Cover Zebra® P630i & P640i Card Printer Service Manual 980006-001 Rev.
Copyright Notice © 2008 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.
Contents 1 • General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 1.2 1.3 1.4 1.5 1.6 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Printer Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Specifications -- P630i / P640i. . . . . . . . . . . .
2.7 2.8 2.9 Changing the Printer Driver Options (Properties) . . . . . . . . . . . . . . . . . .53 2.7.1 General Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 2.7.2 Sharing Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 2.7.3 Ports Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 2.7.4 Advanced Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 2.7.
4.8 Printhead Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 4.9 System Related Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 4.10 Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126 4.10.1 Ribbon Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .126 4.10.2 Printhead Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 4.10.2.
5.12 Flip Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178 5.12.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178 5.12.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183 5.12.3 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187 5.10.4.11 Flip Station Calibration . . . . . . . . . . . . . . . . . . . . . . .187 5.10.4.
5.27 Magnetic Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257 5.27.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257 5.27.2 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259 5.27.3 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 6 • Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 6.1 6.
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1 General Description 1.1 Description The Zebra P630i and P640i Card Printers provide high speed, full color dual-sided card printing. A micro-positioning card transport system provides enhanced color photos. A range of interface, encoder/reader, and security options allow ordering the specific configuration suitable for a particular application. The difference between the P630i and the P640i is that the P630i has a single-sided laminator (i.e.
General Description Printer Features 1.2 Printer Features The following figure shows features of the P630i/P640i Printer.
General Description Controls and Indicators 1.3 Controls and Indicators A limited amount of control and status information is available at the Control Panel on the front of the printer. Additional control functions and status information is available via the host or networked computer(s) Buttons RM DY E INAT LAM REA IA MED BON RIB T PRIN ALA Indicators . 980006-001 Rev.
General Description Controls and Indicators Control Panel Buttons PRINT Button Note • The PRINT button can be disabled via the printer driver; see Advanced Utilities: on page 73. Press the PRINT button to print the image stored in the printer’s memory. When the printer is powered up, the memory is loaded with a checkerboard test pattern. In regular on-line use, the PRINT button reprints the last image downloaded from the computer to the buffer memory.
General Description Controls and Indicators RIBBON button Note • The RIBBON button can be disabled via the printer driver; see Advanced Utilities: on page 73. This button is used to synchronize the ribbon – in other words, to position it correctly under the print head. If you hold the RIBBON button down and power up the printer, it toggles on/off the Ribbon Synchronization feature when the door is closed. In standard applications, the ribbon type is YMCK, and the back of the card is printed first.
General Description Controls and Indicators Control Panel Indicators Depending on the condition they are reporting, the three indicator lights, READY, MEDIA, and ALARM, can be in one of three states: Off, On (steady), or Flashing. Note • The READY indicator is bi-colored. Its two color channels, green and yellow, function independently. READY Indicator Green: Steady = Ready to print. Flashing = Printer busy. Yellow: Steady = Laminator(s) in sleep mode.
General Description Specifications -- P630i / P640i 1.4 Specifications -- P630i / P640i Card size: Dimensions: 54 mm x 86 mm (2.125" x 3.375") nominal Thickness: .75 mm (.03 in) ± 10%, frequently referred to as “30 mil cards” Card hopper: 150 cards Throughput: 120 cards per hour dual-sided printing (YMC on front, K on back) and laminating Print system: Single printhead, with flip station for front and back printing.
General Description Declarations of Conformity 1.5 Declarations of Conformity 89/336/EEC EMC Directive EN 55022 (1998) EMC Directive EN 301489-3 V1.4.1 EMC Directive EN55024 (2001) 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.
General Description Icons 1.6 Icons Throughout 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.
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2 Installation and Setup 2.1 General Information This section will guide you through the installation and setup of your printer. This consists of the following procedures, which should be performed in the order presented. 2.2 Unpacking the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.3 Setting up the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2.4 Connecting Power . . . . . . . . . . . . . . . . . . . . . . . .
Installation and Setup Unpacking the Printer 2.2 Unpacking the Printer Remove the Printer from the Shipping Carton Step 1. Open and remove the plastic handle/latches on either end of the shipping carton. Step 2. Lift the upper part of the shipping carton off the lower part. Step 3. Remove the items from the cutouts in the foam block atop the printer.
Installation and Setup Unpacking the Printer Card Weight Documentation & Driver CD USB Interface Cable Step 4. Remove the foam block from the top of the shipping carton. Step 5. Lift the printer from the shipping carton. Caution • The printer weighs approximately 15.9 kg (35 lbs). Step 6. Remove the protective plastic bag from the printer. Important • Save all the packing material and the shipping carton in case the printer needs to be moved or shipped.
Installation and Setup Unpacking the Printer Step 8. Open the printer Main Cover. Locate and remove the blue tape that secures the flip station in position. 14 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Installation and Setup Setting up the Printer 2.3 Setting up the Printer 2.3.1 Attaching the Output Hopper The Output Hopper is positioned on the right side of the printer to receive the printed cards. Step 1. Install the Output Hopper by inserting the tab on the left side of the Output Hopper into the slot on the right side of the printer. Step 2. Ensure the lip on the Output Hopper locks securely in the slot in the Printer. 980006-001 Rev.
Installation and Setup Setting up the Printer 2.3.2 Installing the Ribbon 2.3.2.1 Attach Take-Up Spool Step 1. Attach the Ribbon Take-Up Spool by sliding it onto the Ribbon Take-Up Spindle and pressing it straight back until in clicks into place. Important • Make sure that the Ribbon Take-Up Spool is attached with its “toothed” end toward the rear of the printer. The two figures below show the right and wrong ways to insert the printing ribbon on either spindle. Right way: the clip is OVER the core.
Installation and Setup Setting up the Printer 2.3.2.2 Install the Ribbon Note • In normal printer operation, when the ribbon is exhausted, a warning message appears on the monitor and the MEDIA indicator on the printer lights. Step 1. Open the printer Main Cover. The printhead will raise for easy ribbon loading. Step 2. If present, remove the used Supply and Take-Up Spools. Step 3. Remove the ribbon from its packaging.
Installation and Setup Setting up the Printer Step 5. Route the Ribbon as shown in the figure below. The Ribbon Supply Spindle is freewheeling; pull ribbon off it as needed. If the tape removed from the new ribbon in Step 3 is undamaged, use it to attach the end of the ribbon to the Take-Up Spool; otherwise use other adhesive-backed tape.
Installation and Setup Setting up the Printer 2.3.3 Installing the Cleaning Cassette Before being printed, each surface of the card is cleaned by a soft tacky roller that is itself cleaned periodically by adhesive tape in the Cleaning Cassette. By default, the roller is cleaned every 10 cards. The printer driver software allows the card count to be modified. By cleaning the roller every 10 cards, the Cleaning Cassette contains sufficient tape for 3,000 cards. Step 1. Open the main cover of the printer.
Installation and Setup Setting up the Printer 2.3.4 Loading Laminate Note • In this description of loading laminate, references to the lower Laminate Cassette apply only to the P640i Printer. The P640i Printer can apply laminate to both surfaces of the card; the P630i Printer only to the upper surface. The Laminate (laminating film) is loaded into cassettes to protect it from dirt or other contaminants. See the figure below.
Installation and Setup Setting up the Printer 2.3.4.1 Removing the Laminate Cassette(s) Step 1. The Laminate Cassette(s) (Upper only for the P630i Printer; Upper and Lower for the P640i) are held in position by latch plates. The Upper Cassette is freed by turning its Latch Plate counter-clockwise to a full vertical position; the Lower Cassette (only present on the P640i Printer) is freed by turning its Latch Plate clockwise. Then pull the cassette straight out from its holder.
Installation and Setup Setting up the Printer Step 2. If there is a suspicion a patch is blocked somewhere, temporarily remove the corresponding Transfer Guide to be sure there are no scraps of laminate remaining. If there are any, remove them. Then slide the Transfer Guide back in until it is held in place by the Retaining Spring. 1. Push and hold the Retaining Springs (A) to the Left (B) 2. Slide the Transfer Guides (B) Straight Out (A) (A) 3. Release the Retaining Springs (A) (B) Step 3.
Installation and Setup Setting up the Printer 2.3.4.2 Loading the Laminate Cassette(s) Important • If you are using partial-width laminate in the Lower Cassette of a P640i Printer, read the following section, Using Partial-Width Laminate, before proceeding with this procedure. (Partial-width laminates are frequently used on the bottom surface of cards that have a signature panel or a magnetic stripe.
Installation and Setup Setting up the Printer Step 3. Pull out an inch or two of laminate past the lip of the cassette. Step 4. Close the cassette by firmly pressing the “clamshell” together. You will hear a click and feel a detent when the halves of the cassette seat together. Step 5. Pull out a little more laminate between the lips of the cassette. If it suddenly stops, resisting further pulling, a spring detent on the cassette has probably snagged a notch on the end of the core.
Installation and Setup Setting up the Printer 2.3.4.3 Laminating Contact Smart Cards The laminating patch on the top surface of a smart card has a rectangular aperture to expose the card’s electrical contacts. In all other respects the laminating process for smart cards is the same as for ordinary cards. Note that this procedure also applies to registered laminates. The special laminate for the top cassette is punched with a repeated pattern.
Installation and Setup Setting up the Printer 2.3.4.4 Using Partial-Width Laminate Note • Since partial-width laminates are only used for the back (i.e., lower) surface of the card, this section only applies to the P640i Printer. Laminate come in three widths: “Full-Width” laminate is 2 in (51 mm) wide. Full-width laminate is used on the front (i.e., upper) or back (i.e., lower) surface of the card. “Partial-Width” laminate is available in two widths: • 1.
Installation and Setup Setting up the Printer Step 2. For 1.3 in (33 mm) laminate for use with magnetic stripe cards, snap the Laminate Edge Guide into the inner hole-and-slot in the lower cassette, as shown in the following pictures. For 1.66 in (42 mm) laminate for use with signature-stripe cards, use the outer hole-and-slot. Inner Holeand-Slot Outer Holeand-Slot Laminate Edge Guide in Inner Hole-and-Slot for 1.33 in (33 mm) Laminate Used With Magnetic Stripe Cards 1.
Installation and Setup Setting up the Printer 2.3.4.5 Installing the Laminator Cassette(s) Step 1. Insert the cassette into its black molded pocket, then close the cassette latch (clockwise for the UPPER, counterclockwise for the LOWER). Upper Laminate Cassette Latch Plate (P630i and P640i) Heater Cores area Lower Laminate Cassette Latch Plate (P640i only) Step 2. Close the main cover.
Installation and Setup Setting up the Printer 2.3.4.6 Clearing the Laminate Channels If your scissor cuts were neat enough to pass for machine-made cuts, continue with printing cards. If not, do not waste a print cycle. Instead, remove the hand-cut patch(es) from the Transfer Roller(s) as follows. Note • Clearing procedures for the upper and lower laminate channels are similar. The upper channel is shown here. Removal of the Transfer Guide gives access to the Transfer Roller.
Installation and Setup Setting up the Printer 2.3.5 Loading Cards The P630i and P640i Printers use standard ISO CR-80 PVC Composite cards. Do not use cards with a paper or peel-off / adhesive backing. • Size 54 x 86 mm (2.125 x 3.375 in) nominal (refer to ISO Specification for exact dimensions and tolerances) • Thickness .75 mm (.03 in) ± 10%, frequently referred to as “30 mil cards” Important • Do not bend cards or touch the print surfaces as this can reduce print quality.
