polarized, 3-wire power cord.

FI: �“Laite on liitettävä suojamaadoitus koskettimilla varustettuun pistorasiaan�”SE: �“Apparaten skall anslutas till jordat uttag�”NO: �“Apparatet må tilkoples jordet stikkontakt�”

Supplemental Information:

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the

89/336/EECmodified by

92/31/EEC and93/68/EEC

EMC Directive EN 55022 (1998) RF Emissions control

EMC Directive EN 301489-3 V1.4.1 RF Emissions and Immunity for radio equipment

EMC Directive EN55024 (2001) Immunity to Electro-Magnetic Disturbances

73/23/EEC modified by 93/68/EEC

Low voltage Directive

EN 60950-1 (2001) Product safety

1999/5/CE R&TTE Directive EN300330-2 V1.1.1 Radio Frequency Interferences

Model P330i conforms to the following specification: FCC Part 15, Subpart A, Section 15.107(a) and Section 15.109(a) Class B digital device.

Page 5: Zebra P330i Service Manual

Foreword

980569-001 Rev. A P330i Card Printer Service Manual iii

user is encouraged to try to correct the interference by one or more of the following measures: Reorient or relocate the receiving antenna. Increase the separation between the equipment and the receiver. Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. Consult the dealer or an experienced radio/TV technician for help.The user may find the following booklet, prepared by the Federal Communications Commission, helpful:How to identify and resolve Radio/TV Interference Problems. This booklet is available from the U.S. Government printing Office, Washington, D.C. 20402, Stock No. 004-000-00345-4. Use of a shielded cable is required to comply within Class B limits of Part 15 of FCC Rules. Pursuant to Part 15.21 of the FCC Rules, any changes or modifications to this equipment not expressly approved by Zebra may cause, harmful interference and void the FCC authorization to operate this equipment.

Industry Canada Notice

This device complies with Industry Canada ICES-003 class B requirements.

Page 6: Zebra P330i Service Manual

iv P330i Card Printer Service Manual 980569-001 Rev. A

Foreword

IconsThroughout this manual, different icons highlight important information, as follows:

Note �• Indicates information that emphasizes or supplements important points of the main text.

Important �• Advises you of information that is essential to complete a task, or points out the importance of specific information in the text.

Provides an example or scenario to demonstrate or clarify a section of text.

Electrostatic Discharge Caution �• Warns you of the potential for electrostatic discharge.

Electric Shock Caution �• Warns you of a potential electric shock situation.

Hot Surface �• Warns you of a situation where excessive heat could cause a burn.

Caution �• Advises you that failure to take or avoid a specific action could result in physical harm to you, or could result in physical damage to the hardware.

Page 7: Zebra P330i Service Manual

980569-001 Rev. A Service Manual v

Contents

Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

1 �• General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Printer Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Controls, Connectors, and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 �• Installation and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.2 Unpacking the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.3 Installing the Print Driver Software and Setting Driver Options . . . . . . . . . . . . . 152.4 Loading a Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162.5 Installing the Card Cleaning Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202.6 Setting the Card Thickness Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222.7 Loading Cards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242.8 Card Output Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262.9 Connecting the Printer to your Computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272.10 Connecting Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282.11 Printing a Test Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302.12 Packing the P330i Printer for Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302.13 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3 �• Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373.1 Card Printing Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373.2 Card Path Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423.3 Card Movement During Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433.4 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453.5 CPU PCBA Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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4 �• Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474.1 Power-Up Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484.2 LCD Panel Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484.3 Printing a Test Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504.4 Card Feed or Transport Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514.5 Print Anomalies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524.6 Troubleshooting the Ethernet Connection and Adapter . . . . . . . . . . . . . . . . . . . . 56

5 �• Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615.2 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625.1 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635.2 Removing the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645.3 Removing the Print Engine from the Lower Cover . . . . . . . . . . . . . . . . . . . . . . . 675.4 Removing the Connector Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685.5 Removing the Power Supply Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715.6 Removing the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 735.7 Removing the Rear Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 755.8 Removing the Cam Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785.9 Removing the Platen Inertia Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 795.10 Removing the Printhead Pressure Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805.11 Removing the Film/Bracket Sensor PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 815.12 Removing the Pressure Spring Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 825.13 Removing the Cam Arm Follower Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 835.14 Removing the Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845.15 Removing the Print Head / Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 885.16 Removing the Print Head Lift Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 925.17 Replacing the Print Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 945.18 Replacing the LCD PCBA and/or LCD Cable Assembly . . . . . . . . . . . . . . . . . 1115.19 Replacing the Encoder Shroud and Exit Pressure Roller . . . . . . . . . . . . . . . . . . 1135.20 Replacing the Exit Pressure Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1165.21 Removing the Balls Retainer Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1255.22 Card Feeder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1275.23 Power / Filter Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1415.24 Removing the CPU PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1425.25 Removing the I/O Daughterboard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1455.26 Removing the RFID Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1475.27 Replacing the Ribbon O-Ring Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1495.28 Replacing the Ribbon Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1515.29 Removing the Ribbon Motor Pulley and the Ribbon Motor . . . . . . . . . . . . . . . 1545.30 Replacing the Stepper Motor Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1565.31 Removing the Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1575.32 Removing the RFID PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1605.33 Replacing the Ribbon Color Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1625.34 Replacing the Card Sensor Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1665.35 Removing the Print Head Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

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980569-001 Rev. A Service Manual vii

5.36 Removing the Print Head Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1805.37 Separating the Front Frame from the Center Frame . . . . . . . . . . . . . . . . . . . . . . 1815.38 Magnetic Stripe Encoder Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1865.39 Smart Card Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1885.40 Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

6 �• Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Appendix A �• Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Appendix B �• P330i Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Appendix C �• Worldwide Service & Support . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Page 10: Zebra P330i Service Manual

viii Service Manual 980569-001 Rev. A

Page 11: Zebra P330i Service Manual

980569-001 Rev. A P330i Card Printer Service Manual 1

1General Description

1.1 Printer Description

The Zebra P330i Card Printer is a photo ID card printer. It can print at 300 dpi resolution on 10-60 mil (0.25 - 1.5 mm) ISO CR-80 plastic cards. When equipped with a YMCK (Yellow, Magenta, Cyan, Black) ribbon, it can print full-color images. A wide range of other ribbons, including monochrome ribbons and ribbons that will additionally apply a protective transparant overprint, are also available.

The P330i Printer has a USB interface as standard. In addition to the USB port, it can optionally be ordered with a 10/100T Ethernet port.

If equipped with the optional Magnetic Encoder, the printer will encode a magnetic stripe on the card. Other options allow encoding of �“smart cards,�” which have embedded logic and/or memory circuitry.

The following shows the main functional features found on your P330i Printer.

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2 P330i Card Printer Service Manual 980569-001 Rev. A

General Description

Panel Button

Print Head

(Optional)Smart Card Contact Station

Output Hopper (shown in open position)

Card Feeder Cover (shown open)

Card Thickness Control

Card Cleaning Cartridge

LCD Display Panel

Print Head Carriage Latch

Print Head Carriage (shown in open position)

Main Cover (shown open)

(Optional) Magnetic Encoding Station

Ribbon Supply Spindle

Ribbon Take-Up Spindle

Page 13: Zebra P330i Service Manual

General Description

980569-001 Rev. A P330i Card Printer Service Manual 3

1.2 Controls, Connectors, and Indicators

The P330i Printer has an LCD Display Panel and a Panel Button on the front and a power connector, power switch, and interface connector(s) on the rear panel. These are shown in the following figures.

LCD Display Panel

Panel Button

Power Switch

Power Connector

Network Status / Activity LED *

Ethernet Adapter Status LED *

10/100base-T Connector *

Ethernet Switch *

USB Connector

* These are on the optional Ethernet Adapter.Optional DB-9

Connector location for Smart Card Contact Station

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4 P330i Card Printer Service Manual 980569-001 Rev. A

General Description

1.2.1 LCD Panel

The LCD Panel can display the following messages:

Message Mode

Operational

INITIALIZING Scrolling

READY Fixed

DOWNLOADING DATA Fixed

PRINTING MONO Fixed

MAG ENCODING Fixed

CONTACT ENCODING Fixed

PRINTING CYAN Fixed

PRINTING YELLOW Fixed

PRINTING MAGENTA Fixed

PRINTING BLACK Fixed

PRINTING OVERLAY Fixed

DOWNLOADING FW Fixed

CLEANING PRINTER Fixed

Warnings

CLEAN PRINTER Scrolling

REMOVE RIBBON THEN CLOSE HEAD Scrolling

EMPTY FEEDER & PRESS BUTTON Scrolling

LOAD CLEANING CARD IN FEEDER Scrolling

PRESS BUTTON TO CONTINUE Scrolling

FEED LONG CLEANING CARD IN EXIT Scrolling

CLEANING PRINTER Scrolling

ENCODING ERROR (printing stops) Blinking

INVALID MAGNETIC DATA (encoding stops)

Scrolling

REMOVE RIBBON Fixed

Errors (Printer will not operate)

OUT OF RIBBON Blinking

MECHANICAL ERROR Blinking

OUT OF CARDS Blinking

PRINT HEAD OPEN Blinking

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General Description

980569-001 Rev. A P330i Card Printer Service Manual 5

1.2.2 Panel Button

During normal printer operation, if the Panel Button is pressed briefly nothing happens.

If the Panel Button is held down for more than three seconds, the printer will start a cleaning cycle and the LCD Panel will prompt the operator to load a cleaning card in the feeder. (If a print operation was in process when the Panel Button was pressed and held down, the print operation will be completed before the printer starts a cleaning cycle.)

If the Panel Button is pressed and held down while power is turned on to the printer, the printer will print a test card. This provides a quick check of printer operation completely independently of a computer or network connection.

In response to LCD Panel prompting messages, press the Panel Button to continue various operations.

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6 P330i Card Printer Service Manual 980569-001 Rev. A

General Description

1.2.3 Card Thickness Control

The Card Thickness Control is used to set the P330i printer for use with cards of different thicknesses. Use of the Card Thickness Control is described in Chapter 2.

Card Thickness Control

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General Description

980569-001 Rev. A P330i Card Printer Service Manual 7

1.2.4 (Optional) Ethernet Adapter

P330i Printers equipped with the optional Ethernet Adapter have the following additional controls and indicators:

Ethernet Reset Switch

If the Ethernet Reset Switch is pressed and held while turning the printer power on, and then released when the Ethernet Adapter Status Indicator turns green, the Ethernet Adapter will be reset to the factory default configuration parameters.

While power is on, if the Ethernet Reset Switch is press and held, a configuration card showing the Ethernet Adapter�’s current confuguration settings will be printed.

Ethernet Adapter Status Indicator

The Ethernet Adapter Status Indicator is a bi-color (red - green) LED, that shows the operational status of the Ethernet Adapter.

Network Status/Activity Indicator

The Network Status/Activity Indicator is a bi-color (orange - green) LED, that indicates network speed, establishment of a link, and network activity.

(Recessed) Ethernet

Reset Switch

Ethernet Adapter Status

Indicator

Network Status / Activity

Indicator

10/100Base RJ45

Ethernet Connector

Note �• Detailed information on the use of these indicators is presented in Chapter 4, Troubleshooting.

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8 P330i Card Printer Service Manual 980569-001 Rev. A

General Description

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980569-001 Rev. A P330i Card Printer Service Manual 9

2Installation and Setup

2.1 General Information

This section will guide you through the installation and setup of your P330i Card Printer. This consists of the following procedures, which should be performed in the order presented.

�• Unpacking the Printer

�• Installing the Print Driver Software and Setting Driver Options

�• Loading a Ribbon

�• Installing the Card Cleaning Cartridge

�• Setting the Card Thickness Control

�• Loading Cards

�• Connecting the Printer to your Computer

�• Connecting Power

�• Printing a Test Card to verify printer operation

The procedure to be followed for Packing the Printer for Shipment is given at the end of this section.

The printer should be placed in a location that allows easy access to all sides. The printer should never be operated while resting on its side or upside down.

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10 P330i Card Printer Service Manual 980569-001 Rev. A

Installation and Setup

2.2 Unpacking the Printer

Your P330i Card Printer ships in a carton and protective anti-static bag. Keep all packaging material in case you need to move or re-ship the printer.

Step 1. Inspect the shipping container to ensure that no damage has occurred during shipment. If any damage is apparent, file a claim with the shipper.

Step 2. Unlatch and remove the handles on either end of the shipping container, as shown in the figure below.

Step 3. (See the figure on the next page as you perform the following steps.) Lift the upper part of the shipping container off of the lower part (which will still hold the printer and its packing material).

Step 4. Remove the packing material around the top of the printer.

Electric Shock Caution �• Limit AC power supplied to the P330i Printer to 110 ~ 230 volts, 60 ~ 50 Hertz. Limit excess current draw to 16 amps or less, using an associated circuit breaker or other such device. Never operate the printer in a location where operator, computer, or printer can get wet. Personal injury could result. The printer must be connected to an earthed electrical power source and properly protected against electrical surges and grounding faults; the electrical reliability of the printer is based on the reliability of the mains power source and with the earth connection.

The printer�’s power supply is an internal unit that can only be serviced or replaced by trained and authorized personnel.

UP

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Installation and Setup

980569-001 Rev. A P330i Card Printer Service Manual 11

Step 5. Lift the printer out of the carton by holding it with both hands.

Step 6. Please ensure that you have a clean and nearly dust free environment for proper operation and storage of the printer.

Step 7. Make sure the following items are included with your P330i printer:

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12 P330i Card Printer Service Manual 980569-001 Rev. A

Installation and Setup

If any items are missing, please contact your dealer. To reorder, please refer to Appendix D of this manual.

Step 8. Remove packing tape securing the printer�’s Main Cover and Card Feeder Cover.

Step 9. Your P330i Printer ships with warning tape where the Card Cleaning Cartridge will be installed, and a pad that protects the print head from possible damage in shipment. To remove the tape and pad, follow the following steps:

a. Open the printer�’s main cover by lifting at its lower front lip.

Power Cables (2)

Cleaning Kit

CD-ROM with Driver Wizard and User�’s Manual

Card Cleaning Cartridge

USB Cable

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Installation and Setup

980569-001 Rev. A P330i Card Printer Service Manual 13

b. Locate the Print Head protection pad and the Card Cleaning Cartridge location tape (see below).

c. Release the Print Head Carriage by pushing the Print Head Carriage Latch to the left, and raise the Print Head Carriage. It will remain open at about a 45° angle.

INSTALL

Remove me

Print Head Protection Pad

Card Cleaning Cartridge Location Tape

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14 P330i Card Printer Service Manual 980569-001 Rev. A

Installation and Setup

d. Remove the print head protection pad. Keep the pad, as well as the other packing material and the shipping carton, in case the printer is shipped or moved. If the original material is lost, a replacement Shipping Kit can be ordered from Zebra; please refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer.

Print Head Carriage Latch

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Installation and Setup

980569-001 Rev. A P330i Card Printer Service Manual 15

2.3 Installing the Print Driver Software and Setting Driver Options

Printing with the P330i Printer requires the Windows Printer Driver and your card design/issuing software or printer command level programming through the printer interface.

The P330i Card Printer can be used with any Windows 2000 or Windows XP computer, using the drivers provided on CD with the printer.

This section contains information on the printing of a sample card in color (using the 5-panel color ribbon YMCKO and the Windows Printer Driver).

Note �• If updating the printer driver from a previous version, before installing the updated printer driver version, always delete the existing version from your computer.

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2.3.1 Installing the P330i Print Driver

To install the P330i Printer Driver automatically on all Operating Systems, use the Zebra Install Wizard.

The Install Wizard will walk you through the appropriate installation steps. The Wizard will:

�• Delete previous versions of the driver and clean up any necessary Registry entries. You must select �“Remove�” from the install options to remove any previous driver versions.

�• Automatically launch when the driver CD is inserted.

�• From the main menu of your documentation CD, select your desired language and then select �“DRIVERS�” from the subsequent menu. The Install Wizard will walk you through the appropriate steps.

2.4 Loading a Ribbon

i Series Printers require the use of i Series ribbons for full color printing. The Resin Thermal Transfer and Dye Sublimination ribbons for P330i are specifically designed for your P330i Printer.

Step 10. Place the printer power switch in the OFF (0) position.