Installation and Setup Setting up the Printer Step 4. Push the stack back and forth to an angle of about 45° from vertical, so as to separate all of the cards. Important • 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 Card Feeder; if not separated, feeding or printing problems may occur. Step 5.
Installation and Setup Connecting Power 2.4 Connecting Power The AC Power is connected and turned on so that in the next procedure, Ribbon Installation, when the printer’s main cover is opened the Print Head will raise automatically. Power Switch Step 1. Verify that the printer’s Power Switch is set to OFF (O). Step 2. Select the proper power cord for the local ac power source from the accessories that are shipped with the printer.
Installation and Setup Connecting the Printer to your Computer 2.5 Connecting the Printer to your Computer The P630i and P640i Printers have a USB interface as standard. As options (must be specified at time of order), the printer can additionally have a 10/100T Ethernet port for connection to an Ethernet Network. Only one interface at a time will be connected. USB Connector (Standard) 980006-001 Rev.
Installation and Setup Installing the Printer Driver 2.6 Installing the Printer Driver Each computer that will use the P630i or P640i Printer must have the Printer Driver installed. A common Printer Driver serves both P630i and P640i Printers. To install the Printer Driver, insert the User Documentation, Drivers, and Training CD, included with your printer, into the host computer and the InstallShield Wizard will walk you through the required installation steps.
Installation and Setup Installing the Printer Driver 2.6.1 Installing the USB Printer Driver Note • To install the Ethernet driver, see Section 2.6.2. Step 1. Connect the printer power (see Section 2.4), and connect the USB port on the rear of the printer to the computer’s USB port (see Section 2.5). Turn the Printer on, and let it initialize until the READY LED on the front panel is lit. Step 2. The Windows “Found New Hardware” screen will appear. Click “Cancel”. Step 3.
Installation and Setup Installing the Printer Driver Step 5. The Main Menu will open in the selected language (English shown below). Step 6. From the Main Menu, click Install Printer Driver. The Printer Setup window will open. 36 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Installation and Setup Installing the Printer Driver Step 7. If an older P630i or P640i Printer and Driver is installed on your computer, click on Uninstall Printers and Drivers to remove it. Follow the screen prompts. At the end of the uninstall process you will be asked to re-boot your computer. Before re-booting, exit from the Driver Installation program and remove the CD. Then re-boot your computer, and start over with Step 1.
Installation and Setup Installing the Printer Driver Step 9. This will bring up the End User License Agreement. To proceed with the installation, click Accept. Step 10. This will bring up the Add Zebra Printer Port window. Select the USB Port, and then click Next >. 38 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Installation and Setup Installing the Printer Driver Step 11. This brings up the Browse Printers window, shown below. If your P640i / P630i Printer is listed, select (highlight) it and click OK. If your printer is not listed, make sure the printer is powered on and check the USB cable connections; then click Rescan. When it appears, select (highlight) it and click OK. Step 12. This brings up the Configure USB Port window. If your printer is not listed in the Printer info area, click Browse.
Installation and Setup Installing the Printer Driver Step 14. This opens the Add Printer Wizard welcome window. Click Next >. Step 15. This brings up the Add Printer Wizard Local or Network Printer window. For a standard USB installation, select Local Printer attached to this computer and check the box to detect a Plug and Play printer. Then click Next >. 40 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Installation and Setup Installing the Printer Driver Step 16. This brings up the Found New Hardware Wizard welcome window. In general, select Yes, this time only and then click Next >. Step 17. The next window helps install the software driver. Select Install the software automatically (Recommended) and then click Next >. 980006-001 Rev.
Installation and Setup Installing the Printer Driver Step 18. The Wizard will search for the Printer. The screen that appears while searching appears on the next page. Step 19. When the Wizard finds the Printer, it may display a window referring to compatibility, as shown below. If so, click Continue Anyway. 42 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Installation and Setup Installing the Printer Driver Step 20. Wait while the Wizard installs the software. Step 21. When software installation is complete, the following window will display. Click Finish. Step 22. This completes software driver installation. To use the P630i or P640i Printer, you would select it just like you would any other printer connected to a Windows system. 980006-001 Rev.
Installation and Setup Installing the Printer Driver 2.6.2 Installing the Ethernet Printer Driver Note • To install the USB driver, see Section 2.6.1. Important • The Ethernet Network must be configured correctly, with the Printer and the host computer on the same subnet mask. If you are not sure how to verify this or change the configuration, consult someone knowledgeable on Ethernet Networks. Important • A valid static IP address must be assigned to the printer. Important • See Section 4.
Installation and Setup Installing the Printer Driver Step 4. The Main Menu will open in the selected language (English shown below). Step 5. From the Main Menu, click Install Printer Driver. The Printer Setup window will open. Click Install an Ethernet Printer and Driver. 980006-001 Rev.
Installation and Setup Installing the Printer Driver Step 6. This will bring up the End User License Agreement. To proceed with the installation, click Accept. Step 7. This brings up the Configure Ethernet Port screen. Click the Browse button. 46 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Installation and Setup Installing the Printer Driver Step 8. Any Zebra printers will be located. Select (highlight) the desired printer (for this procedure it is a P640i, but the steps would be the same for a P630i) and click the OK button. Note • If the Printer is not found, check to make sure the Printer is powered on and the Ethernet connector is engaged. Also, the Ethernet Network must be configured correctly, with the Printer and the host computer on the same subnet mask.
Installation and Setup Installing the Printer Driver Step 10. This brings up the Add Printer Wizard. Click Next >. Step 11. The next screen lets you specify the type of printer to set up. Select “Local printer attached to the computer.” “Automatically detect and install my Plug and Play printer” should be un-checked. Then click Next >. 48 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Installation and Setup Installing the Printer Driver Step 12. The Add Printer Wizard / Select a Printer Port screen will now appear. Step 13. Click on “Use the following port”; scroll to “ENETxxx (Zebra Ethernet (internal))” where “xxx” is the number of the port - any Zebra Ethernet port number can be used. 980006-001 Rev.
Installation and Setup Installing the Printer Driver Step 14. Check that the printer is turned on (and the READY LED is lit), then click Next >. This will bring up the “Add Printer Software Wizard” screen. Step 15. Select the Manufacturer (Zebra Technologies) and the printer model number; then click Next >. Step 16. This brings up the “Name Your Printer” screen. Step 17. Verify that the printer name is correct.
Installation and Setup Installing the Printer Driver Step 18. Specify whether or not you want to allow printer sharing, then click Next >. Step 19. Specify if you wish to print a test page (note that card printers consider each card to be a page); then click Next >. 980006-001 Rev.
Installation and Setup Installing the Printer Driver Step 20. Click Finish. Step 21. The following screen will appear. Step 22. Click on Continue Anyway. You will see files being copied to the Windows folder. Step 23. When the file copying is complete, your printer is ready to use. 52 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Installation and Setup Changing the Printer Driver Options (Properties) 2.7 Changing the Printer Driver Options (Properties) Note • The screen shots shown in this section are for the printer using the USB interface. If you are using the Ethernet interface, the screens will refer to the “Network Printer.” You can change the default settings for the printer driver. Change the options as follows: Step 1.
Installation and Setup Changing the Printer Driver Options (Properties) 2.7.1 General Tab The General tab shows the printer model and lists the features of the printer. To access the General tab, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > General. 54 1. Printing Preferences - Changes the card settings; see Changing the Printing Preferences on page 77. 2. Print Test Page - Prints the standard Windows test page.
Installation and Setup Changing the Printer Driver Options (Properties) 2.7.2 Sharing Tab On the Sharing tab (Sharing Property Page), you can choose to share the printer over the network and install additional drivers to accommodate different operating systems. To access the Sharing tab, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Sharing. Share names can also be assigned.
Installation and Setup Changing the Printer Driver Options (Properties) 2.7.3 Ports Tab Use the Ports tab to specify the computer port to which the P630i or P640i is connected. This will have been established at the initial installation of the printer, and will not normally require attention. To access the Ports tab, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Ports.
Installation and Setup Changing the Printer Driver Options (Properties) 2.7.4 Advanced Tab Determines the spooling (queuing) of print jobs, and how spooled jobs are handled relative to the most recent job. Printing Defaults allows the system administrator to establish selected default settings. To access the Advanced tab, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Advanced. 980006-001 Rev.
Installation and Setup Changing the Printer Driver Options (Properties) 2.7.5 Color Management Tab Color Management settings allow you to associate color profiles on the printer based on the type of media being used and printer configuration. The Add button allows the operator to add additional profiles to the color profile list. To access the Color Management tab, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Color Management.
Installation and Setup Changing the Printer Driver Options (Properties) 2.7.6 Security Tab This is the standard Windows security screen, showing user access to various printer control options. Both Print and Manage Printers must be checked for full functionality of the printer. To access the Security tab, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Security. 980006-001 Rev.
Installation and Setup Changing the Printer Driver Options (Properties) 2.7.7 Device Settings Tab The Device Settings screen allows you to access various adjustment and calibration screens. To access the Device Settings tab, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Device Settings. 60 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Installation and Setup Changing the Printer Driver Options (Properties) 2.7.7.1 Printer Adjustment Caution • Modifying these values could cause undesirable results. To access the Printer Adjustment screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Device Settings > Printer Adjustment The following procedures can be performed via the Printer Adjustment screen: 980006-001 Rev. A • Print Station Adjustment . . . . . . . . . . .
Installation and Setup Changing the Printer Driver Options (Properties) Print Station Adjustment To access the Print Station Adjustment screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Device Settings > Printer Adjustment > Print Station Adjust... Important • Checking the box (circled in the figure below) will enable the greyed-out Print Station Adjustment settings to be changed. 1.
Installation and Setup Changing the Printer Driver Options (Properties) 3. 4. Black Panel (Changing Black Panel values is not recommended.): • Black Panel Speed (mm/s): These parameters determine the speed of the receptor movement during printing for black printing and overlay printing. This value should always be set to 25.
Installation and Setup Changing the Printer Driver Options (Properties) Laminate Station Adjustment To access the Laminate Station Adjustment screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Device Settings > Printer Adjustment > Laminate Station Adjust... The standard laminate patch length is 3.25” (82.55mm). Accurate positioning of the laminate is important for practical and aesthetic reasons.
Installation and Setup Changing the Printer Driver Options (Properties) 3. Heater Temperature This is the set point temperature (i.e., the temperature desired) not the actual temperature. For actuals, see Sensor Data on page 71. Note • Temperatures are monitored by thermocouples at the core of the heated rollers. Surface temperatures may differ significantly. 4. Line Voltage Caution • Running the printer at 220V, 60Hz in Auto mode may cause premature failure of the heaters.
Installation and Setup Changing the Printer Driver Options (Properties) Flip Station Adjustment To access the Flip Station Adjustment screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Device Settings > Printer Adjustment > Flip Station Adjust... 66 1. Flip Station Max. Height Adjust: This parameter modifies the position to which the flip station rises while flipping a card.
Installation and Setup Changing the Printer Driver Options (Properties) Advanced Adjustments To access the Advanced Adjustments screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Device Settings > Printer Adjustment > Advanced Adjust... Note • These adjustments should only be made if the normal auto-calibration procedures do not allow these functions to work properly. 1.
Installation and Setup Changing the Printer Driver Options (Properties) 2.7.7.2 Color Calibration To access the Color Calibration screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Device Settings > Color Calibration Color rendering in the printer can be described in terms of a curve, which determines how much power is put into the printhead for a given shade.