Step 11. If the printer�’s Main Cover is closed:

a. Open the printer�’s Main Cover; lift it by the lip at the bottom front as shown in the figure below left.

Note �• Ensure that you have administrative privileges to perform this installation, or contact your IT department.

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b. Raise the Print Head Carriage by pressing the release latch to the left (toward the output hopper) and lifting as shown below to about a 45° angle. The Print Head Carriage will stay in that position, as shown at the right below.

Electrostatic Discharge Caution �• DO NOT TOUCH the Print Head or the electronic components on the Print Head Carriage. Discharges of electro-static energy that accumulate on the human body or other surfaces can damage the Print Head or other electronic components used in the printer.

Note �• Avoid any direct contact with the print head to prevent transfer of oils or contamination. Outside of normal operation, only the Zebra-approved cleaning materials should come in contact with the print head.

Ribbon Supply Spindle

Ribbon Take-up Spindle

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Step 12. Locate the Ribbon Supply Spindle and the Ribbon Take-up Spindle (see above). Load ribbon onto the supply spindle (under the print head carriage) flange side in, and load the empty core (with tape attached) onto the take-up spindle. Make sure the ribbon comes off the top of the supply spindle and feeds to the top of the take-up spindle.

Flange

Supply Spool

Take-up Spool

Hot Surface �• Do not touch the print head if the printer has been in service within the last 10 minutes. It could be very hot and cause a burn.

Electrostatic Discharge Caution �• A static discharge is possible if you touch any exposed metal parts. Use of an anti-static wrist strap or comparable anti-static protection is required.

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Step 13. Gently press the print head carriage down until it is fully lowered, as shown below. Very little force is neccessary to perform this step.

Note �• During normal operation (with power connected and turned on), the ribbon would automatically synchronize when the Print Head is restored to its fully-down position. The ribbon would be identified and the corresponding parameters sent to the driver.Since power is not connected at this point in the Installation and Setup Procedure, nothing will happen when the Print Head Carriage is closed. The ribbon will synchronize when power is turned on.

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2.5 Installing the Card Cleaning Cartridge

The Card Cleaning Cartridge cleans the cards entering the printer. The Card Cleaning Cartridge consists of a Cartridge Frame and an Adhesive Roller, which are packed together.

Step 1. Remove the Cartridge Frame and the Adhesive Roller from their packaging. Insert the Adhesive Roller into the Cartridge Frame, as shown below. To avoid contamination, always hold the frame and the roller by the ends.

.

Step 2. Peel the protective wrapper from the Adhesive Roller.

Step 3. If the printer�’s main cover is closed, open it. Locate the area where the Card Cleaning Cartridge will be installed (initially, this area was covered by a warning tape).

Card Cleaning Cartridge Mounting

Location

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Step 4. Locate the slot at the rear of the Card Cleaning Cartridge mounting location; see below.

Step 5. Hold the Card Cleaning Cartridge by the extended �“handle�” (so the large arrow on the top is pointing away from you). With the cartridge at about a 30° angle (pointing downward), insert the lip of the cartridge into the slot, until the cartridge seats against the back wall. Then press the front of the cartridge down until it seats all the way down and latches with an audible �“click�”. See below.

Card Cleaning Cartridge Positioning Slot

Slot

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Step 6. Close the printer�’s Main Cover.

2.6 Setting the Card Thickness Control

The Card Thickness Control is set by the user to adjust the gap as cards enter the printer, to prevent double-feeds (which could cause a jam) or mis-feeds.

Step 1. Open the Card Feeder cover. The cover is hinged; lift it by the lip at the right front corner.

Card Cleaning Cartridge in final position

Note �• Set the Card Thickness Control before loading cards.

Note �• To reduce contamination and ensure better print quality, minimize the time the Card Feeder cover is open.

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Step 2. The Card Thickness Control Lever is at the front of the left-side opening of the Card Feeder area.

Step 3. There are four detents to set the position of the Card Thickness Control. Slide the Card Thickness Control to the position corresponding to the following:

Detent Position Card Thickness

Highest 50 mil (1.27 mm) to 60 mil (1.52 mm)

3rd position 30 mil (0.76 mm) to 50 mil (1.27 mm)

2nd position 20 mil (0.51 mm) to 40 mil (1.02 mm)

Lowest 10 mil (0.25 mm) to 20 mil (0.51 mm)

Card Thickness Control

Note �• The overlap in settings above accomodates variations in environmental conditions (especially humidity) and cards from different manufacturers. In general, start at the lowest position and move the lever up until cards feed reliably.

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2.7 Loading Cards

This section shows how to load plastic cards into the P330i Printer. The P330i can use cards with a range of thickness from 10 mil (0.25 mm) to 60 mil (1.5 mm).

The P330i Printer can also load and print cards fed individually. Information on this is given in the next chapter.

The plastic cards generally come in decks of 100 cards; the Card Feeder can hold a full deck of 100 30-mil cards. Cards sometimes will stick together; this can cause mis-feeding or double-feeding. To avoid this, separate the cards before loading, as described in steps 2 through 4 below.

Step 1. If the Card Feeder cover is closed, open it. The cover is hinged; lift it by the lip at the right front corner.

Note �• �“60 mil�” (�“1.524 mm�”) cards may have a significant variation (over 10%) in the actual thickness of the cards; do not use these cards unless each card has been measured to have a thickness less than 66 mil (1.676 mm).

Note �• Do not mix cards of different thicknesses!

Note �• DO NOT bend cards or touch print surfaces as this can reduce print quality. The surface of the cards must remain clean and dust free. Always store cards in an enclosed container. Ideally, use cards as soon as possible.

Note �• For cards with magnetic stripe, refer to Appendix A for loading instructions.

Note �• To reduce contamination and ensure better print quality, minimize the time the Card Feeder cover is open.

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Step 2. Remove all wrapping from the card deck.

Step 3. Holding the card deck by the sides, hold it vertically against a flat surface such as a desktop. If the deck is too thick for your hand to hold it comfortably, use about half a deck at a time.

Step 4. Push the stack back and forth to an angle of about 45° from vertical, so as to separate all of the cards.

Caution �• Do not touch print surfaces of the cards; this can reduce print quality

Note �• Static charges and edge burrs from the card die-cutting process can render individual cards stuck together with significant adhesion force. These cards must be physically separated from each other before inserting into the feeder; if not separated, feeding or printing problems may occur.

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Step 5. Restore the card stack to its original squared-off condition, and place the cards in the input hopper.

Step 6. Note that there will be a �“gap�” in the card stack, with several cards lying flat and the cards above angled upward, as shown in the exaggerated drawing below. This is normal and ensures proper feeding.

2.8 Card Output Hopper

The card output hopper is normally extended to receive the printed cards. The printer may be operated with the card output hopper in its closed position; in this case the cards will not be collected in the output hopper.

Step 1. Pull the card output hopper out to place it in its functional position.

Note �• Do not try to eliminate the gap by pressing down on the card stack in the input hopper; this can cause misfeeds.

Note �• The output hopper is a very snug fit to prevent it from moving during shipping or operation; firm force is required to change its position.

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Step 2. When not using the printer, slide the card output hopper back into its closed position to protect the printer from dust and protect the output hopper from damage.

Step 3. The output hopper can be completely removed from the printer if necessary by inserting a thin, blunt object (such as a pencil) up through the hole in the bottom of the printer enclosure and pressing (up) to release the hopper while simultaneously pulling the hopper out. To re-install the output hopper, simply slide the output hopper in until it locks in place.

2.9 Connecting the Printer to your Computer

The P330i Printer includes a standard USB interface.

As an option, the printer can be ordered with a 10/100base-T Ethernet Adapter (in addition to the USB interface). The Ethernet Adapter can also be ordered as an add-on option and installed in the field by a Zebra factory certified technician.

Step 1. If using the USB interface, use the supplied USB cable to connect between the USB connector on the printer and a USB port on the computer, as shown below. (Note that the figure below shows the optional Ethernet Adapter directly above the USB Connector; this may not be present on your printer.)

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Step 2. If your printer includes the optional Ethernet Adapter as well as the standard USB connection, use either the supplied USB cable or a standard Ethernet cable to connect the printer to a corresponding port on the computer or network.

2.10 Connecting Power

The P330i Printer includes an internal AC power supply that accepts nominal input voltage in the range from 110 to 230 volts at 50 to 60 Hertz. The power source must be grounded.

Depending on specific model number, your P330i Printer will include one or two power cords; use the one that is appropriate for the AC power source connection at your location. If neither has an appropriate connector, AC power cords may be purchased locally; make sure it is a three-wire (grounded) cord.

USB Connector

Power Connector

Power Switch

(Optional) Ethernet Connector

Important �• Do not use both USB and Ethernet connections at the same time!

Important �• Intermittent or unpredictable operation may occur from unsecured connectors. If damaged, the power cable must be replaced by an exact equivalent.

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Step 1. Place the Printer�’s power switch in the OFF ( O ) position.

Step 2. Depending on your local AC voltage, plug the appropriate power cord into the printer�’s power connector and a grounded AC power source connection.

Step 3. To turn the Printer on, set the Printer�’s power switch to the ON ( | ) position.

Power Connector

Power Switch

Caution �• If the power cord appears damaged in any way, or if the power cord will not securely plug into the Printer�’s power connector or the AC power source connection, STOP! Use of a damaged or incorrect power cord could cause equipment damage, result in an electrical fire, or possibly cause injury.

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2.11 Printing a Test Card

With ribbon and cards loaded, your P330i Printer is ready to print. To check the operation of the printer, you should print a test card. (Printing a test card does not require that the printer be connected to your computer or network, but power must be applied.)

Step 1. Set the printer�’s power switch (on the back of the printer) to the OFF ( O ) position.

Step 2. While pressing the Printer�’s front panel button (next to the LCD display panel), switch the printer ON ( | ).

Step 3. Hold the panel button until the LCD display panel reads �“SELF TEST�”.

Step 4. Release the panel button, and the test card will print.

This is an example of the test card:

2.12 Packing the P330i Printer for Shipment

If the P330i Printer is to be shipped, it is important to use the original packing and shipping material to prevent damage to the Printer. If the original material is lost, a replacement Shipping Kit can be ordered from Zebra; please refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer.

Step 1. Remove cards in the card feeder:

PRINTER: P330iMSerial N°: XXXXXFirmware: XXXXXXX

Head resistance: XXXXOffset: XXXX-XXXX

EC:XXPrinting counter: XXXXX

300 dpi

PLASTIC CARD PRINTER

TEST CARD

Note �• The specifics of the shipment and the printer�’s condition may influence which of the following steps are followed; common sense should prevail.

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a. While the printer still has power applied and is turned on, and is still connected to the host computer, remove cards from the card feeder. The last card may be difficult to remove. If so, use the Eject Card command available through the driver on the host computer to eject the last card that is staged in the feeder.

b. Close the Card Feeder Cover.Step 2. If the printer still has power applied and is turned on, and is still connected to the host

computer, set the printer�’s power switch (on the back of the printer) to the OFF ( O ) position, and disconnect the interface and power cables to the printer.

Step 3. Open the Main Cover. Open the Print Head Carriage and remove the Ribbon. (If you wish to save the ribbon for future use, you may want to put it in a plastic bag for storage.)

Step 4. Insert the print head protection pad, and close the Print Head Carriage. Remove the Card Cleaning Cartridge and place it in the upper foam insert. Close the Main Cover.

Step 5. Slide the Output Hopper in all the way against the Printer.

Step 6. Place the Printer in its protective plastic bag.

Step 7. Place the lower foam insert in the lower part of the shipping carton.

Step 8. Use both hands to carefully place the Printer into the recess in the lower foam insert.

Step 9. Place the upper foam insert onto the Printer and gently press it down so it makes a snug fit on the Printer; the top of the upper foam insert should be even with the upper edge of the lower part of the shipping carton.

Step 10. Slide the upper part of the shipping carton down over the lower part.

Step 11. Insert and close the handles/latches.

Caution �• Do not physically pull the last card out of the feeder staging area. This could damage the printer and void the warranty, as well as damage the card.

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2.13 Operation

Printing with the P330i Card Printer is similar to printing with any other printer in a Windows environment.�• The Printer Driver Software is installed on your computer (see Chapter 2).

�• The P330i Printer is connected to the power source and the computer (see Chapter 2).

�• The P330i Printer is selected by either the Operating System or the appropriate application software program.

�• Printer Properties are set (the factory default values will be appropriate for many applications).

�• Card printing is directed by the appropriate application software program.

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2.13.1 Setting Printer Properties

Printer Properties can be set either at the Operating System level or within the application software program used for printing cards.

Preferences settings can configure the P330i Card Printer for Landscape (wide) or Portrait (tall) printing orientation, and allow the user to verify that the desired ribbon is installed in the printer. (Monochrome ribbons are selected via the drop-down menu.) Detailed instructions on setting printer parameters is presented in Appendix A.

If the P330i Printer includes the optional magnetic card stripe encoder, encoding parameters and coercivity can be set.

Printer cleaning can be initiated from the Tools window (printer cleaning can also be initiated at the printer; see Chapter 4).

Also from the Tools window, the Test Card can be selected from several pre-loaded styles.

�“Single Feed Options�” allows Disabling or Enabling Single Feed Support.

�• If �“Disable Single Feed Support�” is selected, when the P330i Card Printer runs out of cards in the feeder, the LCD display will read OUT OF CARDS. To continue, press the panel button.

�• If �“Enable Single Feed Support�” is selected, when the P330i Card Printer runs out of cards in the feeder it will wait until a card is inserted in the single-card slot or cards are loaded in the feeder, and then will automatically continue.

Note �• In the following description of setting Printer Properties, only those properties and options that are suitable for being set by the User are described. The User should not make selections or set parameters unless they are specifically described in this section

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2.13.2 Printing a Sample Card

Sample card designs are installed with the printer driver. Sample cards require Microsoft Word or Microsoft Paint application software. The cards are accessed via the Start menu. Select Start, select Programs, select Zebra Card Printers, and select a sample card, or follow the directions below to design a card.

Follow these steps to design and print your first card:

Step 1. Launch Microsoft Word Software. Depending on your computer configuration this may be done by double-clicking an icon on your desktop, or by clicking the Windows Start icon, selecting Programs, and navigating to Microsoft Word

Step 2. Go to the File menu and choose Page Setup.

Step 3. Select the Paper Size tab, choose Card. Under orientation, select Landscape.

Step 4. Select the Margins tab, and set the Top, Bottom, Left, and Right margins to 0 (zero).

Step 5. Click OK to close the Page Setup window.

Step 6. The card appears on the screen.

Step 7. Design a card with both black and colored text and with colored pictures (see example below).

Step 8. Once you are ready to print, go to the File menu and select Print.

us!http://www.zebracard.com

Note �• For cards thinner than 20 mils (0.51 mm), the card design must be limited to (1) no more than two 30 mm x 30 mm areas of full color, (2) black information (text and barcode, for example) must cover no more than 50% of the card area, and (3) there must be at least a 5mm unprinted border along all edges.For cards thicker than 40 mils (1.02 mm), the card design must have at least a 5mm unprinted border along all edges.For cards with thickness between 20 mils (0.51 mm) and 40 mils (1.02 mm), these restrictions do not apply; full color printing is permitted edge to edge in both directions.

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Step 9. If the printer was not selected as the default printer, go to the File menu, select Print Setup and choose Zebra P330i Card Printer from the printer names list. Then Close the Print Setup dialog box.

Step 10. The printer will feed in a card and start printing (the data download time will vary depending on the complexity of the card design and the processing speed of your computer).

Step 11. Once the printing job is complete, the card is ejected from the printer.

2.13.3 Feeding One Card at a Time

A Manual Feed Slot is available below the Card Input Hopper for feeding single cards. The Card Input Hopper must be empty for single-card feeding to work properly.

Step 1. Open the Card Feeder cover. Verify that there are no cards in the feeder, then close the Card Feeder cover.

Step 2. Insert a single card into the slot below the Card Feeder. Do not feed more than one card at a time.

Note �• If single-card feeding will be the normal mode of operation, you may select that mode through the driver software. In single-card feed mode, the card will not be printed until the print job has been sent to the printer and the card to be printed has been inserted into the single-card feed slot.

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3Theory of Operation

This chapter includes five major topics:

�• Card Printing Basics

�• Card Path Elements

�• Card Movement During Printing

�• Block Diagram

�• CPU PCBA Connections

3.1 Card Printing Basics

This section provides an overview description of how images are printed on plastic cards by the Zebra P330i Card Printer.

Print HeadThe Print Head is a thin-film device that consists of a row of individually addressable heating elements. Each heating element is approximately 0.0033 inch (0.08 mm) wide, giving a print resolution of 300 dots per inch.

Heating Elements

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There are a total of 672 heating elements. Since the width of the plastic card is 2.125 inches (54 mm), 638 elements provide full-width coverage. The �“extra�” 34 elements (17 on either side of the card�’s nominal width) are present to support programmable image centering and full bleed imaging even if a card is slightly oversize.

The Print Head Assembly mounts in the Print Head Carriage Assembly. The Print Head Carriage assembly can be raised for ribbon installation.

The Print Head Assembly and Print Head Carriage Assembly hold the Print Head at a right angle to the card�’s long surface, while allowing the tilt angle of the Print Head to be adjusted to give optimum print quality.

Platen Roller Ribbon Supply SpindleRibbon Take-Up Spindle

Print Head

Print Head Carriage Assembly (Shown Raised)

Print Head Assembly

Print Head Assembly Tilt Adjustment Range

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3.1.1 Printing Technologies and Ribbons

There are two types of printing technology used in the Printer: Dye Sublimation and Thermal Transfer. The technology to use is determined by the type of dyeor ink on the ribbon.

Monochrome Ribbons have a single color 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 of different dye. RFID Multi-Panel Ribbons have an RFID tag on the supply spool; the RFID code identifies the ribbon typr and panel count. (Note that the lack of an RFID tag will be interpreted by the Printer as being a Monochrome Ribbon.) Printing with a Multi-Panel Ribbon requires multiple passes of the card under the Print Head, once per panel.

For full-color printing, a �“YMCKO�” Multi-Panel Ribbon is generally used. A YMCKO ribbon will have successive panels as follows:

Color Technology Function / Usage

Yellow (�“Y�”) Dye Sublimation Full-Color Printing and DyeSublimation Black Printing

Magenta (�“M�”) Dye Sublimation Full-Color Printing and DyeSublimation Black Printing

Cyan (�“C�”) Dye Sublimation Full-Color Printing and DyeSublimation Black Printing

Black Resin (�“K�”) Thermal Transfer K Resin Black Printing

Varnish Overlay (�“O�”) Thermal Transfer U. V. Protective Coating

Other ribbons are available for the P330i Card Printer; see the Supplies List on the Driver and Documentation CD that came with your printer, or go to the Zebra Card Printer Solutions website at http://www.zebracard.com.

Ribbon Movement From Supply Spool

(YMCKO Pattern

Repeats)Yellow (�“Y�”)

DyeCyan (�“C�”)

DyeMagenta (�“M�”) Dye

Black (�“K�”) Resin

Varnish for Overlay

(�“O�”)

Dye Sublimation Printing Process Thermal TransferPrinting Process

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The ribbon synchronizes to it�’s �“starting�” position whenever the Print Head is opened and then closed. For a YMCKO ribbon, the starting position will be with the leading edge of a Yellow Panel at the Print Head location.

The following figure shows how the ribbon and card move relative to each other during printing.

1. Ribbon Moves Yellow Panel into Position at Print Head

Print Head at Fixed Position

2. Card is Fed to Printing Position Under the Print Head

3. Card and Ribbon Move Together as Yellow Panel is Printed

4. Card and Ribbon Stop at End of Yellow Panel

5. Ribbon is Stationary; Card is Moved Back to Printing Position

6. Card and Ribbon Move Together as Magenta Panel is Printed

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Dye Sublimation Printing

In Dye Sublimation Printing, each Print Head heating element is applied voltage at one of a number of pulse widths. A wider pulse results in the element getting hotter, which converts more of the dye (at that pixel location) to a gas and diffuses it into the surface of the card (a wider pulse gives more intense color at that pixel). This is repeated for each of the dye panels (i.e., Yellow, Magenta, and Cyan), to result in full-color images.

Thermal Transfer Printing

In Thermal Transfer, voltage is either applied or not applied to each Print Head printing element. If voltage is applied, the ink at that location is transferred to the surface of the card.

Each pixel is either printed (i.e., the ink transferred to the card) or 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.

Print Head

Platen Roller

Ribbon Carrier Layer

Ribbon Dye Layer

Card

Gaseous Dye is Absorbed by Card

Print Head

Platen Roller

Ribbon Carrier Layer

Ribbon Ink Layer

Card

Ink Transfered to Surface of Card

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3.2 Card Path Elements

The figure below shows the rollers that transport Cards as they make their way through the P330i printer. The rollers keep the card on a horizontal path, reducing the chance of a card edge catching on anything.

The figure below shows the sensors that track card and ribbon position and movement.

Card Path

Card Feed Rollers

Cleaning Roller

Transport and Platen Rollers

Single Card Feed Sensor (on enclosure)

Ribbon Color

Sensor

Card Entry

Sensor

Feeder Sensor

Cam Sensor (PCBA)

Magnetic Encoder Sensor (if equipped)

Smart Card Sensor (if equipped)

Head Open

Sensor

Ribbon Sync.

Sensor

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3.3 Card Movement During Printing

The P330i printer moves a card through a specific sequence of movements as it encodes and prints the card.

�• The card is fed from the bottom of the stack in the Card Input Hopper, or in through the Single Card Feed Slot.

�• The card moved along in contact with the exposed sticky area of the Cleaning Cartridge; this cleans dust or dirt particles from the (upper) card surface.

�• If the printer includes an optional Smart Card Encoder (either contact-style or contactless), the smart card is encoded.

If encoding fails, the card is moved directly to the card exit, without printing. This is done to avoid wasting time and ribbon panels on a defective card.

Card Input

Hopper

Single Card Feed Slot

Cleaning Cartridge

(Optional) Smart Card

Contact Station

Print Head

(Optional) Magnetic Stripe

Encoding Station

Output Hopper

Card Exit

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�• If the printer includes an optional Magnetic Stripe Encoder, the card is moved past the print head to the magnetic encoder, and the stripe is encoded.

Note that the card goes past the print station without being printed at this time. After magnetic encoding, the card is moved back to just before the print head.

As with smart-card encoding, if magnetic encoding fails, the card is moved directly to the card exit, without printing.

�• The leading edge of the card is moved under the Print Head, and the print head is lowered.

When the printer was turned on, the ribbon was automatically �“synchronized,�” bringing the leading edge of the yellow ribbon panel under the print head.

Lowering the print head reduces space between the print head, the ribbon, and the card, reducing spread of the printed spot and giving sharper images.

As the card and ribbon move along, each element of the print head is energized to one of 32 levels (from completely off to maximum heat), which melts a corresponding amount of yellow dye onto that particular spot on the card.

If using a resin ribbon (used when printing a bar code on a card), the head elements are energized to either on or off. The on level actually transfers the spot of resin under the print head element to the card. This results in the sharpest possible images; for bar codes you want the sharpest edges and highest contrast between dark and unprinted areas.

�• After this yellow pass is completed, the print head is raised, the card is moved back, and printing continues with the Magenta ribbon panel, then the Cyan panel, then the Black (�“K�”) panel if present, then an Overlay panel.

When using a monochrome ribbon, the card makes a single pass under the print head.

�• When printing is completed, the card is moved (past the magnetic encoder, if present) to the Card Exit, where it falls into the Output Hopper.

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980569-001 Rev. A P330i Card Printer Service Manual 45

3.4 Block Diagram

Most of the circuitry in the P330i is on the CPU PCBA. Since the CPU PCBA is not a serviceable unit, circuit analysis to the component level is pointless.

Below is a block diagram of the functional circuits of the P330i Printer; the block diagram also shows how signals are passed to and from the CPU PCBA to the rest of the printer.

(Mag Encoder Option Components)

(Smart Card Option Components)

Ribbon RFIDCircuitry

PowerControl

AC Voltage PowerSupply

24 VDCMagneticEncoder

LCD Display Panel

PrintheadPrintheadCircuitry

Smart Card Encoder Circuitry

Contact or ContactlessSmart Card

Encoder

SensorCalibration

Circuitry

Ribbon and Card Transport

Motors

MotorDrivers

I/ODaughter-

boardA/D Circuitryfor OpticalSensors

OpticalSensors

USBCircuitryUSB Port

EthernetConnection

Circuitry

EthernetExtension

Board

EthernetPrintserver

Board

EthernetPort

Memoryfor CPU

Clock

CPU

RFIDTransponder

(Ethernet Option Components)

Magnetic Encoder Circuitry

RFID Tag inRibbon Core

LCD Display and Panel

Button Circuitry Panel

Button

P330i CPU PCBA

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Theory of Operation

3.5 CPU PCBA Connections

Most of the circuitry in the P330i is on the CPU PCBA. Since the CPU PCBA is not a serviceable unit, circuit analysis to the component level is pointless; but a basic understanding of how the CPU PCBA connects to the rest of the printer helps to better understand the P330i printer.

J11(Ribbon RFID)

J7(Smart Card)

J1(Mag Encoder Head)

J8(Auxiliary RS-232;factory use only)

J6(USB Port)

J12(+24 VDC Input from

Power Supply)

J3(Out of Cards Sensor)

J4(Not Used)

J10(LCD Panel)

J9(Print Head, Head Lock,

Head Temp. Sensor)

J13(Motors and Sensors -

Connects to I/O Daughterboard)

J2(Mates with Ethernet

Extension Board)

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4Troubleshooting

The objective of troubleshooting is to relate a problem to an associated assembly or system function, in order to most efficiently isolate and repair the problem. Typically this involves determining the failure symptom and then checking one or more possible causes of the failure.

Only a symptom-related list of possibilities appears. In general, for a given failure symptom one or more possible causes are listed, with suggested corrective action to take. These causes should be checked and corrective actions taken in the order given; they are listed in order of likelihood and complexity.

When the suggestions presented fail to lead to a repair, a CPU Board replacement, if not prescribed, should nevertheless be tried. A check for broken or disconnected cables and any loss of power should also take place along with checks for obvious mechanical damage.

The Test Software described in Appendix A includes selections to exercise most printer functions. Beyond this, Zebra Card Printer Solutions offers Technical Support and factory repair as options.

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4.1 Power-Up Failures

Some problems are evident as soon as power is applied to the printer. The following table will help in diagnosing these problems.

4.2 LCD Panel Messages

The LCD Panel on the front of the printer continuously displays messages as to what operation the printer is performing as well as certain fault messages. The following table lists possible causes and solutions to the fault messages.

Symptom Possible Cause Corrective Action

When power is turned on, nothing at all happens (no sound, LCD panel stays dark).

1. No power to printer.

2. Defective EMI filteringcomponents.

3. Check Fuse in Power Supply.

4. Defective Power Supply.

1. Check AC power source,verify power cord is pluggedinto printer, try a differentpower cord.

2. Check EMI filteringcomponents.

3. If Fuse in Power Supply isblown, replace it. Ifreplacement fuse blows,replace Power Supply.

4. Replace Power Supply.

When power is turned on, sounds are heard inside printer and ribbon advances, but LCD Panel stays dark.

1. Cable from CPU PCBA toLCD Panel unplugged at eitherend.

2. Defective LCD Panel.

3. Defective CPU PCBA.

1. Verify cable from CPU PCBAto LCD Panel securelyplugged in at both ends.

2. Replace LCD Panel.

3. Replace CPU PCBA.

When power is turned on, sounds are heard inside printer, LCD Panel lights up and INITIALIZING message scrolls, but LCD Panel message does not change to a steady READY message within about 30 seconds.

1. Defective CPU PCBA. 1. Replace CPU PCBA.

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Problem / Description Cause / Solution

The LCD Panel displays OUT OF CARDS message.

1. Check for cards in the cardfeeder. If no cards present,load cards.

2. Check that Card ThicknessControl lever is properlyadjusted (see Loading Cards inChapter 2).

3. Press the Panel Button for 1second. The printing job willrestart.

The LCD Panel displays OUT OF RIBBON message.

1. Check ribbon. Replace ifdefective or entirely used.Ribbon will automaticallysynchronize and printing willrestart with a new card.

The LCD Panel displays PRINT HEAD OPEN message.

1. Check that Print HeadCarriage is closed and latched.If not, close and latch it.

The LCD Panel displays MECHANICAL ERROR message.

1. Check that you are using thecorrect card type (seeTechnical Specifications).

2. Check that Card ThicknessControl lever is properlyadjusted (see Loading Cards inChapter 2).

3. If two cards are fed into theprinter at the same time: Opencover and remove CardCleaning Cartridge, empty theCard Feeder, and pull thejammed cards out. Replace theCard Cleaning Cartridge.Separate the cards as shown inLoading Cards in Chapter 2,and replace.

4. Check that ribbon is loadedcorrectly.

The LCD Panel displays ENCODING ERROR message.

1. Check that you are using thecorrect magnetic card type (forlow or high coercivityencoding).

2. Verify command syntax.3. Contact Zebra technical

support.

The LCD Panel displays CLEAN PRINTER message.

1. Clean the printer (see Chapter4).

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4.3 Printing a Test Card

Printing a Test Card is an efficient way to determine if there is a card transport problem or a printing problem.

Test Card Emerges

from Printer?

Print a Test Card(See Section 2.11)

No Check Problems Associated WithCard Transport. See Section 4.4.

Yes

No Check Problems Associated WithPrint Anomalies.See Section 4.5.

Yes

No Problem With BasicPrinting.

Test Card OK?

P75i

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4.4 Card Feed or Transport Failures

Troubleshooting of card feed or transport failures generally involves seeing where the failure occurs or what type of failure it is. That determination leads to checking certain assemblies or components.

Symptom Possible Cause Corrective Actions

Cards don�’t feed at all. 1. Card Thickness Control is improperly adjusted.

2. Defective Feeder Sensor.

3. Dirty or torn/missing CardFeeder Belt.

4. Defective Card Feed Roller.

5. Broken Card Feed Drive Belt.

6. Defective Card Feed Motor.

1. Set Card Thickness Controlcorrectly (see section 2.6).

2. Replace Feeder Sensor.

3. Clean or replace Card FeederBelt.

4. Replace Card Feed Roller.

5. Replace Card Feed Drive Belt.

6. Replace Card Feed Motor.

Multiple card jam. 1. Card Thickness Control isimproperly adjusted.

2. Cards are sticking together.

1. Set Card Thickness Control correctly (see section 2.6).

2. Be sure to separate the cardswhen loading them into theCard Feeder, as described insection 2.7.

Partial Card Feed. 1. Card Thickness Control isimproperly adjusted.

1. Set Card Thickness Control correctly (see section 2.6).

Card stalls near Cleaning Cartridge.

1. Dirty or defective Clean DriveRoller.

2. Defective 63T x 4mm StepperMotor Belt.

3. Defective Stepper Motor.

1. Clean or replace Clean DriveRoller.

2. Replace 63T x 4mm StepperMotor Belt.

3. Replace Stepper Motor.

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4.5 Print Anomalies

A careful examination of the cards that are printed will lead to efficient troubleshooting of printing problems.

Keep in mind that cleanliness and the card stock are two factors that strongly affect print quality.

Card stalls at Platen (i.e., under the Print Head).

1. Dirty or defective Print HeadPlaten Roller.

2. Defective 56T x 1/8 TimingBelt.

1. Clean or replace Print HeadPlaten Roller.

2. Replace 56T x 1/8 TimingBelt.

Card doesn�’t exit printer 1. Defective 104T x 1/8 TimingBelt.

2. Dirty or defective ExitPressure Roller.

3. Dirty or defective Exit CardDrive Roller.

1. Replace 104T x 1/8 TimingBelt.

2. Clean Exit Pressure Roller orreplace Exit Pressure RollerAssembly.

3. Clean or replace Exit CardDrive Roller.

Symptom Possible Cause Corrective Actions

Note �• For optimum print quality, always keep the Main Cover and the Card Feeder Cover of the printer closed,

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Symptom Possible Cause Corrective Action

No Image. 1. Ribbon is not an i-SeriesRibbon.