Installation and Setup Changing the Printer Driver Options (Properties) Note • The values shown on the previous page are the default values; recommended settings (different from the default values) are given in the following descriptions. 1. Gain - Adjusts steepness of the curve. Lighter shades will remain unchanged, but darker shades will get darker or lighter as the number is increased or decreased. Recommended setting = 95%. 2. Offset - Shifts the color curve up (darker) and down (lighter).
Installation and Setup Changing the Printer Driver Options (Properties) 2.7.7.3 Status The Status screen displays the current state of the printer and provides standard printer information and sensor data, which is updated every few seconds. To access the Status screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Device Settings > Status 1.
Installation and Setup Changing the Printer Driver Options (Properties) Sensor Data These are of several different types of sensors and interlock switches, but they have one thing in common - they tell the printer’s control logic what is happening and where, enabling it to continue with the process or, if a malfunction occurs, to light the appropriate indicator light and report a specific error condition on the host computer screen. 1. Ribbon Panel Detect - The current reading of the Color Sensor. 2.
Installation and Setup Changing the Printer Driver Options (Properties) 2.7.7.4 Control The Control screen allows manual control over the printer. Some of these functions are similar to the buttons on the front of the printer. To access the Control screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing.
Installation and Setup Changing the Printer Driver Options (Properties) Advanced Utilities: 1. 2. 980006-001 Rev. A Tests: Activate various flip tests, used to troubleshoot flip station problems; and activate a card eject cycle. • Flip Test 1 - Picks up a card, runs it to the flip station, flips it, raises it to the laminator infeed, then ejects it through the laminator. The sequence repeats until the PRINT button is pressed and released.
Installation and Setup Changing the Printer Driver Options (Properties) 3. 74 Calibration: Use these to adjust the mag head and printer sensors: d. Mag Position Adjust e. Mag Amplitude Adjust f. Show Sensor Data g. Flip Station Calibration: This routine determines the number of motor steps it takes for the carrier to descend from the upper limit position to the lower limit position; i.e., the carrier’s physical end stop.
Installation and Setup Changing the Printer Driver Options (Properties) 4. Update Backup Config: Causes the printer to update its backup configuration with the printer's current settings. 5. Upgrade Firmware: Caution • This should only be done when you have downloaded an upgrade firmware file from Zebra. Sends a new version of firmware to the printer. 6. Send Features File: Send a Features File to the printer.
Installation and Setup Changing the Printer Driver Options (Properties) 8. 9. ID/Code: ID/Code is a security feature that restricts the use of the printer to PC's which have had a password entered. Once entered, the PC will send this password to the printer. If the printer does not receive the password, it will not print. • To enable the password, click “Set ID/Code”. Leave the Old Password field blank, and enter the new password into the New Password and Confirmation fields. Click “OK”.
Installation and Setup Changing the Printing Preferences 2.8 Changing the Printing Preferences To access the Printing Preferences screens, select Start > Printers and Faxes, then right click Zebra P630i or Zebra P640i printer and select Printing Preferences. 980006-001 Rev. A • Card Setup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 • YMC (Color) Printing Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and Setup Changing the Printing Preferences 2.8.1 Card Setup Tab Card Setup allows the user to adjust selected card parameters. To access the Card Setup screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Printing Preferences > Card Setup. 78 1. Image Size - Sets the image area for both front and back of the card (1 inch = 300 pixels). 2. Cards - Specifies the type of card loaded in the hopper. “Zebra Card” is the only option.
Installation and Setup Changing the Printing Preferences 2.8.2 YMC (Color) Printing Tab YMC (Color) Printing allows the user to adjust selected color printing parameters. To access the YMC (Color) Printing screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Printing Preferences > YMC (Color) Printing. The printer accepts 24-bit color images, meaning that each of the colors (Y, M and C) is represented by 8 bits per pixel.
Installation and Setup Changing the Printing Preferences 2.8.3 K (Black) Panel Tab When the Card Setup screen is set for YMC and K on the same side of a card, a process called Black Extraction is enabled. The K (Black) Panel screen displays available options for Black Extraction. To access the K (Black) Panel screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Printing Preferences > K (Black) Panel.
Installation and Setup Changing the Printing Preferences Elements Selection - Depending on the program used to create the card layout, elements of the design may be identified in different ways to the printer driver. This printer driver recognizes five types of elements: • Text is text which is sent explicitly as such to the printer driver. • Lines and pixels are lines and dots (pixels) sent as such to the printer driver. • Area fills are color-filled geometric shapes.
Installation and Setup Changing the Printing Preferences 2.8.4 Image Adjustment Tab From the Image Adjustment screen, the operator can adjust the brightness and contrast of the images printed on the cards. To access the Image Adjustment screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Printing Preferences > Image Adjustment.
Installation and Setup Changing the Printing Preferences Here are some sample prints to illustrate the effects of changing the brightness and contrast settings: Contrast 50 Brightness 25 Contrast 0 Brightness 50 Contrast 25 Brightness 50 Contrast 50 Brightness 50 Contrast 50 Brightness 75 Contrast 75 Brightness 50 Contrast 100 Brightness 50 Click the Reset button to return to default Brightness (50) and Contrast (50) settings. 980006-001 Rev.
Installation and Setup Changing the Printing Preferences 2.8.5 Magnetic Encoding Tab Important • If you have the Magnetic Stripe Encoder option installed, ensure that the Mag. Encoder Verify On checkbox is checked. The Magnetic Encoding screen allows the user to set various magnetic encoding options. To access the Magnetic Encoding screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Printing Preferences > Magnetic Encoding.
Installation and Setup Changing the Printing Preferences 2.8.6 ID/Log Tab The ID/Log is a driver utility that builds a database of card transactions in the printer’s host computer. Important • Make sure Status Polling Frequency is enabled by selecting Normal or Reduced. To access the Status Polling Frequency option, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Device Settings > Control > Advanced Utilities.
Installation and Setup Changing the Printing Preferences 1. Enable Logging - If this box is checked, the logging feature is enabled. 2. Log File Definition - Choose one of the following options: 3. • If the “Create New Log File Each Day” box is unchecked, click Browse (...) to navigate to a directory (folder) in which to save the log file. • If the box is checked, “File” changes to “Path”, and the Browse button becomes inoperative, requiring the directory to be entered manually.
Installation and Setup Changing the Printing Preferences 2.8.7 Advanced Tab The Advanced screen allows the user to Disable support for multiple cards per job, Enable Turbo Mode, and Enable Enhanced Barcode Printing (for 3-pixel or 2-pixel reduction). Other functions include Enhanced Flipping Options and Magnetic encode only. To access the Advanced screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Printing Preferences > Advanced. 1.
Installation and Setup Changing the Printing Preferences 2.8.8 About Tab The About screen displays copyright and version information about the printer driver. To access the About screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Printing Preferences > About. 88 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Installation and Setup Packing the Printer for Shipment 2.9 Packing the Printer for Shipment If the printer is to be shipped, use the original printer packing and shipping material for shipping the printer only. It is important to use the original packing and shipping material to prevent damage to the printer. Important • Do not ship the printer with the Hopper Weight, the Ribbon, or the Cards in the printer. Important • Ship the printer with the Truck (card carrier) positioned as indicated below.
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3 Theory of Operation 3.1 Introduction This section includes five major topics: Card Printing Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Sensors and Interlock Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Card Movement During Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theory of Operation Card Printing Basics 3.2 Card Printing Basics This section provides an overview description of how images are printed on plastic cards. 3.2.1 Printhead The Printhead Assembly mounts in the Printhead Bracket, which holds the Printhead at a right angle to the card’s long surface. The Printhead is a thin-film device that consists of a row of individually addressable heating elements. Each heating element is approximately 0.0033 inch (0.
Theory of Operation Card Printing Basics 3.2.2 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 dye or 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.
Theory of Operation Card Printing Basics The ribbon synchronizes to it’s “starting” position whenever the Main Cover is opened and then closed. For a YMCKK ribbon, the starting position is with the leading edge of a Black Panel at the Printhead location. The figure below shows how the YMCKK ribbon and card move relative to each other during printing. 1. Ribbon Moves Black Panel into Position at Printhead 2. Card is Fed to Printing Position Under the Printhead 3.
Theory of Operation Card Printing Basics Dye Sublimation Printing In Dye Sublimation Printing, each Printhead 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 fullcolor images.
Theory of Operation Sensors and Interlock Switches 3.3 Sensors and Interlock Switches These are of several different types of sensors and interlock switches, but they have one thing in common - they tell the printer’s control logic what’s happening and where, enabling it to continue with the process or, if a malfunction occurs, to light the appropriate indicator light and report a specific error condition on the host computer screen.
Theory of Operation Card Movement During Printing 3.4 Card Movement During Printing The printer moves a card through a specific sequence of movements as it encodes and prints the card. This example describes dual-sided printing with a YMCKK ribbon.
Theory of Operation Card Movement During Printing • The last time the Main Cover was opened and closed, the ribbon was automatically “synchronized,” thereby bringing the leading edge of the Black (K) ribbon panel under the Printhead. • The leading edge of the card is moved under the Printhead, the Printhead is lowered, and printing begins. • After this Black pass is completed, the Printhead is raised; and the card is moved to the Card Flipper.
Theory of Operation Block Diagram 3.5 Block Diagram Most of the circuitry in the printer 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 printer; the block diagram also shows how signals are passed to and from the CPU PCBA to the rest of the printer.
Theory of Operation CPU PCBA Connections 3.6 CPU PCBA Connections Most of the circuitry in the printer 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 printer.
Theory of Operation CPU PCBA Connections CPU PCBA Connections 980006-001 Rev.
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4 Troubleshooting 4.1 Introduction 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. 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.
Troubleshooting Error Messages 4.2 Error Messages Most error conditions are identified by the printer itself and are reported by the computer as error messages, with corrective actions listed. The following are examples of computer reported error messages. 104 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Troubleshooting Indicator Light Status 4.3 Indicator Light Status READY MEDIA ALARM ORANGE RED PRINTER STATUS GREEN YELLOW Ready to print. Printer busy. Laminator(s) in sleep mode. When not in use, the heaters cool at 1o F per minute. Laminator(s) heating up, but not yet at operating temperature. Normal. ✔ No cards in hopper, color ribbon out, cleaning tape out, laminator cassette(s) out. Mag encoding write failure. ✔ Normal.
Troubleshooting Preventive Maintenance 4.4 Preventive Maintenance There is almost no preventive maintenance to be performed. Dust and debris should be vacuumed out every 12 months, or more frequently in adverse environments. Most of the problems described in the following pages are correctable by the user, but please note there is the potential for unexpected results if the procedures are not followed carefully. If in doubt, call Zebra Technical Support.
Troubleshooting Unusual Noises/Unreported Events 4.5 Unusual Noises/Unreported Events Color ribbon runs for longer than 2 or 3 seconds when cover is closed (MEDIA light stays on) • Color ribbon not in Color Sensor. • Both ribbon cores not fully engaged on Spindles. • Ribbon not secured to Take-up Core. ALARM light stays ON after error condition is cleared Note • There is a delay after closing the cover before the ALARM light goes out. • Some alarms require recycling power in order to clear.
Troubleshooting Unusual Noises/Unreported Events Card has both front and back images printed on same side • Both pages print on the same side (with YMCK). Check the ribbon settings. Select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Printing Preferences > Card Setup. • Card does not flip. Run the Flip Tests to check flip action. To run the Flip Test, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing.
Troubleshooting Unusual Noises/Unreported Events Completely unexpected print results • Color ribbon out, or nearly out. Replace ribbon. • Main cover opened during a print job. Open and close main cover, then press RIBBON to re-sync ribbon. Reprint last job. • Color ribbon panels out of sync, see previous action. • Color ribbon not advancing consistently. Color ribbon supply and/or take-up cores not engaging properly on spindles. • Front (color side) of card printed with black.
Troubleshooting Unusual Noises/Unreported Events Unusual events In any of the following cases, and all other unusual events, try power cycling first, then investigate specific issues: • Printhead descends before card arrives. Contact Zebra Customer Service. • Printhead stays down after card has gone away. Contact Zebra Customer Service. • Laminate cutter fails to operate. • Unusual media light indications.
Troubleshooting Print Quality Problems 4.6 Print Quality Problems Important • The use of Zebra cards and True Colours® ribbons will give the best print quality. This section will help you resolve print quality problems. The print quality is dependent on several factors. The two most important factors that will increase your print quality are cleanliness and card stock.
Troubleshooting Print Quality Problems Example • There are non-printing horizontal lines (white) on the card surfaces. • Possible Cause: Ribbon cartridge is not correctly positioned. Solution: Ensure that the ribbon is properly rolled onto the ribbon cores of the cartridge and that there are no wrinkles in the ribbon. Replace ribbon cassette. • Possible Cause: Printhead is dirty. Solution: Clean the printhead. • Possible Cause: Printhead elements are damaged (e.g., scratched or burnt).
Troubleshooting Print Quality Problems Example • Printing shows very pale or inconsistent results. • Possible Cause: Ribbon cartridge has been stored improperly or is damaged. Solution: Change the ribbon cartridge and print again. • Possible Cause: Cards may not meet specifications. Solution: Use a different supply of cards. • Possible Cause: Contrast and/or intensity may be set to values which are too high. Solution: Adjust contrast and/or intensity values in software.
Troubleshooting Print Quality Problems Example • Printing shows blurry printed image. • Possible Cause: Ribbon cartridge may not be correctly positioned. Solution: Check that the ribbon is properly rolled onto the ribbon cores of the cartridge, with no wrinkles. Replace ribbon cartridge, making sure it locks in place, and print again. • Possible Cause: Ribbon may not be synchronized on the correct color panel position. Solution: Open lid, then close lid to synchronize ribbon.
Troubleshooting Print Quality Problems Example • No printing on the card. • Possible Cause: Ribbon cartridge may not be installed in the printer. Solution: Check for ribbon cartridge in the printer. • Possible Cause: Cards may not meet specifications. Solution: Use a different supply of cards. • Possible Cause: Cable on printhead may be disconnected. Printhead elements may be scratched or burnt. Solution: Call Service for printhead repair or replacement information. 980006-001 Rev.
Troubleshooting Print Quality Problems Example • Irregular white lines in the print, like the ribbon is wrinkling -- Ribbon Wrinkle. • Possible Cause: Ribbon cartridge may not be correctly positioned. Solution: Check to make sure that the ribbon is loaded correctly. • Possible Cause: Cards may not meet specifications. Solution: Use a different supply of cards. • Possible Cause: Dirty printhead and/or print path. Solution: Clean the printhead. Clean the print path.
Troubleshooting Print Quality Problems Faint, non-uniform image • Printhead pressure too low. Adjust downward; see ‘Printhead Position (Height/ Pressure) Adjustment’ on page 133. • Printhead not pivoting freely. Gaps in image at edges and corners • Possible de-lamination/wear of Platen’s rubber surface. Try cleaning Platen. If unsuccessful, replace Platen; see ‘Platen’ on page 177. • Possible non-uniformity of card thickness, or card surface defects.
Troubleshooting Print Quality Problems Poor color rendering Important • Changes in contrast settings will not take effect until power is cycled. 118 • Possible source issues - poor quality photos or graphics, card layout application settings. Isolate the problem by printing a known image. • To vary the brightness and contrast, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Printing Preferences > Image Adjustment.
Troubleshooting Print Quality Problems • 980006-001 Rev. A To adjust the contrast, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Device Settings > Color Calibration.
Troubleshooting Laminate Problems 4.7 Laminate Problems Laminate not centered on card • Vertical offset adjust (mechanical adjustment); for the upper cassette, see ‘Vertical Offset Adjustment (upper cassette)’ on page 147; for the lower cassette, see ‘Vertical Offset Adjustment (lower cassette)’ on page 148. • Horizontal offset adjust (printer properties adjustment); see ‘Horizontal Offset Adjust’ on page 144.
Troubleshooting Laminate Problems Card jammed in laminator • Dings or rough edges on the card (depending on vendor, card quality can vary, even from batch to batch). • Either of the cutters fails to cut, so the card is stopped dead by a “tail” of laminate, now firmly held by the laminate feed roller, which can not be rotated by tugging on the laminate. Note • All rollers in the main drive train of the laminator (not the cassette out-feeds) are connected by toothed belts.
Troubleshooting Printhead Problems 4.8 Printhead Problems White line across length of the card • The white line is a sign of a blown pixel. • The adjacent black stripe is a printhead driver problem (i.e., components on the head itself). • These are independent problems, not necessarily co-located, that may require replacement of the printhead. Random occurrences of white (un-printed) spots • Possible card quality problem. Run IDPrint Lite with graytone.bmp on cards from a different batch.
Troubleshooting Printhead Problems Random colored patterns on image • Ribbon wrinkling. Reduce take-up torque; see ‘Ribbon Torque Adjustment’ on page 126. Check printhead pressure/height; see ‘Printhead Position (Height/Pressure) Adjustment’ on page 133. • Too much heat being applied to YMC panels. Try reducing gain, offset, and preheat separately for each color in the driver. Select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing.
Troubleshooting Printhead Problems Image missing at top or bottom of card • Ribbon folded over at edge. Slacken ribbon by pulling more out of supply roll, unfold edge then press RIBBON button to re-sync. • Bottom edge and/or right hand edge of image missing could be card layout application sending wrong image size (should be 952 x 578 pixels). Select appropriate image size (if available) in Preferences, or modify layout application.
Troubleshooting System Related Issues 4.9 System Related Issues • Printer self-test takes more than a few minutes to complete • READY indicator LED is not lit on the panel • A communications problem exists Invalid IP address A valid static unique IP address must be assigned to the printer. The default setting has DHCP disabled. If you do not specify either, the printer may incur an extended latency while being identified in your network.
Troubleshooting Adjustment Procedures 4.10 Adjustment Procedures 4.10.1 Ribbon Torque Adjustment To perform the procedure ensure you have a Clutch Burn-In Tool Kit, a 7/16” nut driver, and the IDPrint test and adjustment program. The Clutch Burn-In Tool Kit, P/N: 105927-430, consists of: • Clutch Pulley Assembly • Grooved Splined Cores (2) • O-rings (2) Step 1. Find Low Ribbon Torque. e. Plug in and power up the printer f. Ensure the Payout Spindle rotates freely.
Troubleshooting Adjustment Procedures g. Ensure that there is very little end-to-end play (detent) in the Take-up Spindle; adjust the take-up spindle nut as required. h. Install the two Grooved Splined Cores. Core O-ring Core i. Install the one of the O-ring in the front slots on the two cores. j. Start IDPrint. k. Select Control > Ribbon Tasks > Find Low Ribbon Torque: l. Observe the two cores rotate counterclockwise for approximately two minutes. m. When the motor stops turning, go to the next step.
Troubleshooting Adjustment Procedures Step 2. Find High Ribbon Torque n. Place the Clutch onto the Guide Shaft. Note that you may have to move the Printhead down to access the Guide Shaft. O-ring O-ring Clutch o. Place one O-ring around the Clutch (in the rear slot) and around the left core (in the rear slot). p. Install the other O-ring in the front slots on the two cores. q. From the IDPrint screen, select Control > Ribbon Tasks > Find High Ribbon Torque: r.
Troubleshooting Adjustment Procedures t. Remove the O-ring in the front slots on the cores. u. Remove the Clutch and associated O-ring. v. Reinstall an O-ring in the front slots on the two cores. O-ring w. From the IDPrint screen, select Control > Ribbon Tasks > Run Ribbon Motor (Clutch Burn-In): x. Observe the two cores rotate counterclockwise. 980006-001 Rev.
Troubleshooting Adjustment Procedures y. Tighten the payout spindle nut until the O-ring bows, then back off slightly. z. Listen to the “hum” of the motor. aa. Adjust the tightness of the payout spindle nut until the motor hum is constant. ab. This test takes approximately ten minutes. When the motor stops turning, go to the next step. Step 4. Adjust Payout Clutch Note • You may need to repeat this step until you are satisfied with the adjustment. ac.
Troubleshooting Adjustment Procedures ae. Observe the panel lights. Note • The panel lights should flash an equal amount of time between Green (Ready) and Red (Alarm) -- the optimum condition would be Yellow (Media) on all the time. af. Adjust the payout spindle nut as required -- if Red, tighten; if Green, loosen. ag. When the motor stops turning and you are satisfied with the adjustment, go to the next step. Step 5. Remove the O-ring and the two Grooved Splined Cores. Step 6. Load the Ribbon.
Troubleshooting Adjustment Procedures 4.10.2 Printhead Adjustments 4.10.2.1 Printhead Resistance Setting After changing the Printhead, go into the Printer Driver; and enter the Printhead resistance. 132 Step 1. Select Start > Printers and Faxes, right click the Zebra Card Printer, and select Properties from the pop-up menu. Step 2. From the Card Printer Properties screen, select Device Settings > Printer Adjustment > Print Station Adjust... Step 3.
Troubleshooting Adjustment Procedures 4.10.2.2 Printhead Position (Height/Pressure) Adjustment Step 1. Select Start > Printers and Faxes, right click the Zebra Card Printer, and select Properties from the pop-up menu. Step 2. From the Card Printer Properties screen, select Device Settings > Printer Adjustment > Print Station Adjust... Step 3. In the Printhead Position Adjust field, decrease the value by 10. Step 4. Print a card. Step 5.
Troubleshooting Adjustment Procedures 4.10.2.3 Printhead Angle Adjustment Step 1. If not already done, remove the Printhead Cover; and move the ground wire out of the way. Step 2. Loosen the inside mounting screw just enough to allow sliding movement of the printhead bracket. Inside Mounting Screw Access Hole for Angle Adjust Screw Step 3. Unlock the angle adjust screw, turn it a quarter-turn counterclockwise, then re-lock it.
Troubleshooting Adjustment Procedures 4.10.2.4 Image Skew Adjustment Step 1. With a 3/32 hex driver, loosen the Skew Adjust Screw. Step 2. With a 7/64 hex driver, loosen the Inside Mounting Screw. 980006-001 Rev.
Troubleshooting Adjustment Procedures 136 Step 3. With the two screws loosened, the Printhead can now pivot left or right, and the image skew can be corrected. Step 4. Tighten the Inside Mounting Screw first and then the Skew Adjust Screw. Step 5. Print a card to see if the image is centered. If the image is still skewed adjust the printhead again until the image skew is corrected. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Troubleshooting Adjustment Procedures 4.10.3 Flip Station Adjustments 4.10.3.1 Flip Station Calibration This routine determines the number of motor steps it takes for the carrier to descend from the upper limit position to the lower limit position, that being the carrier’s physical end stop. This stored number is used to drive the carrier down to the rest position before each and every flip station action.