2. Ribbon incorrectly installed.

3. Cards may not meetspecifications.

4. Print Head elements may bescratched or burnt.

5. Print Head not beingpositioned correctly.

1. Always use i-Series Ribbonsin the P330i printer.

2. Check that ribbon is installedcorrectly (see section 2.4).

3. Use a different supply of cards.

4. Replace Print Head.

5. Replace CPU PCBA.

Replace Print Head Up/DownMotor.

Check Print Head PositionSensors, replace if defective.

Faint Image. 1. Dirty Print Head.

2. Low Print Head Voltage.

1. Clean Print Head.

2. Replace CPU PCBA.

Artifacts. 1. Particles on Feed or TransportRollers.

Horizontal Lines. 1. Dirty or damaged Print Headelement.

1. Clean the Print Head (seeChapter 4). If horizontal linesare still present, replace thePrinthead Assembly.

Multiple Evenly-Spaced Horizontal Lines.

1. Print Head Registers on CPUPCBA

1. Replace CPU PCBA.

Wavy horizontal lines (these will be especially noticeable in solid blocks of color).

1. Printhead Assembly out ofalignment.

1. Align Printhead Assembly (seePrinthead ReplacementProcedure).

Replace Printhead Assembly.

Vertical Lines.

Sticking Ribbon. 1. Peel Bar on Print HeadAssembly out of adjustment.

1. Adjust Peel Bar or replacePrint Head Assembly.

Washout. 1. Peel Bar on Print HeadAssembly out of adjustment.

1. Adjust Peel Bar or replacePrint Head Assembly.

Sheared Ribbon 1. X-Offset value incorrect. 1. Adjust X-Offset value.

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Image Off-Center1. Excessive border at trailing

edge of card.2. Excessive border at leading

edge of card.3. Excessive border at card

edge nearer front of printer.4. Excessive border at card

edge nearer back of printer.

1. X-Offset value too low.

2. X-Offset value too high.

3. Y-Offset value too low.

4. Y-Offset value too high.

1. Increase X-Offset value.

2. Decrease X-Offset value.

3. Increase Y-Offset value.

4. Decrease Y-Offset value.

CYMK Not Aligned.

Abrupt Color Change.

Small spots appear on the printed card with a non-printed area or a different color.

1. Contamination on the cardsurface.

2. Dust inside the printer and/ordirty Cleaning Cartridge.

1. Check that cards are stored in adust free environment.

2. Clean the printer (see Chapter4).

3. Replace Cleaning Cartridge(see Chapter 4).

There are non-printing horizontal lines (white) on the card surfaces.

1. Ribbon not correctlypositioned.

3. Print Head is dirty.

4. Print Head elements aredamaged (e.g., scratched orburnt).

1. Ensure that the ribbon isproperly rolled onto the ribbonspindles and that there are nowrinkles in the ribbon.

2. Replace ribbon.

3. Clean the Print Head

4. Replace Print Head Assembly.

Symptom Possible Cause Corrective Action

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Printing shows very pale, very dark, or inconsistent results

1. Defective ribbon.

2. Cards may not meetspecifications.

3. Contrast and/or Intensity maybe set to incorrect values.

4. Head Settings are too low /high.

5. Dust or embeddedcontamination on elements ofthe Print Head.

1. Change ribbon and print again.

2. Use a different supply of cards.

3. Adjust Contrast and/orIntensity values in software.

4. Adjust Head Settings higher /lower.

5. Clean the Print Head (seeChapter 4). If contaminationcannot be removed, replace thePrinthead Assembly.

Printing shows blurry printed image.

1. Ribbon cartridge may not becorrectly positioned.

2. Ribbon may not besynchronized on the correctcolor panel position.

3. Cards may not meetspecifications.

4. Dust or embeddedcontamination inside theprinter and/or dirty CleaningCartridge.

1. Check that the ribbon isproperly rolled onto thespindles.

.Replace ribbon and printagain.

2. Open the Print Head Carriage,then close it. This will causethe ribbon to re-synchronize.

3. Use a different supply of cards.

4. Clean the Printer.

Replace the CleaningCartridge.

Only one panel of a color ribbon prints.

1. Using the wrong type ofribbon.

1. Use only i Series ribbons forfull color printing.

Text prints ok but graphics have image distortion, blotches of color, color dots or grid.

1. Graphics incompatibility. 1. Use different format forgraphics.

Use higher-resolutiongraphics.

Symptom Possible Cause Corrective Action

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4.6 Troubleshooting the Ethernet Connection and Adapter

4.6.1 Resetting to Factory Defaults

To reset the Ethernet Adapter configuration parameters to the factory defaults, press the Ethernet Switch and hold it in while turning the printer power on. Keep the Panel Button pressed until the Status Indicator light turns green, then release the Ethernet Switch. To print a configuration card, press and hold the Ethernet Switch until a card starts to print.

Ethernet Reset Button

Ethernet Adapter Status Indicator

Network Status /Activity Indicator

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4.6.2 Ethernet Adapter Status Indicator

A bi-color Status Indicator displays the operational status of the Ethernet Adapter. The following conditions might occur:

During normal operation, the LED is solid green for more than 30 seconds. This indicates all the hardware is functioning properly and the Ethernet Adapter has detected the presence of the network. It does not mean the Ethernet Adapter has an IP address or is attached to a printer queue.

If the LED is rapidly flashing green (9 times/sec), the Ethernet Adapter has not detected the presence of a network cable. To solve the problem:

Verify that the network cable is appropriate for the network and has an RJ-45 connector.

Turn the printer power off (O). Remove the network cable from the Ethernet Adapter. Plug the network cable back in until you hear a positive click. Check the other end of the cable in the same manner. Turn the printer power on; if the Ethernet Adapter still does not detect a cable, continue.

Connect the Ethernet Adapter to a known good network connection. If the Ethernet Adapter is still unable to detect the network cable, contact Technical Support for assistance.

If the LED is slowly flashing green (1 time/sec), the Ethernet Adapter is trying to print a job. If the job does not print, check the following:

Verify that the printer has media and ribbon. If the printer is showing any errors, it is unlikely that the Ethernet Adapter can send data to the printer. The LED continues to blink until the printer malfunction is resolved or until the printer is turned off (O).

Flashing red indicates the Power On Self Test (POST) is in progress.

If the LED is solid red for more than 30 seconds, the Ethernet Adapter has failed the POST. A failed POST can be caused by any of the following:

The printer attached to the Ethernet Adapter device is malfunctioning. Turn the printer power off, wait 10 seconds, then turn the printer back on ( | ).

If the Ethernet Adapter still fails the POST, the Ethernet Adapter has a hardware problem that can be fixed only by replacing or returning the unit. Contact Technical Support for repair or replacement information.

If the LED is alternately flashing red and green for longer than 2 minutes, the Ethernet Adapter is in firmware-download mode. This means it is waiting for new firmware data to be sent before it continues normal functioning. Perform the following:

Important �• Cables with a rating higher than CAT-6 have not been tested.

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If the Ethernet Adapter was purposely put into firmware-download mode, finish the download with the proper update utility. Contact the Zebra web site at http://www.zebra.com to download this utility.

Contact Technical Support for help recovering this unit.

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4.6.3 Network Status/Activity Indicator

A bi-color Status/Activity LED indicates network speed, established link, and network activity.

If the LED is off, no link was established.

If the LED is solid green, a 100Base link is established.

If the LED is flashing green, a 100Base link is established and network activity has been detected.

If the LED is solid orange, a 10Base link is established.

If the LED is flashing orange, a 10Base link was established and network activity has been detected.

Network activity detected by this LED does not mean the activity is data for the print server. The activity is all activity on the network as seen by the Ethernet Adapter.

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5Replacement Procedures

5.1 Introduction

The following sections describe removing both major assemblies and, where applicable, subassemblies and/or components that are considered replaceable. In general, only removal directions are presented; unless otherwise noted, replacement would be performed by reversing the removal steps. Replacement instructions for some items are not presented; removal and replacement of these items are considered too obvious to warrant a detailed description.

Electric Shock Caution �• Before performing any of the procedures in this chapter, set the printer power to OFF (O) and disconnect the power cord.

Caution �• Before beginning any of the procedures that follow, read completely through the procedure. If you do not have the specified tools, or if any step(s) seem beyond your skill or experience level, do not attempt the procedure. You may cause additional damage to the printer.

Note �• Some of the photographs in this section may show printers with different configuration or options than your particular printer. They may also show additional parts removed in addition to removals for the process being described. Please disregard these differences; the information pertaining to the replacement process being described will still apply to your printer.

still

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5.2 Required Tools

This section lists the tools required for the replacement procedures described in this chapter. Naturally, not all tools are required for a particular procedure; specific tools are called out in each step as appropriate.

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1. Flat-Blade Screwdrivers, from 1/16 inch (2 mm) to 1/4 inch (6.5 mm)

2. Numbers 0, 1, and 2 Phillips Screwdrivers

3. Torx T10 and T15 drivers

4. Small Gear Puller (strongly recommended)

5. Small Crescent Wrench or locking pliers

6. Fine-Point, Offset Fine-Point, and Needle-Nose pliers

7. Small Diagonal Cutters or other cutter for cutting cable ties

8. 1.5 mm and 2.0 mm hex keys

9. 5.5 mm hex driver (this can also be used for securing push nuts)

10. Small and Medium Spring Hook Tools

11. Soldering Iron with fine pointed tip

Important �• When removing any of the nylon or plastic pulleys or gears, the use of a gear puller is strongly recommended. If a gear puller is not available, use pliers and/or a flat-blade screwdriver to pry the gear or pulley off its shaft.In either case, remove any loctite residue from the shaft and the gear/pulley.Inspect the old gear/pulley very carefully. If any teeth have burrs, are missing, or are damaged, or if the center hole is distorted or enlarged, the gear/pulley must be replaced rather than the old one re-installed.

Note �• Unless specifically stated, all screws noted in this document use the Torx T10 driver.

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5.1 Removal Sequence

This figure shows the recommended removal sequence. For example, to remove the CPU PCBA, you would remove the Top Cover (procedure given in section 5.2 on pg 64), remove the Print Engine from the Lower Cover (section 5.3 on pg 67), remove the Connector Plate (section 5.4 on pg 68), and then remove the CPU PCBA (section 5.24 on pg 142).

5.2 Top Cover (pg 64)

5.3 Remove Print Engine from Lower Cover (pg 67)

5.4 Connector Plate (pg 68)

5.5 Power Supply Cover (pg 71)

5.6 Power Supply (pg 73)

5.7 Rear Plate (save bear-ings and wavy washers) (pg 75)

5.8 Cam Lever (pg 78)

5.9 Platen Inertia Roller (pg 79)

5.10 Printhead Pressure Spring (pg 80)

5.11 Film/Bracket Sensor PCBA (pg 81)

5.12 Pressure Spring Plate (pg 82)

5.13 Cam Arm Follower Assy (pg 83)

5.14 Clutch Assembly (pg 84)

5.15 Print Head / Carriage Assembly (pg 88)

5.16 Print Head Lift Cam (pg 92)

5.19 Encoder Shroud & Exit Pressure Roller (pg 113)

5.20 Exit Pressure Roller Assy (pg 116)

5.21 Balls Retainer Plate, Springs, Balls (pg 125)

5.22.1 Card Sensor Cable Assy (pg 127)

5.22.2 Card Feeder Drive Belt, Card Feeder Motor (pg 129)

5.22.3 Card Feeder Assy, ESD Brush, Card Feeder Belt, Card Feeder Roll-ers (pg 134)

5.18 LCD PCBA (pg 111)

5.23 Power and Filter Components (pg 141)

5.24 CPU PCBA (pg 142)

5.25 I/O Daughterboard (pg 145)

5.37 Replace Parts that Require Separating the Front Frame from the Center Frame (pg 181)

5.30 Stepper Motor Drive Belt (pg 156)

5.31 Stepper Motor (pg 157)

5.34 Card Sensor Cable Assy (pg 166)

5.35 Print Head Cable Assy (includes Sensor & Fan) (pg 171

Start Here

Complete P330i Printer

5.38 Magnetic Stripe Encoder Option (pg 186)

5.39 Smart Card Options (pg 188)

5.36 Print Head Lift Motor (pg 180)

5.32 RFID PCBA (pg 160)

5.33 Ribbon Color Sensor (pg 162)

5.27 Ribbon O-Ring Drive Belt (pg 149)

5.28 Ribbon Pulley Assy, Ribbon Take-Up Spindle (pg 151) 5.29 Ribbon Motor Pulley,

Ribbon Motor (pg 154)

5.17 Print Head Assembly (pg 94)

5.18 LCD Cable Assy (pg 111

5.26 RFID Cable (pg 147)

Remove I/O Daughterboard if not already removed (pg 145)

Remove Print Head Assembly if not already removed (94)

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5.2 Removing the Top Cover

Step 1. Turn the printer power off, and disconnect the power cord. If an interface cable (USB or ethernet) is plugged into the printer, disconnect it. Remove any plastic cards from the Card Input Hopper.

Step 2. Turn the printer over, and rest it upside-down on a work surface.

Step 3. Press a screwdriver or similar tool into the Hopper Release Hole and slide the Card Output Hopper out of the printer.

Step 4. Remove five screws securing the top cover from underneath. Four of them are at the Card Input Hopper end of the printer, as shown below.

Step 5. The fifth Top Cover attachment screw is located above the card output opening (this is why the Card Output Hopper was removed). See below.

Top Cover Attachment

Screws

Hopper Release

Hole

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Step 6. Turn the printer over, so it is right-side up. Remove two screws into the upper part of the back of the printer.

Step 7. Remove one remaining screw attaching the top cover.

Top Cover Attachment

Screw

Remove These Screws

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Step 8. Carefully remove the top cover. Be careful to avoid damaging the cable to the LCD Panel PCBA or the wires to the card sensor.

Remove This Screw

Top Cover

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5.3 Removing the Print Engine from the Lower Cover

Step 1. Remove two screws from the back of the lower cover to release the print engine.

Step 2. Remove the print engine from the lower cover.

Remove These 2 Screws

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5.4 Removing the Connector Plate

Step 1. Remove the two Phillips-head screws shown in the figure below.

Step 2. Disconnect the ground lug as shown below.

Remove These 2 Phillips-head Screws

Ground Lug

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Step 3. Remove the screws attaching the print engine to the Connector Plate as shown in the two pictures below.

Remove This Screw

Remove This Screw

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Step 4. Swing the Connector Plate away from the Print Engine as shown below. If your printer includes the �“Contact Station�” Smart Card Option, disconnect wires to the Smart Solenoid PCBA as you swing the Connector Plate.

Step 5. Then detach the wires at the Power Switch that go to the Power Supply, freeing the Connector Plate from the Print Engine.

Connector Plate

Smart Solenoid PCBA (Part of �“Contact Station�” Smart Card Option)

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5.5 Removing the Power Supply Cover

Step 1. Remove four screws holding the Power Supply Cover in place, as shown in the next two pictures, and remove the Power Supply.

Power Supply Cover

Remove These Two Screws

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Remove These Two Torx T-10 Screws, then Remove the Power Supply Cover.

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5.6 Removing the Power Supply

Step 1. Unplug the two connectors shown in the picture below. The mating part of each connector has a tab/latch that must be moved out of the way to allow removal of the connector; this is easier with the use of a small flat-blade screwdriver.

Step 2. Remove four Torx T-10 screws shown in the picture below, and remove the Power Supply.

Power Supply

Unplug These Connectors

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5.7 Removing the Rear Plate

The Rear Plate is removed to provide access to the I/O Daughterboard and many other mechanical and electrical components of the printer.

Step 1. This step only applies for printers that include a Magnetic Stripe Encoder.

Using a small flat-blade screwdriver, pry open the Cable Clip that secures the Magnetic Encoder cable.

Note �• In the pictures that follow, the Power Supply has been removed from the Rear Plate. The Rear Plate can be removed without removing the Power Supply, but it is suggested that you remove the Power Supply Cover so the wires to the Power Supply can be disconnected.