Troubleshooting Adjustment Procedures 4.10.3.2 Max Height Adjust The card carrier needs to move high enough to actuate the flipping mechanism, but should not over-travel excessively. To access the Flip Station Adjustment screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Device Settings > Printer Adjustment > Flip Station Adjust... Increase this parameter only if there is an occasional failure to flip.
Troubleshooting Adjustment Procedures 4.10.3.3 Insertion Height Adjust “Insertion height” is the intermediate (non flipping) elevation to which the card is driven for insertion into the laminator. To access the Flip Station Adjustment screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Device Settings > Printer Adjustment > Flip Station Adjust... Adjust the parameter if the ejector arm misses the card.
Troubleshooting Adjustment Procedures 4.10.3.4 Rest Position Adjust This procedure adjusts how far down the carrier drives. If the truck fails to pull the card out of the flip station after the flipping action, chances are: 1. The card position is wrong; see ‘Card Position Adjust’ on page 141. 2. The carrier is not coming down all the way; repeat ‘Flip Station Calibration’ on page 137. Another adjustment for this: 140 Step 1.
Troubleshooting Adjustment Procedures 4.10.3.5 Card Position Adjust This procedure adjusts how far the truck drives into the Flip Station. The adjustment should be set so that the card is centered in the flip arms (if it is not centered, the truck may have difficulty removing the card after the flipping action). To move the card into the Flip Station, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing.
Troubleshooting Adjustment Procedures 4.10.4 Laminator Adjustments Correctly positioned top (front) and bottom (back) laminate patches If there is no magnetic stripe on the underside, a full width patch should be used. Positioning of the patch is affected by three variables: 1. Horizontal offset (left-right), 2. Skew (rotation); 3. Vertical offset (up-down). Horizontal offset is a software adjustment. Skew and vertical offset are mechanical adjustments. 4.10.4.
Troubleshooting Adjustment Procedures 4.10.4.2 Pocket Adjustment Skew and vertical offset are adjusted by screws in the cassette pocket (7/64" hex wrench for skew, flat blade screwdriver for vertical offset, see diagram below). DO NOT ADJUST Skew Adjust Vertical Offset Adjust Before adjusting for skew or vertical offset, remember that there is significant interaction between the latch and the adjusting screws in the pocket.
Troubleshooting Adjustment Procedures 4.10.4.3 Horizontal Offset Adjust To access the Laminate Station Adjustment screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Device Settings > Printer Adjustment > Laminate Station Adjust... Accurate positioning of the laminate is important for practical and aesthetic reasons.
Troubleshooting Adjustment Procedures 4.10.4.4 Skew Adjustment Procedure (upper cassette) Note • The following procedure assumes that the horizontal offset has been software corrected as described in the previous section. Step 1. Check the action of the cassette latch. If necessary adjust its fore-aft position so that its ears smoothly engage the cassette without nudging the cassette. Step 2. Print and laminate a few test cards in the usual way, noting the direction of skew.
Troubleshooting Adjustment Procedures 4.10.4.5 Skew Adjustment Procedure (lower cassette) Once the front surface skew is consistently acceptable, inspect the back surface patches of the last few cards to pass through the laminator. Note the direction of skew on the back surface. (Don’t worry about vertical offset at this stage unless the laminate overhangs grossly, in which case proceed to the Vertical offset adjustment procedure.
Troubleshooting Adjustment Procedures 4.10.4.6 Vertical Offset Adjustment (upper cassette) Note • The following procedure assumes that the horizontal offset has been software- corrected, and that skew has been corrected. Step 1. Check the action of the cassette latch. If necessary adjust its fore-aft position so that its ears smoothly engage the cassette without nudging the cassette. Step 2.
Troubleshooting Adjustment Procedures 4.10.4.7 Vertical Offset Adjustment (lower cassette) Once the front surface offset is consistently acceptable, inspect the back surface patches of the last few cards to pass through the laminator. Note the offset on the back surface. When flipping the cards for inspection, keep the mag stripe (if present) toward you.
Troubleshooting Adjustment Procedures 4.10.4.8 Cassette Pocket Reset Skew is caused by misalignment of the laminate cassette relative to the left-right axis of the printer, looking down on the printer from above. The skew adjust screw causes the pocket to rotate relative to the left-right axis. The vertical offset adjust screw controls the depth of the cassette in the pocket. Note that the front ear of the latch must be in close contact with the cassette, without changing its position.
Troubleshooting Adjustment Procedures 4.10.4.9 Laminator Parameters in the Driver To access the Status screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Device Settings > Control > Advanced Utilities > Show Sensor Data 1. Heater Temperatures -Temperatures measured by thermocouples in the top and bottom laminator heater cores. 2. Laminate Sensors - Reflective sensors that detect the presence of laminate on the transfer rollers.
Troubleshooting Adjustment Procedures 4.10.4.10 Functional Test of the Laminator Sensors Step 1. From each of the laminators, upper and lower, remove the transfer guide and the laminate patch, if any, beneath it.The sensor should read high, around 250. Step 2. Replace the guide, and the sensor should read no lower than 180. If lower than 180, move the sensor board away from the transfer rollers, to the left, diagram below. Step 3.
152 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
5 Replacement 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.
Replacement Procedures Required Tools 5.2 Required Tools This section lists the tools required for the replacement procedures described in this section. Naturally, not all tools are required for a particular procedure; specific tools are called out in each step as appropriate. Important • When removing any of the nylon or plastic pulleys or gears, the use of a gear puller is strongly recommended.
Replacement Procedures Rear Cover & Cooling Fan 5.3 Rear Cover & Cooling Fan Step 1. With a Phillips #2 screwdriver, remove the seven screws holding the Rear Cover in place. Note that the orange arrows point out the seven screws. Step 2. Set the Rear Cover, face down, on the table top. 980006-001 Rev.
Replacement Procedures Rear Cover & Cooling Fan Step 3. Disconnect the Cooling Fan plug from connector J2 on the Main PCBA. Connector J2 156 Step 4. Remove the Rear Cover. Step 5. With a Phillips #1 screwdriver, remove the four screws holding the Cooling Fan in place. Step 6. Cut the cable ties, as required, to free the Cooling Fan cable and connector. Step 7. Remove the Cooling Fan. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Ethernet PCBA 5.4 Ethernet PCBA Note • The Ethernet PCB is only installed if you have the Ethernet option. Step 1. Locate the Ethernet PCBA. Step 2. With a TORX T15 driver, remove the screw from the bottom right-hand corner of the Ethernet PCBA. 980006-001 Rev.
Replacement Procedures Ethernet PCBA Step 3. “Pop” the three pins on the Ethernet PCBA out of the mounting holes on the Main PCBA. Mounting Hole Pin Ethernet Connection 158 Step 4. Pull the Ethernet PCBA away from the Main PCBA to access the Ethernet connection. Note that the PCBA is connected to the Ethernet cable. Step 5. Remove the Ethernet PCBA. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Main PCBA 5.5 Main PCBA Important • Save the Printer’s Configuration -- to do that you need IDPrint, and follow the steps below. a. Run the IDPrint.exe program. b. From the IDPrint Main Menu, select Configure > Save Config to File. c. This saved configuration information will be used to update your replacement Main PCBA. 980006-001 Rev.
Replacement Procedures Main PCBA 5.5.1 160 Removal Step 1. With the Rear Cover and the Ethernet PCBA removed, the Main PCBA is visible and accessible. Step 2. Carefully disconnect the various wires and connectors that attach to the Main PCBA. Step 3. With a TORX T15 driver, remove the eleven screws holding the Main PCBA in place. Note that the orange arrows point out the eleven PCBA mounting screws. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Main PCBA Step 4. With the Main PCBA removed, the view from the back of the printer looks like the following picture. Step 5. Set the Main PCBA aside. Step 6. The following figure and table show the connections to the Main PCBA. 980006-001 Rev.
Replacement Procedures Main PCBA Main PCBA Connections J14 J53 J54 J23 J20 J26 J19 J16 J2 J3 J22 J1 J45 J55 J5B J5A J13 J18 J35 J36 J32 J29 J31 J34 J33 J30 J37 J40 J39 J38 J15 J9 J17 J46 J4 J27 J24 J6 J7 J8 J44 J43 J42A J42B J12 J47 162 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Main PCBA Main PCBA Connections 980006-001 Rev.
Replacement Procedures Main PCBA 5.5.2 Tests and Adjustments 5.5.2.1 Reload The Configuration Information After changing the Main PCBA, reload the configuration information (saved in at the beginning of this procedure) into the printer. 164 Step 1. Run the IDPrint.exe program. Step 2. From the IDPrint Main Menu, select Configure > Load Config File. Step 3. This saved configuration information will update your replacement Main PCBA. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Main PCBA 5.5.2.2 Adjust Ribbon Torque The Main PCBA needs to “learn” the amount of voltage required to run the ribbon drive motor. To do this, you need to perform the Ribbon Torque Adjustment Procedure. To perform the procedure ensure you have a Clutch Burn-In Tool Kit, a 7/16” nut driver, and the IDPrint test and adjustment program. The Clutch Burn-In Tool Kit, P/N: 105927-430, consists of: • Clutch Pulley Assembly • Grooved Splined Cores (2) • O-rings (2) Step 1.
Replacement Procedures Main PCBA c. Ensure that there is very little end-to-end play (detent) in the Take-up Spindle; adjust the take-up spindle nut as required. d. Install the two Grooved Splined Cores. Core O-ring Core e. Install the one of the O-ring in the front slots on the two cores. f. Start IDPrint. g. Select Control > Ribbon Tasks > Find Low Ribbon Torque: h. Observe the two cores rotate counterclockwise for approximately two minutes. i. When the motor stops turning, go to the next step.
Replacement Procedures Main PCBA Step 2. Find High Ribbon Torque a. Place the Clutch onto the Guide Shaft. Note that you may have to move the Printhead down to access the Guide Shaft. O-ring O-ring Clutch b. Place one O-ring around the Clutch (in the rear slot) and around the left core (in the rear slot). c. Install the other O-ring in the front slots on the two cores. d. From the IDPrint screen, select Control > Ribbon Tasks > Find High Ribbon Torque: e.
Replacement Procedures Main PCBA Step 3. Run Ribbon Motor (Clutch Burn-In) a. Remove the O-ring in the front slots on the cores. b. Remove the Clutch and associated O-ring. c. Reinstall an O-ring in the front slots on the two cores. O-ring d. From the IDPrint screen, select Control > Ribbon Tasks > Run Ribbon Motor (Clutch Burn-In): e. Observe the two cores rotate counterclockwise. 168 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Main PCBA f. Tighten the payout spindle nut until the O-ring bows, then back off slightly. g. Listen to the “hum” of the motor. h. Adjust the tightness of the payout spindle nut until the motor hum is constant. i. This test takes approximately ten minutes. When the motor stops turning, go to the next step. Step 4. Adjust Payout Clutch Note • You may need to repeat this step until you are satisfied with the adjustment. a.
Replacement Procedures Main PCBA b. Observe the two cores rotate counterclockwise. c. Observe the panel lights. Note • The panel lights should flash an equal amount of time between Green (Ready) and Red (Alarm) -- the optimum condition would be Yellow (Media) on all the time. d. Adjust the payout spindle nut as required -- if Red, tighten; if Green, loosen. e. When the motor stops turning and you are satisfied with the adjustment, go to the next step. 170 Step 5.
Replacement Procedures Main PCBA 5.5.2.3 Printhead Resistance Step 8. After changing the Main PCBA, go into the Printer Driver; and enter the Printhead resistance. a. Select Start > Printers and Faxes, right click the Zebra Card Printer, and select Properties from the pop-up menu. b. From the Card Printer Properties screen, select Device Settings > Printer Adjustment > Print Station Adjust... c. In the Printhead Resistance (Ohms) field, enter the resistance of the Printhead.
Replacement Procedures Doors (Main and Card Load) 5.6 Doors (Main and Card Load) Step 1. With a Phillips #1 screwdriver, remove the eight screws holding the Main Door and the Card Load Door in place. Note that the orange arrows point out the eight screws. Card Load Step 2. 172 Main Remove the two Doors. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Front Panel Switch Assembly 5.7 Front Panel Switch Assembly Step 1. With a Phillips #1 screwdriver, remove the two left-side screws and two frontmounting screws holding the Front Panel Switch Assembly in place. Note that the orange arrows point out the four screws. Step 2. If not already disconnected, remove the DISPLAY Connector from J19 on the Main PCBA. Step 3. Remove the Front Panel Switch Assembly. 980006-001 Rev.
Replacement Procedures Lower Front Panel 5.8 Lower Front Panel Note • The Front Panel Switch Assembly must be removed to access the left-side screw. 174 Step 1. With a Phillips #1 screwdriver, remove the two screws holding the Lower Front Panel in place. Note that the orange arrows point out the two screws. Step 2. Remove the Lower Front Panel. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures End Panel (Right-Side) 5.9 End Panel (Right-Side) Step 1. With a Phillips #1 screwdriver, remove the two outside screws holding the End Panel in place. Note that the orange arrows point out the two screws. Step 2. With a Phillips #1 screwdriver, remove the three inside screws holding the End Panel in place. Note that the orange arrows point out the three screws Step 3. Remove the End Panel. 980006-001 Rev.
Replacement Procedures RFID Antenna Assembly 5.10 RFID Antenna Assembly Step 1. Locate the RFID Antenna Assembly (Antenna Cover and Antenna Flex Cable). Screws 176 RFID Antenna Assembly Step 2. Remove the Antenna Cover from the Payout Spindle. Note that the Antenna Cover snaps in place. Step 3. Separate the Antenna Flex Cable from the Antenna Cover. Step 4. With a TORX T25 driver, remove the two screws shown in the figure above.
Replacement Procedures Platen 5.11 Platen Step 1. Using the Card Transport Knob, move the Truck back to its home position, stopping when the right hand edge of the Platen is even with the right hand inner surface of the Card Input Hopper. Step 2. Push the Platen to the left against its spring. Step 3. Pry the Platen out using a CR-80 card. Important • Do not lose the spring! It holds the platen tight against the right of the truck and is essential for good print registration. Step 4.
Replacement Procedures Flip Station 5.12 Flip Station 5.12.1 178 Removal Step 1. Locate the Flip Station. Step 2. If not already done, remove the Rear Cover (see Section 5.3) and the Main PCBA (see Section 5.5). Step 3. From the rear of the printer, locate the drive motor. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Flip Station Step 4. With a TORX T25 driver, remove the two screws holding the Drive Motor to the Frame. Step 5. Cut the associated cable tie(s). Step 6. Disconnect the ground wire. Step 7. Remove the drive motor. Step 8. Move the drive belt to the left, out of the way. Step 9. With a Phillips #0 screwdriver, loosen the screw that holds the shaft in place. 980006-001 Rev.
Replacement Procedures Flip Station Step 10. Remove the shaft by pulling it up and out of the Flip Station. Step 11. With a Phillips #0 screwdriver, remove the screw holding the Cam in place. Step 12. Remove the Cam and screw. 180 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Flip Station Step 13. Slide the entire carrier assembly up (to its highest point) and out of the printer. Step 14. Remove the carrier assembly. 980006-001 Rev.
Replacement Procedures Flip Station Step 15. With a flat-blade screwdriver, remove the lower two 5/16 screws that hold the Backplate to the Frame; refer to figure below. Step 16. With a Phillips #2 screwdriver, remove the upper two screws holding the Backplate to the Front Bezel; refer to figure above. Step 17. Cut the cable ties, as required, to free the Backplate. Step 18. Remove the Backplate by pulling it out and down from the printer.
Replacement Procedures Flip Station 5.12.2 Replacement Step 19. From the rear of the printer, install the Backplate by lifting it up and into the printer. Ensure the two tabs at the top of the Backplate are on the outside of the support beam on the front. Step 20. Install (finger-tight) the two 5/16 screws that hold the Backplate to the Frame. Step 21. With a Phillips #2 screwdriver, install the two screws holding the Backplate to the Front Bezel. Step 22.
Replacement Procedures Flip Station Step 27. Position the Cam and Flip Arm. Note that the large side (lobe) of the Cam is on the same side as the extended Flip Stop. Extended Flip Stop Cam Lobe Step 28. With a Phillips #0 screwdriver, install the screw holding the Cam and Flip Arm in place. Step 29. Adjust the Azimuth. a. Locate the azimuth adjustment screw. 184 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Flip Station b. Adjust the azimuth (via the adjustment screw) until the pin is aligned in the middle of the notch. c. Lift and lower the carrier assembly to verify position. Step 30. Adjust the Gap. a. With a 1/4” socket, adjust the back Flip Arm until it just misses the Platen. 980006-001 Rev.
Replacement Procedures Flip Station b. With a 1/4” box wrench, adjust the front Flip Arm until it just misses the Platen. Step 31. Install the Drive Motor. a. Set the Drive Motor in place. a. With a TORX T25 driver, lightly tighten the two screws holding the Drive Motor to the Frame. b. Ensure that the drive belt is aligned properly, around the drive motor pulley. c. Manually rotate the drive motor to tighten the belt. d.
Replacement Procedures Flip Station 5.12.3 Adjustments 5.10.4.11 Flip Station Calibration This routine determines the number of motor steps it takes for the carrier to descend from the upper limit position to the lower limit position, that being the carrier’s physical end stop. This stored number is used to drive the carrier down to the rest position before each and every flip station action.
Replacement Procedures Flip Station 5.10.4.12 Max Height Adjust The card carrier needs to move high enough to actuate the flipping mechanism, but should not over-travel excessively. To access the Flip Station Adjustment screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Device Settings > Printer Adjustment > Flip Station Adjust... Increase this parameter only if there is an occasional failure to flip.
Replacement Procedures Flip Station 5.10.4.13 Insertion Height Adjust “Insertion height” is the intermediate (non flipping) elevation to which the card is driven for insertion into the laminator. To access the Flip Station Adjustment screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Device Settings > Printer Adjustment > Flip Station Adjust... Adjust the parameter if the ejector arm misses the card.
Replacement Procedures Flip Station 5.10.4.14 Rest Position Adjust This procedure adjusts how far down the carrier drives. If the truck fails to pull the card out of the flip station after the flipping action, chances are: 1. The card position is wrong; see “Card Position Adjust” on page 191. 2. The carrier is not coming down all the way; repeat “Flip Station Calibration” on page 187. Another adjustment for this: 190 Step 1.
Replacement Procedures Flip Station 5.10.4.15 Card Position Adjust This procedure adjusts how far the truck drives into the Flip Station. The adjustment should be set so that the card is centered in the flip arms (if it is not centered, the truck may have difficulty removing the card after the flipping action). To move the card into the Flip Station, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing.
Replacement Procedures Printhead Assembly 5.13 Printhead Assembly Electrostatic Discharge Caution • The Printhead is extremely susceptible to Electrostatic Discharge (ESD) damage. Do not touch the bottom surface of the Printhead. The replacement must be performed at a static-free work station, an antistatic wrist strap must be worn and properly terminated, or other appropriate protection must be used. Important • This procedure describes replacing the Printhead Assembly.
Replacement Procedures Printhead Assembly Step 2. With a 5/64” hex driver, remove the front mounting screw (LONG SHOULDER). Back Mounting Screw DO NOT LOOSEN or REMOVE Front Mounting Screw Step 3. With a 5/64” hex driver, remove the back mounting screw (SHORT SHOULDER). Step 4. With a 3/32” hex driver, remove the two screws holding the Printhead Cover in place. Note that the ground wire is attached via the longer rear screw. Step 5. Remove the Printhead Cover. Step 6.
Replacement Procedures Printhead Assembly 194 Step 7. Disconnect the Printhead Cable. Step 8. With a TORX T10 driver, remove the inside mounting screw. Step 9. Remove the Printhead Assembly. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Printhead Assembly 5.13.2 Replacement Caution • Do not touch the bottom edge of the print head. Grease or other contaminants from the hands can attract particles that may in time damage the head Step 1. Note the resistance (e.g., R=2597) listed on the replacement Printhead Assembly. Also, change the value on the printhead cover to reflect the new resistance value. Step 2. Preset the angle adjust screw to approximately 30 mils (the thickness of a card). 980006-001 Rev.
Replacement Procedures Printhead Assembly Caution • Make sure power is disconnected before working on the print head. Also note that the head will likely be destroyed if power is reapplied while you are in process of reconnecting the cable, or if the plug is not seated properly. Step 3. Connect the cable to the replacement printhead, making sure it is seated properly. Step 4. Install the back mounting screw. Note that the back screw is the shorter of the two mounting screws. Step 5.
Replacement Procedures Printhead Assembly 5.13.3 Tests and Adjustments Step 1. Enter the Printhead Resistance. a. Select Start > Printers and Faxes, right click the Zebra Card Printer, and select Properties from the pop-up menu. b. From the Card Printer Properties screen, select Device Settings > Printer Adjustment > Print Station Adjust... c. In the Printhead Resistance (Ohms) field, enter the resistance of the replacement Printhead noted in Step 1of the Printhead Replacement section. Step 2.
Replacement Procedures Printhead Assembly Step 3. Adjust the Printhead Angle. a. If not already done, remove the Printhead Cover; and move the ground wire out of the way. b. Loosen the inside mounting screw just enough to allow sliding movement of the printhead bracket. Inside Mounting Screw Access Hole for Angle Adjust Screw c. Unlock the angle adjust screw, turn it a quarter-turn counterclockwise, then re- lock it.
Replacement Procedures Printhead Assembly Step 5. Adjust the Printhead Height/Pressure. a. Select Start > Printers and Faxes, right click the Zebra Card Printer, and select Properties from the pop-up menu. b. From the Card Printer Properties screen, select Device Settings > Printer Adjustment > Print Station Adjust... c. In the Printhead Position Adjust field, decrease the value by 10; and print a card. d.
Replacement Procedures Power Supply 5.14 Power Supply 5.14.1 Removal Electric Shock Caution • Before performing this procedure, set the printer power to OFF (O) and disconnect the power cord. 200 Step 1. Locate the Power Supply. Step 2. With a TORX T15 driver, remove the four screws holding the Bottom Plate to the Frame. Step 3. Carefully slide the Power Supply (attached to the bottom plate) out of the printer. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Power Supply Step 4. With a TORX T10 driver, remove the four screws holding the power supply cover to the bottom plate. Step 5. Remove the power supply cover. Step 6. Disconnect the AC power connector. Step 7. Disconnect the DC power connector. Step 8. With a TORX T10 driver, remove the four screws holding the power supply to the bottom plate. Step 9. Remove the Power Supply. 980006-001 Rev.
Replacement Procedures Power Supply 5.14.2 Tests and Adjustments Step 1. Mount the replacement Power Supply to the bottom plate. Step 1. Attach the AC and DC connectors to the Power Supply. Step 2. Plug in and power up the printer. Electric Shock Caution • Do not touch the Power Supply Board or the Main PCBA. Step 3. With a Volt Meter in the VDC mode, attach the black probe to a black wire in the 24V DC Power connector; and attach the red probe to a red wire in the 24V DC Power connector.