1. Use small flat-blade screwdriver to pry the Cable Clip open, being VERY careful to not crush any of the wires.

2. Then unplug this connector from the CPU PCBA.

(These wires are present only if your printer has a Magnetic Stripe Encoder Option.)

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Remove these 3 screws, and lift the Rear Plate back from the Print Engine.

As you remove the Rear Plate, pass this cable through the rectangular cutout.

Important �• When you remove the Rear Plate, take careful note of the Wavy Washers and Bearings as shown in the picture below. They are held in place by the Rear Plate; when the Rear Plate is removed they can fall off their shafts. It is suggested that you remove them and store them until the Rear Plate is to be replaced. When you replace them, make sure each Bearing�’s flange side is �“inward�” and that the Wavy Washer is centered and seated on the Bearing�’s body.

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5.8 Removing the Cam Lever

Step 1. Remove the Cam Lever The upper (smaller) hole in the Cam Lever fits over a peg in the Upper Cam; the lower (larger) hole fits over the raised cam of the Printhead Lift Cam. (The Cam Lever is not attached at either end; it is held in place by the Rear Plate.)

Platen Inertia RollerCam LeverPrint Head Lift Cam

Upper Cam

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5.9 Removing the Platen Inertia Roller

Step 1. The Platen Inertia Roller is secured to the Step Motor shaft with a small setscrew. Since access to the setscrew is limited, turn the Platen Inertia Roller so the setscrew is accessible, and use an L-shaped 2-mm hex key to loosen the setscrew; then slide the Platen Inertia Roller off the shaft.

Platen Inertia Roller

Shaft That Held Platen Inertia Roller

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5.10 Removing the Printhead Pressure Spring

Step 1. With a heavy Spring Hook or similar tool, free the Printhead Pressure Spring from the Pressure Spring Plate, as shown below. The Printhead Pressure Spring is under a lot of tension, it will snap off the Pressure Spring Plate when freed.

Step 2. Then remove the Printhead Pressure Spring from the Cam Arm Follower Assembly.

Spring Hook ToolPrinthead Pressure Spring

Pressure Spring Plate

Cam Arm Follower Assembly

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5.11 Removing the Film/Bracket Sensor PCBA

Step 1. Open the Aluminum �“Cable Tie�” to free the Film/Bracket Sensor PCBA�’s cable.

Step 2. Follow the Film/Bracket Sensor PCBA�’s cable to where it plugs into the I/O Daughterboard. Unplug it. Then work it out from behind the RFID Cable Assembly.

Step 3. Remove the screw securing the Film/Bracket Sensor PCBA to the Print Engine Center Frame, and remove the Film/Bracket Sensor PCBA.

Aluminum �“Cable Tie�”Film/Bracket Sensor PCBA

Film/Bracket Sensor PCBA�’s Cable

RFID Cable Assembly

Screw that Secures the Film/Bracket Sensor PCBA

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5.12 Removing the Pressure Spring Plate

Step 1. After removing the Film/Bracket Sensor PCBA, remove the screw securing the Pressure Spring Plate to the Print Engine Center Frame, and remove the Pressure Spring Plate

Pressure Spring Plate Mounting Screw

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5.13 Removing the Cam Arm Follower Assembly

Step 1. Remove the two Torx T15 screws that hold the Cam Arm Follower Assembly in place, as shown below. The upper one screws into the threaded end of the Print Head U-Support Assembly; it can be removed easily.

Step 2. The lower T15 screw goes into the threaded end of the Printhead Bracket Shaft; to remove this one it will be necessary to prevent the Printhead Bracket Shaft from turning. The best way to do this is to hold the shaft in place with a medium flat-head screwdriver from the �“front�” of the Print Engine, as shown in the next picture.

Cam Arm Follower Assembly

Torx T15 Screws

Printhead Bracket Shaft

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5.14 Removing the Clutch Assembly

Important �• Do not attempt to take the Clutch Assembly apart! If the Clutch Assembly is damaged, it is replaced as a unit.

Clutch Assembly

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Step 1. Hold the Ribbon Supply Spindle, and use a Number 1 Phillips screwdriver to remove the screw securing the Ribbon Supply Spindle to the Clutch Assembly Shaft, as shown in the next picture. If necessary to prevent the shaft from turning, use a small crescent wrench on the flat of the Clutch Assembly Shaft to prevent the shaft from turning, as shown in the second picture.

Remove Phillips-Head Screw

Prevent the Clutch Assembly Shaft from turning

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Step 2. Remove the Ribbon Supply Spindle from the Clutch Assembly Shaft by pulling and turning the spindle.

Step 3. Now pull the Clutch Assembly straight out from the rear of the Print Engine. If the Clutch Assembly is to be re-installed, be careful to avoid bending the Flag Disk.

Flag Disk

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When replacing or re-installing the Clutch Assembly, make sure the hole in the tab on the Clutch Assembly fits over the raised pin through the RFID PCBA, as shown below.

Clutch Assembly Tab

Raised Pin Through RFID PCBA

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5.15 Removing the Print Head / Carriage Assembly

Step 1. Note that when the Clutch Assembly is removed, the entire Print Head / Carriage Assembly can be removed from the Print Engine (the shaft which had held the Clutch Assembly will be sticking through the Center Frame, and the Printhead Bracket Assembly will rest against the Front Frame, as shown in the next two pictures).

Shaft which had held the Clutch Assembly

Printhead Bracket/Fan Cable Assembly

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Step 2. As you remove the Print Head / Bracket Assembly, gently pull the Print Head Cable Assembly through the opening in the Center Frame.

Hole that the Printhead Bracket Shaft normally passes through

Print Head Cable Assembly (Normally Plugs into CPU PCBA)

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Caution �• Don�’t touch the Print Head Elements, shown in the picture below.

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Print Head Elements

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5.16 Removing the Print Head Lift Cam

Step 1. Rotate the Print Head Lift Cam clockwise until the Setscrew lines up with the cut out in the Center Frame, as shown in the second picture below.

The best way to rotate the Cam is to place both index fingers on the inner surface (toward the front of the printer) and both thumbs on the outer surface (nearest you). Do not try to rotate the Cam in a counter-clockwise direction; this could damage the Print Head Lift Motor.

Print Head Lift Cam

Setscrew

�“Cut Out�” in Center Frame

Rotate Clockwise Only

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Step 2. Use a Number 0 Phillips Screwdriver to loosen the Print Head Lift Cam Setscrew. Then pull the Print Head Lift Cam off the Motor shaft.

Setscrew

Important �• When re-installing the Print Head Lift Cam, do not over-tighten the Setscrew; it should only be snug against the shaft.

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5.17 Replacing the Print Head Assembly

5.17.1 Replacement Procedure

Step 1. Turn the printer power off, and disconnect the power cord.

Step 2. Open the printer�’s main (translucent blue) cover. Then remove the cover by pressing inward and twisting at the pivot points.

Step 3. Press the Print Head Carriage Latch to the left, and open (raise) the Print Head Carriage.

Electrostatic Discharge Caution �• The Print Head is extremely susceptible to Electrostatic Discharge (ESD) damage. Do not touch the bottom surface of the Print Head. The replacement must be performed at a static-free work station, an anti-static wrist strap must be worn and properly terminated, or other appropriate protection must be used.

Important �• This procedure describes replacing the Print Head Assembly. The Print Head Assembly is supplied with components in correct alignment with each other. These alignments are critical to proper operation of the printer. Do not deviate from the procedure given here, do not loosen or tighten any screws except those specifically noted in this procedure, and do not attempt to adjust any part of the Print Head Assembly.

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Step 4. Remove the ribbon by pulling both the supply and take-up spools straight out.

Step 5. Using the Torx T10 driver, remove the retaining screw on the front side of the Print Head Carriage.

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Step 6. While removing the retaining screw, the Print Head Adjustment Screw may slip out of the notch in the front of the Print Head Carriage. Whether it has slipped or not, use a medium flat-blade screwdriver to remove the Print Head Adjustment Screw and its associated washer and spring.

Step 7. Looking at the Print Head Carriage from the rear of the printer, note that the Print Head Assembly Shaft has a notch just �“inside�” the slotted end. That notch will be riding in a reduced-size cutout in the Print Head Carriage Frame, as shown below.

Print Head Adjustment Screw

Washer Spring

End of Print Head Assembly Shaft

Cutout in the Print Head Carriage Frame

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Step 8. Gently rock the Print Head Assembly back and forth (the Print Head Assembly Shaft will be the pivot) until the end of the Print Head Assembly Shaft lines up with the circular opening in the Print Head Carriage Frame.

Step 9. Slide the Print Head Assembly Shaft out of the Print Head Carriage. It can be slid out toward the front or the rear of the printer; you may need to press on the end of the Shaft, and it may be a snug fit.

End of Print Head Assembly Shaft

Print Head Assembly Shaft

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Step 10. Disconnect the Ground Lug Spade Connector, as shown in the picture below (this is more easily done by using needle-nose pliers). Gently use a small flat-blade screwdriver to pry the Print Head Cable Connector up and unplug it.

Step 11. Rock the Print Head back and forth while gently separating the sides of the Print Head Carriage until the Print Head can be slid free from the Print Head Carriage.

Print Head Cable Connector Ground Lug Spade Connector

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Step 12. Remove the replacement Print Head Assembly from its protective packaging.

Step 13. Slide the Print Head Assembly Shaft through the holes in the Print Head Assembly Frame as shown.

Caution �• When handling the Print Head Assembly, be careful to avoid touching the active surface of the Print Head. The Print Head is extremely susceptible to damage from static discharge. Also, oil from your fingers can cause poor print quality and/or shorter Print Head life.

Active Surface of Print Head

Slotted and Notched End of Print Head Assembly Shaft Goes Through This Hole

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Step 14. The Print Head Assembly Shaft should stick through both sides of the Print Head Assembly Frame.

Step 15. Turn the Print Head Assembly Shaft so the threaded hole in the center is accessible through the center cutout in the Print Head Assembly Frame. Start the Print Head Adjustment Screw (with its associated Spring and Washer in place) into the threaded hole in the center of the Print Head Assembly Shaft. Run it in two or three turns; it must stay engaged in the Shaft during the steps that follow.

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Step 16. Position the Print Head Assembly as shown below. Gently separate the sides of the Print Head Carriage while rocking the Print Head Assembly back and forth and slide it into approximate position within the Print Head Carriage. See the following pictures. You want the Print Head Assembly Shaft to (first) engage the circular cutout in the �“back�” side of the Print Head Carriage, and then (at the same time) engage the large cutout in the front of the Print Head Carriage.

Keep the Print Head Assembly Screw Below the Notch in the Print Head Carriage as You Rock the Print Head Assembly Into Place

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Step 17. When the Print Head Assembly Shaft is in position at the circular cutout (above), press the Shaft toward the back of the printer (i.e., so it sticks out about 1/16 inch or 2mm); this will make it easier to rock the front end of the shaft into position, as shown below. Then press the Shaft (forward) so it is approximately centered within the Print Head Carriage.

Print Head Assembly is in Proper Position when the End of the Shaft Sticks Through the Circular Cutout

End of Print Head Assembly Shaft Sticks Through this Large Cutout

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Step 18. Plug in the Print Head Cable Connector, and use a small flat-blade screwdriver to press the connector evenly and firmly into place. Connect the Ground Lug Spade Connector (this is more easily done by using needle-nose pliers).

Step 19. See the following pictures. With your fingertips or a small flat-blade screwdriver, slightly compress the Print Head Adjustment Screw Spring and slide the Washer down; now pivot the Print Head Adjustment Screw upward so it is within the notch in the front of the Print Head Carriage (and the Washer and Spring are inside the Carriage, as shown in the second picture.

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Step 20. With a medium flat-blade screwdriver, turn the Print Head Adjustment Screw clockwise. (Don�’t let the screw head slip out of the notch in the Print Head Carriage.) Note that as the Screw is turned, the Print Head Assembly pivots about the Print Head Assembly Shaft.

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As the Print Head Adjustment Screw is driven clockwise, the Print Head Assembly Shaft Moves Into the Narrower Part of the Cutout

Print Head Shaft in Position, roughly centered laterally and within the middle curved slot.

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Step 21. Drive the Print Head Adjustment Screw in (clockwise) until the single raised bump on the Print Head just makes contact with the front end of the curved slot in the Print Head Carriage.

Step 22. Turn the screw out (counter-clockwise) exactly four and one-half turns. The (upper) single raised bump will be somewhere within the arc of the curved slot. (The Print Head will rotate on its shaft and the two lower raised bumps; ignore their positions as long as they are within their respective curved slots.)

Single Raised Bump at Front of Curved Slot

Single Raised Bump Somewhere Within Curved Slot

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Step 23. Insert and tighten the Torx head retaining screw.

Step 24. Re-install the ribbon; lower the Print Head Carriage until it clicks into place; re-install the printer cover. Connect the power cord, and turn the printer power on.

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5.17.2 Enter the Print Head Resistance

Before proceeding to the Final Adjustment, the resistance value of the replacement must be entered, since the resistance will affect the physical adjustment.

Step 1. From the Windows Start button or from the Printers or Printers and FAXes Control Panel, select the P330i printer. Right click to bring up Properties, select Device Settings, and select Tools / Properties. This will bring up the Tools window, as shown below.

Step 2. As shown above, in the �“Command to send to printer�” area, enter !R followed by a space followed by the resistance value of the replacement print head. (The resistance value will be shown on the replacement print head.) Then click the Execute button, then close the Tools window.

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5.17.3 Print Head Final Adjustment

Print Head final adjustment involves printing a card, inspecting it, and if necessary adjusting the Print Head Adjustment Screw. This sequence is repeated until the card print quality is acceptable.

Step 1. From the Windows Start button or from the Printers or Printers and FAXes Control Panel, select the P330i printer. Right click to bring up Properties, select Device Settings, and select Tools / Properties. This will bring up the Tools window, as shown below.

Step 2. If your printer has a color ribbon, enter IM in the �“Command to send to printer�” area, then click the Execute button.

A card like the following one will be printed.

Step 3. If your printer has a monochrome ribbon, enter IMB in the �“Command to send to printer�” area, then click the Execute button.

A gray (ideally) or moire-pattern card like the following one will be printed.

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Step 4. If the card print quality is acceptable, no additional adjustment is necessary.

If the card print quality is not acceptable, loosen the Torx head retaining screw and turn the Print Head Adjustment Screw one-quarter turn clockwise or counter-clockwise. Print another card.

a. If the print quality is better, turn the Print Head Adjustment Screw one-eighth turn in the same direction.

b. If the print quality is worse, turn the Print Head Adjustment Screw one-half turn in the other direction.

Step 5. Continue making smaller adjustments in either direction until the print quality is optimized. Then tighten the Torx head retaining screw.

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5.18 Replacing the LCD PCBA and/or LCD Cable Assembly

Step 1. Unplug the LCD Cable Assembly from the LCD PCBA. It may help to use a small flat-blade screwdriver to gently pry the cable connector out of the PCBA connector; if you do this be very careful to avoid damaging either connector or bending any pins.

Step 2. If replacing the LCD Cable Assembly, unplug it from J10 on the CPU PCBA.

Note �• To replace the LCD PCBA, detach the Top Cover and proceed as follows. If the LCD Cable Assembly is to be replaced, the Print Engine must be removed from the Lower Cover.

Unplug LCD Cable Assembly

LCD Cable Assembly

Plugs into J10 on CPU PCBA.

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Step 3. While lifting on the right-hand end of the LCD PCBA, use a small flat-blade screwdriver to gently pry the support clip to the right as shown below. Use just enough force to free the PCBA; too much force could damage or break the support clip.

Step 4. When installing the LCB PCBA, place it in position on the Top Cover and press to snap it into place.

Support Clip

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5.19 Replacing the Encoder Shroud and Exit Pressure Roller

Step 1. Remove the protective Encoder Shroud that protects the Magnetic Encoder Sensor and Head (if present). (Note that the Shroud is present whether or not there is a Magnetic Encoder.) Press the two removal tabs toward the rear of the printer, and lift the shroud by the lift tab.

Note �• This procedure covers replacing the Exit Pressure Roller only, not the complete Exit Pressure Roller Assembly (which also includes the Pivot Shaft and Spring). For instructions on replacing the complete Exit Pressure Roller Assembly, see the next procedure.The instructions given in this procedure also apply in general terms to the other Pressure Rollers.