Replacement Procedures Clean Roller 5.15 Clean Roller 5.15.1 Removal Step 1. Locate the Clean Station. Step 2. If not already done, remove the Rear Cover (see Section 5.3) and the Main PCBA (see Section 5.5). Step 3. Remove the Cleaning Tape Cartridge. 980006-001 Rev.
Replacement Procedures Clean Roller 204 Step 4. With a Phillips #0 screwdriver, remove the two screws inside the front openings of the Clean Station Housing; see following view from side. Step 5. With a Phillips #0 screwdriver, loosen the screw holding the Clean Station Housing to the Frame; see following view from top. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Clean Roller Step 6. With a small flat-blade screwdriver, lift the torsion spring out of the groove in the bushing that holds the clean roller shaft. Do not remove the spring from the housing. Step 7. Slide the Clean Station Housing out of the Frame. Note the orientation of the torsion spring should it come loose from the housing. 980006-001 Rev.
Replacement Procedures Clean Roller 206 Step 8. From the rear of the printer, locate the Clean Station. Step 9. With a Phillips #4 screwdriver, remove the two screws holding the Cleaning Encoder Sensor to the Frame. Move the sensor out of the way. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Clean Roller Step 10. Remove the Encoder Wheel from the clean roller shaft by gently turning the wheel back and forth while pulling outward. Step 11. Locate the torsion spring holding the clean roller shaft in place. Step 12. With a small flat-blade screwdriver, lift the torsion spring out of the groove in the clean roller shaft. Do not remove the spring. 980006-001 Rev.
Replacement Procedures Clean Roller Step 13. From the front of the printer, slide the Clean Roller out of the Frame. Step 14. Remove the Clean Roller. 208 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Clean Roller 5.15.2 Replacement Step 1. Install the rear torsion spring, encoder wheel, and sensor first; then install the replacement Clean Roller. Step 2. The Pivot Screw (left-side screw) must not be too tight (tighten, then back off 1/2 turn). Step 3. After installing the replacement Clean Roller, run a clean cycle. Step 4. If the cleaning tape seizes, adjust the Pivot Screw 1/2 turn counterclockwise. Repeat until the clean cycle becomes operational; see figure above.
Replacement Procedures Cleaning Encoder Sensor 5.16 210 Cleaning Encoder Sensor Step 1. If not already done, remove the Rear Cover (see Section 5.3) and the Main PCBA (see Section 5.5). Step 2. From the rear of the printer, locate the Cleaning Encoder Sensor. Step 3. With a Phillips #0 screwdriver, remove the two screws holding the Cleaning Encoder Sensor to the Frame. Step 4. Cut any associated cable ties to free the Cleaning Encoder Sensor. Step 5.
Replacement Procedures Cleaning Encoder Sensor Step 6. 980006-001 Rev. A Remove the Cleaning Encoder Sensor.
Replacement Procedures Laminator Sensor PCBA 5.17 Laminator Sensor PCBA 5.17.1 212 Removal Step 1. Locate the Lam Sensor PCBA. The sensor is behind the Lam Transfer Rollers. Step 2. Remove the upper and lower Flex Guides. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Laminator Sensor PCBA Step 3. With a TORX T15 driver, remove the screw holding the upper Retaining Spring to the Frame. Step 4. With a TORX T15 driver, remove the two screws holding the Lam Sensor PCBA to the Frame. 980006-001 Rev.
Replacement Procedures Laminator Sensor PCBA Step 5. Unplug the Lam Sensor PCBA. Step 6. Remove the Lam Sensor PCBA. Note • When installing the replacement Lam Sensor PCBA, align the screws to the center of the opening. This will help in achieving the optimal sensor reading. 214 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Laminator Sensor PCBA 5.17.2 Tests and Adjustments Laminator Parameters in the Driver To access the Status screen, select Start > Printers and Faxes. Right click on the Zebra P630i or Zebra P640i printer listing. Select Properties > Device Settings > Control > Advanced Utilities > Show Sensor Data 1. Heater Temperatures -Temperatures measured by thermocouples in the top and bottom laminator heater cores. 2.
Replacement Procedures Laminator Sensor PCBA Functional Test of the Sensors Note • The sensor board must be symmetrically positioned relative to the transfer rollers, with its attachment screws central in their slots. It is possible to get a false “good” reading if the sensors are too close to the feed rollers. 216 Step 1. From each of the laminators, upper and lower, remove the transfer guide and the laminate patch, if any, beneath it.The laminate sensor should read high, around 250. Step 2.
Replacement Procedures Laminator Transfer Rollers 5.18 Laminator Transfer Rollers Note • This procedure applies to the removal and replacement of the upper Lam Transfer Roller, which is in both the P630i and P640i card printers. The lower Lam Transfer Roller, which is only in the P640i card printer, is removed similarly. Step 1. Locate the Lam Transfer Rollers. Step 2. Remove the upper Flex Guide. 980006-001 Rev.
Replacement Procedures Laminator Transfer Rollers 218 Step 3. With a TORX T15 driver, remove the screw holding the upper Retaining Spring to the Frame. Step 4. From the rear of the printer, locate the Transfer Roller Gear. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Laminator Transfer Rollers Step 5. With snap-ring pliers, remove the snap retaining ring and roller gear from the transfer roller shaft. Step 6. Push the shaft toward the front of the printer. Step 7. With a TORX T15 driver, remove the two screws holding the Laminator Transfer Roller to the shaft; see figure above. Step 8. Remove the Laminator Transfer Roller from the shaft by pulling the shaft out, toward the front of the printer. 980006-001 Rev.
Replacement Procedures Ribbon Encoder Sensor 5.19 220 Ribbon Encoder Sensor Step 1. Locate the Ribbon Encoder Sensor. Step 2. Remove the RFID Antenna Cover. Note that the cover snaps in place. Step 3. With a TORX T15 driver, remove the two screws that hold the Ribbon Encoder Sensor to the Frame. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Ribbon Encoder Sensor Step 4. If not already done, remove the Rear Cover (see Section 5.3) and the Main PCBA (see Section 5.5). Step 5. From the rear of the printer, locate the Ribbon Encoder Sensor. Step 6. Cut any associated cable ties to free the Ribbon Encoder Sensor. Step 7. If not already disconnected, remove the RIBBON ENCODER Connector from J31 on the Main PCBA. Step 8. From the rear of the printer, slide the Ribbon Encoder Sensor out of its access hole. Step 9.
Replacement Procedures Ribbon Payout Spindle 5.20 Ribbon Payout Spindle 5.20.1 222 Removal Step 1. Locate the Ribbon Payout Spindle. Step 2. Remove the RFID Antenna Cover. Note that the cover snaps in place. Step 3. With a 7/64 hex driver, loosen the two screws that hold the Ribbon Encoder Sensor to the Frame. Step 4. Slide the sensor down to clear the encoder wheel. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Ribbon Payout Spindle Step 5. With a 7/16 socket wrench, remove the lock nut from the Ribbon Payout Spindle. Step 6. Slide the spindle off the shaft. Step 7. Carefully slide the clutch parts out of the spindle. Step 8. Remove the three screws holding the Encoder Wheel to the Spindle, and set the Encoder Wheel aside. Step 9. Set the Spindle aside. 980006-001 Rev.
Replacement Procedures Ribbon Payout Spindle 5.20.2 Replacement Step 1. Attach the Encoder Wheel to the replacement Spindle. Step 1. Install the clutch parts in the order indicated. 1 224 2 3 4 5 6 7 8 9 Step 2. Slide the spindle, with the clutch parts installed, onto the spindle shaft. Step 3. Loosely tighten the lock nut. Step 4. Slide the Ribbon Encoder Sensor up and into its original position. Step 5.
Replacement Procedures Ribbon Payout Spindle 5.20.3 Adjustment To perform the procedure ensure you have a Clutch Burn-In Tool Kit, a 7/16” nut driver, and the IDPrint test and adjustment program. The Clutch Burn-In Tool Kit, P/N: 105927-430, consists of: • Clutch Pulley Assembly • Grooved Splined Cores (2) • O-rings (2) Step 1. Find Low Ribbon Torque. a. Plug in and power up the printer b. Ensure the Payout Spindle rotates freely. Take-up Spindle Payout Spindle c.
Replacement Procedures Ribbon Payout Spindle d. Install the two Grooved Splined Cores. Core O-ring Core e. Install the one of the O-ring in the front slots on the two cores. f. Start IDPrint. g. Select Control > Ribbon Tasks > Find Low Ribbon Torque: h. Observe the two cores rotate counterclockwise for approximately two minutes. i. When the motor stops turning, go to the next step. 226 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Ribbon Payout Spindle Step 2. Find High Ribbon Torque a. Place the Clutch onto the Guide Shaft. Note that you may have to move the Printhead down to access the Guide Shaft. O-ring O-ring Clutch b. Place one O-ring around the Clutch (in the rear slot) and around the left core (in the rear slot). c. Install the other O-ring in the front slots on the two cores. d. From the IDPrint screen, select Control > Ribbon Tasks > Find High Ribbon Torque: e.
Replacement Procedures Ribbon Payout Spindle Step 3. Run Ribbon Motor (Clutch Burn-In) a. Remove the O-ring in the front slots on the cores. b. Remove the Clutch and associated O-ring. c. Reinstall an O-ring in the front slots on the two cores. O-ring d. From the IDPrint screen, select Control > Ribbon Tasks > Run Ribbon Motor (Clutch Burn-In): e. Observe the two cores rotate counterclockwise. 228 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Ribbon Payout Spindle f. Tighten the payout spindle nut until the O-ring bows, then back off slightly. g. Listen to the “hum” of the motor. h. Adjust the tightness of the payout spindle nut until the motor hum is constant. i. This test takes approximately ten minutes. When the motor stops turning, go to the next step. Step 4. Adjust Payout Clutch Note • You may need to repeat this step until you are satisfied with the adjustment. a.
Replacement Procedures Ribbon Payout Spindle b. Observe the two cores rotate counterclockwise. c. Observe the panel lights. Note • The panel lights should flash an equal amount of time between Green (Ready) and Red (Alarm) -- the optimum condition would be Yellow (Media) on all the time. d. Adjust the payout spindle nut as required -- if Red, tighten; if Green, loosen. e. When the motor stops turning and you are satisfied with the adjustment, go to the next step. 230 Step 5.
Replacement Procedures Laminator Heater Cartridge and Heated Roller 5.21 Laminator Heater Cartridge and Heated Roller Hot Surface • Wait 10 - 20 minutes for the printer to cool down. Step 1. Locate the Heated Rollers. Step 2. Loosen the thumb screw that holds the Laminator Heater Cartridge in place. 980006-001 Rev.
Replacement Procedures Laminator Heater Cartridge and Heated Roller 232 Step 3. Remove the Laminator Heater Cartridge. Step 4. With a 1/16 hex driver, loosen the set screws that hold the two brass gears to their respective shafts. Note that each gear has two set screws. Step 5. Remove the two brass gears. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Laminator Heater Cartridge and Heated Roller Step 6. With a TORX T10 driver, remove the three screws that hold the front bracket in place. Step 7. Remove the front bracket. Step 8. With a TORX T15 driver, remove the four screws that hold the rear bracket in place. 980006-001 Rev.