Protective Shroud

Removal Tabs

Lift Tab

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Step 2. With the shroud removed, note the position of the Exit Pressure Roller.

Step 3. Lift the �“legs�” of the Exit Pressure Roller so they disengage from the Pivot Shaft.

Exit Pressure Roller

Exit Pressure Roller Assembly Pivot Shaft

Exit Pressure Roller Assembly Spring

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Step 4. Push the Exit Pressure Roller outward, then pull it the rest of the way out from under the Pressure Spring.

Step 5. When the Exit Pressure Roller has been removed, the Pressure Spring on the Pivot Shaft will look like the picture below.

Pressure Spring

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5.20 Replacing the Exit Pressure Roller Assembly

Note �• This procedure covers replacing the complete Exit Pressure Roller Assembly (which also includes the Pivot Shaft and Spring). For instructions on just replacing the Exit Pressure Roller, see the previous procedure.The instructions given in this procedure also apply in general terms to the other Pressure Roller Assemblies.

Important �• Do not even attempt this procedure if you do not have a thin spring hook tool like the one shown below (shown next to a Pressure Roller for size reference).

Note �• This procedure can also be perfomed with the Exit Pressure Roller already removed, as described in the previous procedure. The pictures and steps are so similar that differences will be readily apparent.

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Step 1. Note the location of the components of the Exit Pressure Roller Assembly shown in the following pictures.

Exit Pressure Roller

Exit Pressure Roller Assembly Pivot Shaft

Exit Pressure Roller Assembly Spring

Exit Pressure Roller

Pivot Shaft(See Next Picture)

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Step 2. Remove the screw that covers and secures the end of the Pivot Shaft, shown in the picture below.

Step 3. In the next picture, you can see the end of the Pivot Shaft after the securing screw has been removed.

Screw Head Securing End of Pivot Shaft

End of Pivot Shaft

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Step 4. With fine-point pliers, grab the Pivot Shaft between the legs of the Pressure Roller and slide it out of the Front Frame. It will be a snug fit; it may help to simultaneously rotate the Pivot Shaft and slide it out. (If the Pressure Roller has already been removed, grab the Pivot Shaft anywhere along its length and slide it out.)

Step 5. If you will be replacing the Exit Pressure Roller Assembly, be sure to keep the three parts as shown in the picture below.

Caution �• As the Pivot Shaft is freed from the bearing in the Front Frame, keep in mind that the Exit Pressure Roller Spring is under tension.

Pivot Shaft

Pressure Roller

Spring

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Step 6. Feed the Pivot Shaft through the hole in the Front Frame.

Step 7. As you feed the Pivot Shaft inward, place the Spring on the Shaft as shown below. The two ends and the large central portion all come from the bottom of the Spring, and the two �“legs�” of the Spring must be facing as shown.

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Step 8. Continue feeding the Pivot Shaft until it is engaged in its bearing on the Center Frame.

Step 9. With fine-nose pliers, bring the �“leg�” of the Spring over the Pivot Shaft as shown in the next two pictures. This may be somewhat easier if you slide the Spring away from the Center Frame about 1/8 inch (4 mm).

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Step 10. Reach in under the Pivot Shaft with the spring hook tool and grab the end of the spring. Then let go with the pliers.

Step 11. Pull the end of the Spring under the Pivot Shaft (again, this may be easier if you slide the spring away from the Center Frame). Continue pulling the end of the Spring around the Pivot Shaft until the Spring�’s �“leg�” can rest in the detent of the ridge as shown below. There is a small hole in the side of the frame next to the detent; the very end of the Spring�’s �“Leg�” should be pressed into that hole.

Detent of Ridge

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Step 12. Then follow the same steps with the end of the Spring closer to the Front Frame, as shown in the following series of pictures.

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Step 13. Then replace the Exit Pressure Roller as described in the previous procedure.

Lift End of Spring onto Flat Area

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5.21 Removing the Balls Retainer Plate

The Balls Retainer Plate is located below the Ribbon Supply Spindle. It covers the access hole for the pivot shaft of a pressure roller assembly. It also holds a pair of springs in place, which in turn provide spring pressure to a pair of Delrin Balls that precisely position the card within the card path.

Step 1. The Balls Retainer Plate is held in place below the ribbon supply spindle by a flat-head Phillips screw. Using a Number 0 Phillips screwdriver, remove the screw and remove the Balls Retainer Plate.

Important �• When the Balls Retainer Plate is removed, be careful to not lose the springs and/or balls that it holds in place.

Balls Retainer Plate

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Step 2. The next picture shows the Balls Retainer Plate removed.

Step 3. The following picture is a magnified view of the springs and Delrin Balls. Actual size of the Balls is 5 mm (about 1/5 inch).

Springs (Delrin Balls not visible)

Pivot Shaft Access

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5.22 Card Feeder Components

This section describes replacing various components of and associated with the Card Feeder. Some of these procedures involve detaching and disassembling the Card Feeder Assembly, others do not.

5.22.1 Replacing the Card Sensor Cable Assembly

The Card Sensor Cable Assembly can be replaced with or without disassembling the Card Feeder Assembly; it can even be replaced without detaching the Card Feeder Assembly from the Print Engine.

Step 1. The Card Sensor Cable Assembly in turn plugs into a Cable Assembly that goes to the I/O Daughterboard. Unplug the connector.

Step 2. The Card Sensor Cable Assembly snaps into a recess in the side of the Card Feeder Assembly frame, as shown in the picture below.

Card Sensor Cable Assembly

(Card FeederAssembly shown detached from the Print Engine)

Unplug this connector from the Cable Assembly that goes to the I/O Daughterboard.

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Step 3. To remove the Card Sensor Cable Assembly, hold the four wires close to the sensor and push up while lifting away from the Card Feeder frame, as shown in the next picture.

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5.22.2 Replacing the Card Feeder Drive Belt and/or Card Feeder Motor

The Card Feeder Drive Belt and/or Card Feeder Motor can be replaced with or without disassembling the Card Feeder Assembly; either or both can even be replaced without detaching the Card Feeder Assembly from the Print Engine; the procedure for detaching the Card Feeder Assembly is given in paragraph 5.24.3.

(The pictures in this section show the Card Feeder Assembly disassembled.)

Step 1. In the following picture, note the location of the push nut on the Roller Shaft.

(Card FeederAssembly shown detached from the Print Engine)

Card Feeder Drive Belt

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Step 2. With a small flat-blade screwdriver, gently pry the pushnut off the shaft.

Step 3. This will allow you to slip the Timing Belt off the Pulleys.

Push Nut

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After removing the Card Feeder Drive Belt, the Card Feeder Motor can be replaced.

Step 4. There is a very small E-Ring that secures the Feeder Pulley to the Motor shaft (see below). With a small flat-blade screwdriver, push this E-Ring around the shaft until the center of the E-Ring is at the flat of the shaft (this will give maximum access to the E-Ring). Then, with a very small flat-blade screwdriver, free the E-Ring from the groove of the Motor shaft.

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Step 5. With the E-Ring removed, lift the Feeder Pulley and two spacer washers from the Card Feeder Motor shaft.

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Step 6. Then remove three screws as shown below to free the Card Feeder Motor. (If the Card Feeder Assembly has not been disassembled, remove the Card Feeder Motor by reaching up through the open bottom of the Card Feeder Assembly.

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5.22.3 Detaching and Disassembling the Card Feeder Assembly

Step 1. The Card Feeder Assembly is attached to the Print Engine by two screws, as shown in the picture below.

Step 2. Unplug the spade lug on the green ground wire at the location shown in the next picture.

Remove This Screw on Front

Remove This Screw on Back

Detach Green Wire at the Spade Lug on This End

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Step 3. Slide a medium flat-blade screwdriver into the gap below the left side of the ESD Brush as shown in the picture below. Then turn the screwdriver clockwise to push the left side of the ESD brush upward, as shown in the next picture.

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Step 4. Lift the left end of the ESD Brush just enough to clear the protective lip of the frame.

Step 5. Gently bring the left end of the ESD Brush in front of the protective lip, so it is approximately in its original horizontal orientation.

Protective Lip

Caution �• Handle the ESD Brush carefully to avoid bending or otherwise damaging it.

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Step 6. Gently push the ESD Brush to the right, so the elongated hole at the right end can disengage from the post on the frame, and remove the ESD Brush.

Step 7. Remove four screws inside the counterbores as shown in the picture below.

Important �• If the ESD Brush appears damaged in any way, replace it.

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Step 8. Use a small flat-blade screwdriver to gently pry the two parts of the Card Feeder Assembly frame apart. (It will probably be necessary to go around the entire �“seam�” several times to gradually separate the parts.)

Step 9. With the Card Feeder Assembly Frame apart, the Card Feeder belt can be removed off its rollers (turning the rollers back and forth will make this somewhat easier). (Note that the picture also shows the Card Feeder Motor in place.) After the Card Feeder Belt is removed, the Card Feeder Rollers can be removed if desired. (If the Roller over the Card Feeder Motor is to be removed, remove the gear from its shaft.)

Card Feeder Belt

Card Feeder Rollers

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Step 10. Reassembling the Card Feeder Assembly is shown in the following series of pictures. First, hold the two sides of the Frame together as shown, and place the Feeder Gate Lever in position. Note that the Feeder Gate Lever must be placed so the hole in the �“arm�” fits over the raised pin on the frame.

Step 11. Place the Ruber Gate over the raised pins on the frame as shown in the next picture.

Feeder Gate Lever

Hole in Feeder Gate Lever fits over Raised Pin on Feeder Frame

Rubber Gate Fits Over Raised �“Pins�”

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Step 12. Place the Feeder Gate Plate in approximate position. Make sure the slot in the Feeder Gate Plate engages the raised pin on the Feeder Gate Lever, then press the Feeder Gate Plate inward on each side to snap it into the groove on each side of the frame.

Step 13. Replace the screws into the counterbores that were removed in step 7.

Step 14. Reinstall the ESD Brush, or install a new one.

Feeder Gate Plate Make Sure Slot in Feeder Gate Plate Engages Pin on Feeder Gate Lever, then Snap Feeder Gate Plate into place.

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5.23 Power / Filter Components

Step 1. The Power / Filter Components are mounted on the Connector Plate, and are shown in the picture below. The two �“unused�” lugs on the left side of the Power Switch connect to the Power Supply.

Power Switch

AC Power Connector

EMI Filter

EMI Ferrite Cable Assembly

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5.24 Removing the CPU PCBA

The CPU PCBA can be removed whether you remove the Connector Plate (as described in section 5.4) or not. If you do not remove the Connector Plate, be careful to avoid damaging components on the Connector Plate or wires to/from it.

Step 1. The CPU PCBA rests on slides below the Rear Plate, as shown below. Note that the CPU PCBA is not secured by any mounting hardware; it is simply held in place by the wires to/from it (and, when the Print Engine is in place on the Lower Cover, by the Lower Cover itself).

Step 2. Slide the CPU PCBA straight out, carefully unplugging connectors as you slide the board out, as shown in the next three pictures.

CPU PCBA

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This Cable goes to the LCD Screen

Use a Small Flat-blade Screwdriver to Remove the Restraining Clip on this connector

RFID Cable

To Card Feeder Sensor

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Step 3. The next figure shows for reference the primary functions of the various connectors on the CPU PCBA.

Step 4. When sliding the CPU PCBA back into position, make sure it is between the guides on either side. Re-attach connectors as you slide the board in.

J11(Ribbon RFID)

J7(Smart Card)

J1(Mag Encoder Head)

J8(Auxiliary RS-232;factory use only)

J6(USB Port)

J12(+24 VDC Input from

Power Supply)

J3(Out of Cards Sensor)

J4(Not Used)

J10(LCD Panel)

J9(Print Head, Head Lock,

Head Temp. Sensor)

J13(Motors and Sensors -

Connects to I/O Daughterboard)

J2(Mates with Ethernet

Extension Board)

Slide CPU PCBA Between Guides On Either Side

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5.25 Removing the I/O Daughterboard

Step 1. When the Rear Plate is removed (see section 5.7), the I/O Daughterboard is visible. It is directly above the CPU PCBA, but it is hidden (and held in position) by the very bottom of the Rear Plate.

I/O Daughterboard CPU PCBA (Shown with Ethernet Adapter)

I/O Daughterboard

(Rear Plate Removed)

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Step 2. Unplug as many of the connectors to the I/O Daughterboard as you can reach before starting to slide it out; unplug other connectors as they become accessible.

Step 3. The following figure shows the connectors on the I/O Daughterboard.

J04 J09J05J01J08J06

J07 J02 J03

Color Sensor

1

Color Sensor

2

(To J13 on CPU PCBA)

Position Bracket Sensor

Synchro Film

Sensor

Stepper Motor

DC Motor

DC Motor

DC Motor

Synchro Card

Sensor

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5.26 Removing the RFID Cable

The RFID Cable connects the RFID PCBA to the CPU PCBA.

RFID Cable

RFID PCBA

CPU PCBA

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Step 1. Use a small flat-blade screwdriver to remove the restraining clip on the connector at each end of the RFID Cable. Open the Aluminum �“Cable Ties�” that hold the RFID Cable in place on the Center Frame. Remove the RFID Cable.

Retaining Clip (on connector at each end of RFID Cable)

Aluminum �“Cable Ties�”

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5.27 Replacing the Ribbon O-Ring Drive Belt

Step 1. Remove the Ribbon O-Ring Drive Belt by slipping it off the Ribbon Motor Pulley and the Ribbon Pulley.

Step 2. To install the Ribbon O-Ring Drive Belt, seat it in the groove of the Ribbon Pulley, pass it around both sides of the Upper Cam, and roll it into the groove of the Ribbon Motor Pulley.

Ribbon O-Ring Drive Belt

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Important �• Make sure that the Ribbon O-Ring Drive Belt passes on the inside of the shield, as shown in the picture below.

CORRECT -- Ribbon O-Ring Drive Belt Inside Shield

INCORRECT -- Ribbon O-Ring Drive Belt Outside Shield

Ribbon Pulley

Ribbon Motor Pulley

Upper Cam

Shield

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5.28 Replacing the Ribbon Pulley Assembly

Step 1. The Ribbon Pulley Assembly Shaft is secured by a screw in the middle of the Ribbon Take-Up Spindle.

Ribbon Pulley Assembly

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Step 2. While holding the Ribbon Take-Up Spindle, use a No. 1 Phillips screwdriver to remove the screw attaching the Ribbon Take-Up Spindle to the Ribbon Pulley Assembly Shaft, and slide the Spindle off the shaft (it may be a snug fit).

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Step 3. Slide the Ribbon Pulley Assembly (which includes the shaft) out of the bearing in the center frame.

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5.29 Removing the Ribbon Motor Pulley and the Ribbon Motor

Step 1. The Ribbon Motor Pulley is secured to the Ribbon Motor Shaft with a setscrew. Use a 1.5 mm hex key to loosen the setscrew, and remove the Ribbon Motor Pulley.

Ribbon Motor Pulley

Ribbon Motor Shaft

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Step 2. Cut the Cable Tie holding the bundle of Cables at the I/O Daughterboard

Step 3. Unplug the Connector for the Ribbon Motor from the I/O Daughterboard.

Step 4. The Ribbon Motor is held in position by three Torx T10 screws. Remove them.

Cut This Cable Tie

These wires go to the Ribbon Motor

Ribbon Motor Mounting Screws

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Step 5. Now reach up into the lower cavity between the Center Frame and the Front Frame and remove the Ribbon Motor.

5.30 Replacing the Stepper Motor Drive Belt

The Stepper Motor Drive Belt should be very snug so it will not slip off the Stepper Motor Drive Pulley during printer operation. Also, if the belt is too loose, vertical lines may appear on cards printed.

A limited amount of tensioning adjustment can be made as follows.

Step 1. Loosen the three 5.5 mm hex nuts securing the Stepper Motor to its Mounting Plate.

Step 2. Reach up into the space between the Front Frame and the Center Frame, and move the Stepper Motor (the holes in the Center Frame are slightly enlarged, permitting some movement).

Step 3. Tighten the three 5.5 mm hex nuts.

Step 4. When pressing with a finger against the mid-point of the Stepper Motor Drive Belt, there should be less than 1/8 inch (3 mm) deflection.

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5.31 Removing the Stepper Motor

Step 1. Remove the Stepper Motor Drive Belt.

Stepper Motor Drive Belt

Stepper Motor Drive Pulley

Stepper Motor Mounting Plate

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Step 2. Remove the Stepper Motor Pulley. (If the �“old�” Stepper Motor will be re-installed and there is no apparent damage to the Stepper Motor Pulley, the Stepper Motor Pulley does not need to be removed.)

Step 3. Remove the three 5.5 mm hex nuts securing the Stepper Motor to its Mounting Plate.

Step 4. Reach up into the space between the Front Frame and the Center Frame, and remove the Stepper Motor.

Stepper Motor Drive Belt

Stepper Motor Mounting Plate

5.5 mm Hex Nuts

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5.32 Removing the RFID PCBA

Step 1. If the RFID Cable is still plugged into the RFID PCBA, use a small flat-blade screwdriver or fine-point plierst remove the retaining clip on the RFID Cable connector, as shown in the picture below. Unplug the RFID Cable.

Step 2. With a Number 1 Philips screwdriver, remove two screws as shown in the next picture.

Retaining Clip

RFID Cable

Note that this pin on the Center Frame passes through a hole on the RFID PCBA.

RFID PCBA Mounting Screws

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Step 3. Remove the RFID PCBA.

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5.33 Replacing the Ribbon Color Sensor

The Ribbon Color Sensor is located under the Ribbon Supply Spindle, as shown below. Note that the Ribbon Color Sensor cannot be removed until items have been removed from the Center Frame through the RFID PCBA.

Ribbon Color Sensor

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Step 1. See the two pictures below. With a small flat-blade screwdriver, gently pry up toward the front of the Ribbon Color Sensor until it pops free of the Print Engine.

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Step 2. The wires from the Ribbon Color Sensor are held in place on the Center Frame by two aluminum �“Cable Ties,�” as shown in the next picture. The wires are also routed through two guides, and secured in the guides by glue.

Step 3. Open the �“Cable Ties�”. Scrape the glue off the surface of the guides, being careful to avoid nicking or crimping the wires. Free the wires from the guides.

Step 4. Unplug the wires from the Ribbon Color Sensor from the I/O Daughterboard. The connectors are behind the Ribbon Lift Cam.

Aluminum �“Cable Ties�”

Guides with glue holding the wires in place

Ribbon Lift Cam

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Step 5. Unplug the wires from the Ribbon Color Sensor from the I/O Daughterboard. The connectors are behind the Ribbon Lift Cam.

Step 6. The Ribbon Color Sensor can now be removed by passing its wires through the rectangular cutout in the Center Frame.

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5.34 Replacing the Card Sensor Cable Assembly

Step 1. The Card Sensor is located just inside the support for the Print Head Carriage, as shown in the picture below. The picture also shows the location of the Mounting Screw; the Mounting Screw location is also shown in the following picture.

.

Step 2. Looking up from under the Print Engine, note the routing of the wires in the Card Sensor Cable Assembly. When replacing or re-installing the Card Sensor, the wires must be routed the same way. If it has not already been done, unplug the Card Sensor Cable Assembly from the I/O Daughterboard.

The picture also shows the location of the Card Sensor Mounting Screw.

Important �• The Torx T10 driver used in this procedure must have a blade at least 4 inches (100 mm) long to reach through the access hole to the Card Sensor Mounting Screw.

Card Sensor

Card Sensor Mounting Screw

2. White and Black Wires come out on this side, then bend over the Card Sensor and route over the Red and Green Wires.

3. All Four Wires then pass �“under�” this post.

1. Red and Green Wires come out on this side, and stay �“below�” the White and Black Wires.

Card Sensor Mounting Screw

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Step 3. See the following picture. If necessary, turn the Print Head Lift Cam and deflect the belt as shown to clear the Card Sensor Mounting Screw Access Hole. With a long-bladed Torx T10 driver, go straight through the Access Hole until the Torx head engages the head of the Mounting Screw. Remove the Mounting Screw (the Card Sensor will remain in place).

Step 4. The following picture (from underneath) shows the Torx T10 driver bit in the Card Sensor Mounting Screw.

Card Sensor Mounting Screw Access Hole

Print Head Lift Cam

Card Sensor Mounting Screw

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Step 5. Using a Number 0 Phillips screwdriver, remove the Balls Retainer Plate and the springs and Delrin Balls it holds in place (more detailed information is given in section 5.21). Be careful to not lose the springs and/or balls.

Step 6. The next picture shows the Balls Retainer Plate, springs, and balls removed. The Card Sensor Cable Assembly is barely visible.

Balls Retainer Plate

Card Sensor Cable Assembly

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Step 7. Using a small flat-blade screwdriver, gently pry the Card Sensor toward the back of the Print Engine, as shown in the next picture. Be very careful to avoid crimping or breaking any of the wires. Pushing the wires upward (from underneath) will make prying the Card Sensor easier.

Step 8. The following picture shows the Card Sensor pried toward the back of the Print Engine.

Use Small Flat-Blade Screwdriver Here...

... To Pry the Card Sensor This Way.

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Step 9. Use a small flat-blade screwdriver to gently pry the Card Sensor upward, while rocking it back and forth until the Card Sensor clears the card path, as shown in the next picture.

Step 10. Lift the Card Sensor free of the Print Engine. Be careful to avoid damaging any of the wires. Continue lifting until the connector clears the hole in the card path.

Rock the Card Sensor back and forth while gently lifting / prying it upward.

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5.35 Removing the Print Head Cable Assembly

The Print Head Cable Assembly includes the Print Head Fan and the Ribbon Sync Sensor.

Step 1. If you have not already done so, remove the Print Head Assembly from the Printhead Bracket Assembly (steps are given in detail in section 5.19, but are repeated here in simplified form for convenience).

a. With a medium flat-blade screwdriver, remove the Print Head Adjustment Screw (and its washer and spring).

Caution �• During this procedure, be careful to avoid touching the Print Head Elements.

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b. With a Torx T10 driver, remove the retaining screw on the front side of the Print Head Carriage. (You may need to use a flat-blade screwdriver on the other end of the Print Head Assembly Shaft to remove the retaining screw.)

c. Remove the Print Head Assembly Shaft.

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d. Unplug the Print Head Cable (you may need to use a small flat-blade screwdriver to pry the plug apart from the connector). Disconnect the Ground Lug Spade Connector.

Print Head Cable Connector

Ground Lug Spade Connector

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e. Rock the Print Head Assembly back and forth while gently separating the sides of the Print Head Carriage until the Print Head Assembly can be slid free of the Print Head Carriage.

Step 2. Cut the Cable Tie and remove the screw that holds the Ribbon Sync Sensor in place, as shown in the picture below.

Cable Tie

Screw Attaching Ribbon Sync Sensor

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Step 3. Push the Print Head Cable Connector, the Ground Lug, and the Ribbon Sync Sensor out of the way so you can see the four latches (two on each side) that hold the Print Head Fan in place, as shown in the next two pictures.

Fan Motor Attachment Latches

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Step 4. Through the cutouts in the Print Head Bracket, note the four Fan Motor �“mounting holes�” (even though they are not used to mount the Fan Motor).

Step 5. While in turn pressing the four Fan Motor Attachment Latches away from the Fan Motor, use a Number 2 Phillips Screwdriver (the blade is too big to go through the Fan Motor Mounting Holes) to press against the Fan Motor Mounting Holes). You may need to go around the four latches and holes more than once, but eventually the Fan Motor will be freed by all four Latches.

Fan Motor �“Mounting Holes�”

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Step 6. Then the Fan Motor can be pulled clear of the Attachment Latches.

Step 7. Remove two screws, shown in the next picture, that attach the Print Head Pivot Bracket to the Print Head Carriage.

Remove These Screws

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Step 8. Press and hold the Print Head Carriage Latch; twist and gently pull the Print Head Pivot Bracket until it separates from the Print Head Carriage.

Step 9. Work the Print Head Cable Assembly through the cut-outs in the Print Head Carriage. Bend the cable so the connector is roughly parallel to the cable to get it through the cut-outs.

1. Press and Hold Print Head Carriage Latch

2. Separate Head Pivot Bracket from the Print Head Carriage

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5.36 Removing the Print Head Lift Motor

Step 1. The I/O Daughterboard and the Print Head Lift Cam must be removed to access the Print Head Lift Motor Mounting Screws. With a Number 0 Phillips screwdriver, remove three Mounting Screws as shown in the picture below.

Step 2. Reach up into the space between the Front Frame and the Center Frame, and remove the Print Head Lift Motor.

Print Head Lift Motor Mounting Screws

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5.37 Separating the Front Frame from the Center Frame

There are only a limited number of parts that would require separating the Front Frame from the Center Frame. These are:

�• The Clean Drive Roller

�• The Card Drive Roller

�• The Platen Drive Roller

�• The Exit Drive Roller

�• The three Transport Rollers past the Platen

�• The Card Pressure Plate attached to the Front Frame

�• The Magnetic Encoder Station Roller attached to the Front Frame (Roller is present whether the printer includes the Magnetic Stripe Encoder Option or not)

Separating the Front Frame from the Center Frame constitutes a significant dismantling of the printer! The suggested procedure follows; procedures that are described in greater detail have references to the appropriate sectiion.

Step 1. Remove the Top Cover (5.2)

Step 2. Remove the LCD PCBA (5.18)

Step 3. Remove the Print Engine from the Lower Cover (5.3)

Step 4. Remove the Card Feeder Assembly (5.22.3)

Step 5. Remove the Connector Plate (5.4)

Step 6. Remove the CPU PCBA (5.24)

Step 7. Remove the Power Supply Cover (5.5)

Step 8. Remove the Power Supply (5.6)

Step 9. Remove the Rear Plate (5.7)

Step 10. Remove the Cam Lever (5.8)

Step 11. Remove the Platen Inertia Roller (5.9)

Step 12. Remove the I/O Daughterboard (5.25)

Step 13. Remove the Printhead Pressure Spring (5.10)

Step 14. Remove the Film/Bracket Sensor PCBA (5.11)

Step 15. Remove the Pressure Spring Plate (5.12)

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Step 16. Remove the Cam Arm Follower Assembly (5.13)

Step 17. Remove the Clutch Assembly (5.14)

Step 18. Remove the Print Head / Carriage Assembly (5.15)

Step 19. Remove the Ribbon Color Sensor (5.32)

Step 20. Remove the Smart Card Contact PCBA, if present

Step 21. Remove the Card Sensor Cable Assembly (5.33)

Step 22. Remove the Encoder Shroud and Exit Pressure Roller (5.19); remove all other Pressure Rollers using the same procedure.

Step 23. Remove the Balls Retainer Plate, Springs, and Balls (5.21)

Step 24. Remove Exit Pressure Roller Assembly (5.20); remove all other Pressure Roller Assemblies using the same procedure.

Step 25. Remove the Stepper Motor Drive Belt (5.30.1)

Step 26. Remove the ESD Brush at the Card Exit. Use a soldering iron to melt the flattened plastic posts and gently pry off the push nuts. When replacing, use the soldering iron to flatten the plastic posts to secure the push nuts.

Step 27. Remove the items shown in the next two pictures in the order shown. Do not remove the Pulleys and Push Nut specified in the second picture.

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1. Stepper Motor Drive Belt 2. Pulley

3. Timing Belt4. Front Pulley5. Timing Belt

6. Push Nut, then Rear Pulley

7. Pulley

8. Timing Belt 9. Pulley

11. Timing Belt

10. Push Nut

13. Position Front Frame/Center Frame with Center Frame Flat on work surface, then remove 7 Torx T10 Screws at bottom of these bores and lift the Front Frame straight up off the Center Frame.

(Do NOT remove Front Pulley, Push Nut, and Rear Pulley)

12. Pulley

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Step 28. Lift the Front Frame straight up off the Center Frame, and note the orientation of the Rollers shown in the next picture. The Rollers simply slip into their bearings in the Center Frame; they are held in place by corresponding bearings in the Front Frame when the Front Frame is attached.

Step 29. The Card Pressure Plate is held in position (inside the Front Frame) by two springs, which provice slight pressure inward to the card in the card path. The Card Bias Guide limits the travel of the Card Pressure Plate

Exit Drive Roller

Clean Drive Roller

Platen Drive Roller

Card Drive Roller

Card Pressure Plate

Magnetic Encoder Station Roller

Card Bias Guide

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Step 30. To remove the Card Pressure Plate, detach the Springs, then remove the Card Bias Plate (it is held by 3 Torx T10 screws).

Step 31. To remove the Magnetic Encoder Station Roller, remove (in order) the outer Pulley, Push Nut, and inner Pulley shown in the picture below. Then slide the Magnetic Encoder Station Roller on its shaft through the bearing in the Front Frame.

Card Pressure Plate Springs

Card Bias GuideMagnetic Encoder Station Roller

1. Outer Pulley 2. Push Nut 3. Inner Pulley

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5.38 Magnetic Stripe Encoder Option

The Magnetic Stripe Encoder Option consists of a Magnetic Encoder Sensor and Magnetic Encoding Head. These can be located below the card path (�“regular�”) or above the card path (�“reverse encoding�”). The instructions presented here are general enough that they can be applied to either.

Step 1. Remove the protective shroud that protects the Magnetic Encoder Sensor and Head. Press the two removal tabs toward the rear of the printer, and lift the shroud by the lift tab.

Protective Shroud

Removal Tabs

Lift Tab

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Step 2. When the shroud is removed, the Magnetic Encoder Sensor and Magnetic Encoding Head are visible, as shown below.

Step 3. The Magnetic Encoding Head and the Magnetic Encoder Sensor are attached with Torx T10 screws.

Step 4. If the Rear Plate has not been removed, remove it (see section 5.7).

Step 5. The wires for either type of Encoding Head and Encoder Sensor pass through a rectangular cut-out in the Center Frame.

Regular:

Reverse:Magnetic Encoder Sensor

Magnetic Encoding Head

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5.39 Smart Card Options

There are four different �“Smart Card�” Options available for the P330i. These can be summarized as follows:

�“Contact Smart Card�” options use a Solenoid below the Card Path and a Contact PCBA above the Card Path. The Solenoid presses the card upward so the Contact PCBA�’s pins make electrical contact with the appropriate pads on the smart card.

For the �“Contact Station�” version, wires from the Contact PCBA connect to a �“Smart Solenoid PCBA�” which mounts on the Connector Plate and includes a db9 connector for an external serial interface.For the �“GEM PLUS�” version, wires from the Contact PCBA (which includes logic for the GEM PLUS version) connect to the CPU PCBA. Additional logic circuitry on the CPU PCBA allows passing �“Smart Card�” signals via the USB connector, along with the normal functions of the USB interface.

�“Contactless Smart Card�” options use either of two short-range radio technologies (�“HID�” or �“MiFARE�”) to communicate with the smart card. One component is a combination antenna and PCBA for the specific technology; this is mounted below the Card Path. There is also an Auxiliary PCBA, which is mounted on the bottom of the Center Frame, which provides an interface between the Antenna/PCBA and the CPU PCBA.

Removal of most of these items is readily apparent.

5.40 Solenoid Assembly

If your printer includes a Contact Smart Card Option, it will include a Solenoid Assembly, which will be apparent by the two mounting screws shown in the following picture.

Solenoid AssemblyMounting Screws

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Step 1. With a Number 0 Phillips screwdriver, remove the two Solenoid Assembly Mounting Screws.

Step 2. Reach up into the space between the Front Frame and the Center Frame, and remove the Solenoid Assembly.

Solenoid AssemblyMounting Holes

Solenoid Assembly

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6Preventive Maintenance

Introduction

The Model P330i Printer is designed for operation with minimal maintenance. If the printer is cleaned on a regular basis, as described in this section, it should provide trouble-free operation.

There are no periodic measurements, adjustments, or other preventive maintenance procedures required in normal usage.

Cleaning the Printer

Clean your P330i Printer using Pre-Saturated Cleaning Cards provided. The regular use of these cards will clean and maintain important parts of your printer that cannot be reached, including the Print Head, Transport Rollers, and optional Magnetic Encoder Station.

Caution �• PROTECT YOUR FACTORY WARRANTY!The recommended cleaning procedures must be performed to maintain your factory warranty. Other than the recommended cleaning procedures described in this manual, allow only Zebra authorized technicians to service the P330i Printer.

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Preventive MaintenanceCleaning the Printer

When to Clean the Printer

Clean the printer when either of the following occurs:

�• When the LCD Panel displays the message CLEAN PRINTER.

�• Approximately every 1000 cards when using 5-panel color ribbon, or every 5000 cards when using a monochrome ribbon.

How to Clean the Printer

Step 1. Leave the Printer power on, or turn it on if it was off.

Step 2. Initiate the cleaning process by either of the following methods:

�• At the printer, press and hold the panel button for several seconds, until the LCD Panel displays the message REMOVE RIBBON THEN CLOSE HEAD.

�• From the computer, enter the P330i Printer Tools software, and click on the CLEAN button. The LCD Panel will display the message REMOVE RIBBON THEN CLOSE HEAD.

Step 3. Open the Main Cover, release the Print Head Carriage, and remove the ribbon. Then close the Print Head Carriage. (For details, see Chapter 2.) The LCD Panel will display the message EMPTY FEEDER & PRESS BUTTON.

Step 4. Open the Card Feeder Cover and remove cards from the Card Feeder. The last card is difficult to remove; leave it in place. Press the Panel Button on the front of the printer. The card remaining in the feeder will be ejected. The LCD Panel will then display the message LOAD CLEANING CARD IN FEEDER.

Step 5. Place a pre-saturated Cleaning Card into the Card Feeder. The Cleaning Card will automatically feed into the printer and the cleaning process will start (there is a several second delay after the Cleaning Card feeds before the cleaning movement starts). While the cleaning process is underway, the LCD Panel will display the message CLEANING PRINTER.

Note �• This cleaning procedure uses two cleaning cards. One cleaning card is the size of a regular plastic card, and is referred to as the �“cleaning card.�” The other is elongated, with a wider section at one end; it is referred to as the �“long cleaning card.�”

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Step 6. At the conclusion of this part of the cleaning process, the Cleaning Card will be ejected, and the LCD Panel will display the message PRESS BUTTON TO CONTINUE.

Step 7. After the user presses the panel button, the LCD Panel will display the message FEED LONG CLEANING CARD IN EXIT. Insert the long end of the long cleaning card into the card exit (directly above the Output Hopper). If the user inserts a �“regular�” cleaning card into the card exit, the LCD Panel will display the message INVALID CARD, PRESS BUTTON until the user presses the panel button and inserts the long cleaning card into the card exit.

Step 8. The long cleaning card will automatically feed into the printer and the printing process will continue. The LCD Panel will again display the message CLEANING PRINTER.

Step 9. When the cleaning process is completed, the long cleaning card will be ejected and the LCD Panel will display the message READY, indicating that the printer is ready to resume normal printing operations.

Step 10. Discard both cleaning cards after a single use.

Note �• If the user does nothing at this point (i.e., does not insert the long cleaning card), after a timeout the LCD Panel display will change to CLEAN PRINTER. The printer will be able to print, but the LCD Panel will continue to display CLEAN PRINTER.

This limited cleaning does not do a thorough cleaning, but may be performed if no �“long cleaning cards�” are available.

To restore the display to READY, you will need to perform a complete cleaning process, using both short and long cleaning cards, from step 2 above through step 9 below.

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Preventive MaintenanceCleaning the Print Head

Cleaning the Print Head

A cleaning using the Cleaning Cards usually suffices. However, a separate Print Head cleaning can remove more stubborn deposits when print anomalies persist. To avoid deposits, only use foam-tipped swabs.

Step 1. Place the printer power switch in the OFF ( O ) position.

Step 2. Open the Main Cover, release the Print Head Carriage, and remove the ribbon. Leave the Print Head Carriage in its raised position. (For details, see Chapter 2.)

Step 3. Clean Print Head by moving an alcohol-moistened swab tip side-to-side across the Print Head elements. Only use moderate force. To re-order swabs, please refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer.

Step 4. The swabs can also be used in a similar manner to clean the optional magnetic encoding head.

Note �• Do not use previously used cleaning cards.

Caution �• Never use a sharp object or any abrasive to scrape deposits from the print head. Permanent damage to the print head will result.

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Card Cleaning Cartridge

Your P330i Printer includes a Card Cleaning Cartridge. This item cleans the cards entering the printer through the card feeder. To ensure print quality, the cleaning roller requires periodic replacement. New cleaning rollers are included with each ribbon or may be purchased separately. (To reorder, please refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer.)

Installation of the Card Cleaning Cartridge is described in Chapter 2 and is not repeated in detail here.

When to Replace the Cleaning Roller

Replace the Cleaning Roller each time you install a new ribbon.

How To Replace the Cleaning Roller

Step 1. Open the main cover and locate the Card Cleaning Cartridge.

Step 2. Gently remove the Card Cleaning Cartridge. Lift the �“handle�” end, and then pull it away from the printer.

Hot Surface �• Do not touch the print head if the printer has been in service in the last 10 minutes. It could be very hot and cause a burn.

Note �• Before replacing the Card Cleaning Cartridge or its cleaning roller, clean the Printer using the Cleaning Cards as described earlier in this chapter.

Card Cleaning Cartridge

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Preventive MaintenanceCard Cleaning Cartridge

Step 3. Remove the cleaning roller from the Card Cleaning Cartridge and discard.

Step 4. Install new cleaning roller into the Card Cleaning Cartridge. To avoid contamination, always hold the cleaning roller by the ends. (For replacement cleaning rollers, please refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer.)

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Step 5. Peel protective wrapper from the cleaning roller by gently pulling on the tape.

Step 6. Replace the Card Cleaning Cartridge into the printer:

Step 7. Close the printer main cover.

Note �• DO NOT touch the adhesive roller surface that contacts the cards.

Card Cleaning Cartridge in final position

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APPENDIX A

Software

Introduction

This section lists software commands to initiate, check, or adjust various system functions, parameters, and variables.

Detailed information on the use of these commands are given in the EPCL Programmer�’s Guide, Zebra document 980415-001, which can be downloaded from the Zebra Card Printer Solutions website at http://www.zebracard.com.

Entering Software Commands

Step 1. From the Windows Start menu or from the Windows Control Panel, navigate to Printer Properties. This will bring up a display like the one below

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SoftwareEntering Software Commands

Step 2. Click on the Device Settings tab, then select Tools, then click on the Properties block that will appear, as shown below.

Step 3. This brings up the Tools display. Type the desired command in the �“Command to send to printer�” window, and click the Execute button.

Type the command here ...

... then click the Execute button.

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Software Commands

The following listing includes the software commands that apply to the P330i Printer. Complete information about each command, including description, syntax, and parameters, is presented in the EPCL Programmer�’s Guide, Zebra document 980415-001, which can be downloaded from the Zebra Card Printer Solutions website at http://www.zebracard.com.

A - - - - - - - - - - Print Test CardATM - - - - - - - Set Card Feeding Mode&B- - - - - - - - - Load Magnetic Encoder Track Write Buffer +BS - - - - - - - - Set Black SynchroB/vB - - - - - - - Write Bar Code&C- - - - - - - - - Set Coercivity+C - - - - - - - - - Adjusts Monochrome Intensity+$C - - - - - - - - Adjust Color Contrast!CC - - - - - - - - Get Number of Cards Printed%CDER - - - - - Get Magnetic Encoder Read Settings&CDER - - - - - Set Magnetic Encoder Track Read Encode Parameters&CDEW- - - - - Set Magnetic Encoder Track Write Encode Parameters+CDOTS - - - - Image Print Quality Compensation Factor+CH- - - - - - - - Adjust Hologram IntensityCHECK - - - - - Return ChecksumCLEAN - - - - - Set Cleaning Card Sequence%CLN - - - - - - Check Due-for-Cleaning ParametersCLNCARD - - - Set Cleaning Parameters+CV- - - - - - - - Adjust Clear Varnish IntensityC/vC - - - - - - - Write Box (Monochrome)!D - - - - - - - - - Move Print Head Down&D - - - - - - - - Change Track DensityD/vD - - - - - - - Draw Diagonal Line (Monochrome/Overlay)E - - - - - - - - - - Retransmit Last Response&E- - - - - - - - - Write Single Track&E* - - - - - - - - Write Track Buffers+EC - - - - - - - - End of Print$F - - - - - - - - - Clear Color Image Buffers!FF- - - - - - - - - Set Ribbon Color Sequence$FP - - - - - - - - Clear Specified Bit-MapsFS - - - - - - - - - Control Use of Card Feed SensorF/vF - - - - - - - - Clear Monochrome Image BuffersGS - - - - - - - - - Download Color GraphicG/vG - - - - - - - Initialize Monochrome Graphic (B/W)%HEAD - - - - - Get Print Head Serial NumberI - - - - - - - - - - Print Monochrome Panel

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IH - - - - - - - - - Print Hologram OverlayIM - - - - - - - - - Print Color Test CardIMB - - - - - - - - Print Gray Test CardIS- - - - - - - - - - Print Card Panel+ISC - - - - - - - Set Smart Card Serial Port Data Rate+ISC2- - - - - - - Set Smart Card Serial Port Data Rate (Advanced)ISERIES - - - - - i-Series Printer TestIV - - - - - - - - - Print Clear VarnishJ - - - - - - - - - - Print Multiple Monochrome Cards!L - - - - - - - - - Check Status of Printer Sensors $L - - - - - - - - - Draw a Horizontal Line/Rectangle in a Color Buffer&L- - - - - - - - - Read Single Track+$L - - - - - - - - Adjust Specified Color Intensity$LD - - - - - - - - Initialize a Color Buffer to a Specified Intensity Level L/vL- - - - - - - - Draw Horizontal Line (Monochrome/Overlay)!M - - - - - - - - - Move Print Head UpMB - - - - - - - - Return Card To Card FeederMC - - - - - - - - Clear Media PathMCL - - - - - - - Move ContactlessME - - - - - - - - Exit Card To Output HopperMI - - - - - - - - - Move Card Into Print Ready PositionMIB - - - - - - - - Move Card Back To Print Ready PositionMM - - - - - - - - Move Card Through PrinterM/m- - - - - - - - Multiple CommandMO - - - - - - - - Move Card To Output HopperMR - - - - - - - - Check for Card PresenceMS- - - - - - - - - Move Card To Smart Card Programmer&N - - - - - - - - Select Magnetic Encoding Standard!NL - - - - - - - - Get Printer Impression and Error Counters+O - - - - - - - - - Print Offset X-Axis+OCL- - - - - - - Offset Contactless+OS - - - - - - - - Smart Card X-axis OffsetO/vO - - - - - - - Load Single Line Bit-map (Monochrome)+OY- - - - - - - - Print Offset Y-axis!P- - - - - - - - - - Move Card Forward 8 cm+PRF - - - - - - - Pre-Feed a Card Close to the Print AreaPS - - - - - - - - - Download Color Image BufferP/vP - - - - - - - - Draw Single Dot (Monochrome/Overlay)R - - - - - - - - - - Reset!R - - - - - - - - - Print Head Resistance&R- - - - - - - - - Reset Magnetic Encoder>R - - - - - - - - - Read Data From Smart Card Serial Interface

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>RB - - - - - - - - Read Data From Smart Card Serial Interface in ASCII hex Form>RG- - - - - - - - Contact Internal Gemplus Smart Card Read Command!RIBBON - - - - Get ribbon type installed!RIBPN - - - - - Get ribbon part number!RIBLEN - - - - Get number of remaining panels on ribbon+RO- - - - - - - - X-Axis Offset, Relative+ROY - - - - - - Y-Axis Offet, Relative!SA - - - - - - - - Self Adjust!SAN - - - - - - - Perform pre-calibration baseline testingSDATA- - - - - - Force immediate save of parameters%SERIE - - - - - Get Printer Serial Number&SVM - - - - - - Disable/Enable Magnetic Encoding Verifications&T- - - - - - - - - Magnetic Encoder Card EjectT/vT- - - - - - - - Draw Text (Monochrome/Overlay)V - - - - - - - - - - Check Printer Type/Version!V - - - - - - - - - Return Operational Parameter+V - - - - - - - - - Black Print Speed!W - - - - - - - - - Move Card Backward 8 cm&W - - - - - - - - Change Encoding Direction>W - - - - - - - - Write Data To Smart Card Serial Port>WB - - - - - - - Write Data Formatted in ASCII HEX To Smart Card Serial Port>WG - - - - - - - Contact Internal Gemplus Smart Card Write Command!X - - - - - - - - - Check Command Initiator+X - - - - - - - - - Change Command Initiation Character!Z - - - - - - - - - Re-Synchronize CardZ/vZ- - - - - - - - Load Bit-map (Monochrome).- - - - - - - - - - - Clear Error Status Lines

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APPENDIX B

P330i Model Numbers

Specific model numbers include identifiers that specify options using the following lettering conventions:

Part Number Description

P 3 3 0 i - _ _ _ _ _ - _ _ _Base Printer

P330i Color Card Printer

_ _ _ _ _ - 0 _ _ _ _ - _ _ __ _ _ _ _ - B _ _ _ _ - _ _ __ _ _ _ _ - C _ _ _ _ - _ _ __ _ _ _ _ - D _ _ _ _ - _ _ __ _ _ _ _ - E _ _ _ _ - _ _ __ _ _ _ _ - F _ _ _ _ - _ _ __ _ _ _ _ - H _ _ _ _ - _ _ _

Smart Card OptionsNoneContact EncoderContact encoder & HID iCLASS contactlessContact encoder & MIFARE contactlessContact stationHID iCLASS contactlessMIFARE contactless

_ _ _ _ _ - _ 0 _ _ _ - _ _ __ _ _ _ _ - _ M _ _ _ - _ _ _

Magnetic EncoderNoneYes (select defaults below)

_ _ _ _ _ - _ _ 0 _ _ - _ _ __ _ _ _ _ - _ _ 1_ _ _ - _ _ _ _ _ _ _ _ - _ _ 3 _ _ - _ _ _

Magnetic Encoder DefaultsNoneStripe Down, HiCoStripe Up, HiCo

_ _ _ _ _ - _ _ _ 0 _ - _ _ _Memory Expansion

None

_ _ _ _ _ - _ _ _ _ A - _ _ __ _ _ _ _ - _ _ _ _ C - _ _ _

InterfaceUSB OnlyUSB and Ethernet

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P330i Model Numbers

_ _ _ _ _ - _ _ _ _ _ - I _ __ _ _ _ _ - _ _ _ _ _ - U _ _

Power CordsU. S. and EuropeU. K. and Australia

_ _ _ _ _ - _ _ _ _ _ - _ D 0

Windows Drivers and User Documentation / Training CD

Windows Drivers and User Documentation / Training included on one CD (Software & Documentation Package) which contains Multi-language documentation.

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APPENDIX C

Worldwide Service &Support

Service and Support Locations

North America RegionZebra Technologies

Card Printer Solutions

1001 Flynn Road

Camarillo, CA 93012-8706 USA

Phone: 800-511-9909

e-mail: [email protected]

Europe, Middle Ease, and Africa RegionZebra Technologies

Card Printer Solutions, Europe, Middle East, Africa

The Valley Centre, Gordon Road, High Wycombe

Buckinghamshire HP13 6EQ, England

Phone: + 44 (0) 870 241 1527 (from outside U.K.)

Phone: 0870 241 1527 (from isside U.K.)

e-mail: [email protected]

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Worldwide Service & SupportWebsite

Latin America RegionZebra Technologies

Card Printer Solutions, Latin America

9800 NW 41st Street, Suite 220

Doral, FL 33178 USA

Phone: + 1 (305) 558 3100

e-mail: [email protected]

Asia Pacific RegionZebra Technologies Asia Pacific, LLC

16 New Industrial Road

#05-03 Hudson TechnoCentre

Singapore 536204

Phone: + 65 6885 0833

Fax: + 65 6885 0836

e-mail: [email protected]

Website

www.zebracard.com