Replacement Procedures Laminator Heater Cartridge and Heated Roller Step 9. With a small flat-blade screwdriver, remove the two C-rings. Step 10. Remove the rear bracket. Note that the two flanged bearings should remain in the rear bracket. 234 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Laminator Heater Cartridge and Heated Roller Step 11. From the front of the assembly, remove the C-ring that corresponds to the Heated Roller that needs replacing. Step 12. From the rear of the assembly, remove the Heated Roller. 980006-001 Rev.
Replacement Procedures Heater Elements 5.22 Heater Elements 5.22.1 Removal Hot Surface • Wait 10 - 20 minutes for the printer to cool down. 236 Step 1. If not already done, remove the Rear Cover (see Section 5.3). It is not necessary to remove the Main PCBA. Step 2. Locate the Heater Elements. Step 3. Disconnect the Heater Elements from the Main PCBA (Remove the top heater from J42A and J43, and remove the bottom heater from J42B and J44). Step 4.
Replacement Procedures Heater Elements Step 5. Slide out the top Heater Element. Step 6. Slide out the bottom Heater Element. Step 7. Remove the Heater Elements. 980006-001 Rev.
Replacement Procedures Heater Elements 5.22.2 Replacement Step 1. Replace the Triflunox 722 (lubricant). Note • Note that Triflunox 722 is a lubricant, which provides a tough coating that is extremely heat resistant while protecting against rust and oxidation at high temperatures. a. Loosen the thumb screw that holds the Laminator Heater Cartridge in place. b. Remove the Laminator Heater Cartridge. 238 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Heater Elements c. Turn the Laminator Heater Cartridge around, and brush Triflunox 722 all around toothed surfaces and inside both gears. d. Reinstall the Laminator Heater Cartridge into the Laminator. Ensure that the gears mesh properly. 980006-001 Rev.
Replacement Procedures Heater Elements Step 2. Slide the Heater Elements into place. Ensure the top and bottom heaters are in their respective positions. Note • In the next step, use the replacement screws that come in the Spare Parts Kit -- they have a dry-to-the-touch film applied to the threads which lock and seal the screws in place. 240 Step 3. With a TORX T10 driver, secure the three screws that hold each heater to the Frame. The screws must not be too tight (tighten, then back off 1/2 turn).
Replacement Procedures Nip Rollers (Laminator) 5.23 Nip Rollers (Laminator) 5.23.1 Removal Step 1. If not already done, remove the Rear Cover (see Section 5.3). It is not necessary to remove the Main PCBA. Step 2. Locate the Nip Rollers. Step 3. Remove both Laminate Cassettes. Step 4. Remove the Laminate Cassette Receivers (top and bottom). a. Use the 7/64” hex driver to remove both the top and bottom spring loaded cap screws. Be careful not to lose the screws and springs. 980006-001 Rev.
Replacement Procedures Nip Rollers (Laminator) b. Use the 7/64” hex driver to remove the skew adjust screws from both the top and bottom cassette receivers. c. Remove the top Laminate Cassette Receiver. d. Remove the bottom Laminate Cassette Receiver. Turn the cassette receiver clockwise until it can be easily removed from the printer. 242 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Nip Rollers (Laminator) Step 5. With snap-ring pliers, remove the top snap ring that holds the nip roller shaft in place. Step 6. With snap-ring pliers, remove the bottom snap ring that holds the nip roller shaft in place Step 7. Turn the printer around. Step 8. With a TORX T10 driver, loosen both motors; i.e., remove two of the three screws for each motor, and just loosen the third screw. Step 9. Pivot the motors out of the way to access the Nip Rollers. 980006-001 Rev.
Replacement Procedures Nip Rollers (Laminator) Step 10. With a flat-blade screwdriver, remove the E rings from each nip roller shaft. a. Remove the top E-ring. b. Remove the bottom E-ring. Step 11. Before removing the gears, mark each one for correct orientation when reinstalled; e.g., FT = front top and FB = front bottom. 244 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Nip Rollers (Laminator) Step 12. Slide the top and bottom gears off their respective shafts. Step 13. Gently slide each shaft back, up, and out of the printer. Step 14. Remove the Nip Rollers. Note that the long end of the shaft goes to the back of the printer when installing the replacement Nip Rollers. 980006-001 Rev.
Replacement Procedures Nip Rollers (Laminator) 5.23.2 Adjustment Pocket Adjustment Skew and vertical offset are adjusted by screws in the cassette pocket (7/64" hex wrench for skew, flat blade screwdriver for vertical offset, see diagram below). DO NOT ADJUST Skew Adjust Vertical Offset Adjust Before adjusting for skew or vertical offset, remember that there is significant interaction between the latch and the adjusting screws in the pocket.
Replacement Procedures Nip Rollers (Laminator) Latch Adjustment The cassette is held in place by two ears on the cassette latch. Using a piece of 1 mil laminate as a feeler gauge, set the front ear close to, but not touching, the cassette. A hex head screw (arrowed) sets front-back position of the latch. Adjust the latch position using a 7/64" hex wrench. Latch Adjust Latch Ears 980006-001 Rev.
Replacement Procedures Nip Rollers (Laminator) Cassette Pocket Reset Skew is caused by misalignment of the laminate cassette relative to the left-right axis of the printer, looking down on the printer from above. The skew adjust screw causes the pocket to rotate relative to the left-right axis. The vertical offset adjust screw controls the depth of the cassette in the pocket. Note that the front ear of the latch must be in close contact with the cassette, without changing its position.
Replacement Procedures Color Sensor Assembly 5.24 Color Sensor Assembly Step 1. Locate the Color Sensor Assembly. Step 2. If not already done, remove the Rear Cover (see Section 5.3) and the Main PCBA (see Section 5.5). Step 3. With a TORX T10 driver, remove the screw holding the Color Sensor Assembly in place. 980006-001 Rev.
Replacement Procedures Color Sensor Assembly Step 4. Turn the printer around (view from back). Step 5. Cut the associated cable tie(s). Step 6. If not already disconnected, remove the RIBBON SYNC Connector from J35 on the Main PCBA. Step 7. Remove the Color Sensor Assembly. Note • When replacing the Color Sensor Assembly, ensure the round tab is inserted in the hole before tightening. 250 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Contact Smart Card Assembly 5.25 Contact Smart Card Assembly Step 1. Locate the Contact Smart Card Assembly. Step 2. If not already done, remove the Rear Cover (see Section 5.3) and the Main PCBA (see Section 5.5). Step 3. Remove the Contact Smart Card PCBA. a. With a Phillips #0 screwdriver, remove the two screws holding the Contact Smart Card Cover in place. 980006-001 Rev.
Replacement Procedures Contact Smart Card Assembly b. With a 2mm hex driver, remove the screw holding the Contact Smart Card PCBA to the shaft. c. If not already disconnected, remove the connector from J16 on the Main PCBA. d. Remove the Contact Smart Card PCBA and shaft. 252 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Contact Smart Card Assembly Step 4. Remove the Contact Smart Card Solenoid. a. Locate the Contact Smart Card Solenoid. b. With a Phillips #2 screwdriver, remove the two screws holding the solenoid in the bracket. c. If not already disconnected, remove the connector from J16 on the Main PCBA. d. Remove the Contact Smart Card Solenoid. 980006-001 Rev.
Replacement Procedures Eject Arm 5.26 254 Eject Arm Step 1. Locate the Eject Arm. Step 2. If not already done, remove the Rear Cover (see Section 5.3) and the Main PCBA (see Section 5.5). Step 3. If the Contact Smart Card Option is installed, remove the Contact Smart Card PCBA (see Section 5.25). Step 4. With a TORX T10- driver, remove the screw holding the Color Sensor in place. Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Eject Arm Step 5. Move the Color Sensor out of the way. Step 6. With a 5/32 ball-end hex driver, loosen the two screws shown below. This will allow the backplate to move. Step 7. Turn the printer around (view from back). Step 8. With a flat-blade screwdriver, remove the two screws shown below. This will allow the backplate to move. 980006-001 Rev.
Replacement Procedures Eject Arm Step 9. Turn the printer around (view from front). Step 10. Push and hold the backplate far enough to the rear of the printer to access the screw at the back of the Eject Arm. Step 11. With a 9/64 hex driver, remove the screws at the back and front of the Eject Arm. Step 12. Remove the Eject Arm. 256 Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Replacement Procedures Magnetic Encoder 5.27 Magnetic Encoder 5.27.1 Removal Step 1. Locate the Magnetic Encoder. Step 2. If not already done, remove the Rear Cover (see Section 5.3) and the Main PCBA (see Section 5.5). Step 3. With a 5/64 hex driver, remove the shoulder screw, nylon washer, compression spring, and flat washer from the right side of the Magnetic Encoder. Step 4.
Replacement Procedures Magnetic Encoder Step 5. Turn the printer around (view from back). Step 6. With a flat-blade screwdriver, disconnect the ground wire attached to the Frame. Step 7. If not already disconnected, remove the Magnetic Encoder Connector from J14 on the Main PCBA. Step 8. Turn the printer around (view from front). Step 9. Carefully pull the cable and connector through the opening behind the Hopper. Step 10. Remove the Magnetic Encoder.
Replacement Procedures Magnetic Encoder 5.27.2 Replacement Step 1. Set the replacement Magnetic Encoder in place. Important • Use the 30-thousandths shim while installing the shoulder screws (and associated hardware), then remove it once the screws are tightened. Step 2. Install the shoulder screws, nylon washers, compression springs, and flat washer. Note that there is no flat washer on the left side. Step 3. Remove the shim. Step 4.
Replacement Procedures Magnetic Encoder 5.27.3 Adjustment Step 1. After replacing the Magnetic Encoder, go into the Printer Driver; and perform the Magnetic Encoder Position Adjustment. a. Select Start > Printers and Faxes, right click the Zebra Card Printer, and select Properties from the pop-up menu. b. From the Card Printer Properties screen, select Device Settings > Control > Advanced Utilities. c. Load a few magnetic stripe cards. d. Click the Mag Position Adjust button. e.
Replacement Procedures Magnetic Encoder Important • Do not perform Step 2 if the encoder successfully writes to the magnetic stripe and all three tracks on the stripe read properly. Step 2. If there is a magnetic encoder error, go into the Printer Driver; and perform the Magnetic Encoder Amplitude Adjustment. a. Select Start > Printers and Faxes, right click the Zebra Card Printer, and select Properties from the pop-up menu. b.
Replacement Procedures Magnetic Encoder f. Observe the Mag Data Monitor window which shows the amplitude values of all three tracks. All three tracks should be close in value and be greater than 100. g. With a 3/32 hex wrench, adjust the amplitude by turning the adjusting screw 1/4 turn clockwise. h. Continue turning the adjusting screw clockwise 1/4 turn until any or all amplitudes drop off sharply; then back off the adjustment 1/2 turn. i.
6 Preventive Maintenance There is almost no preventive maintenance to be performed. Dust and debris should be vacuumed out every 12 months, or more frequently in adverse environments. 6.1 Card Cleaning System Your Printer includes a simple cleaning system using a Cleaning Cassette. Cleaning Cassette Before being printed, each surface of the card is cleaned by a soft tacky roller that is itself cleaned periodically by adhesive tape in the Cleaning Cassette.
Preventive Maintenance Print Head Cleaning 6.2 Print Head Cleaning The card cleaning system using the Cleaning Cassette will normally do an adequate job of cleaning the cards. However, a separate Printhead cleaning, using swabs, can remove more stubborn deposits when print anomalies persist. Caution • Only use foam-tipped swabs. Never use a sharp object to scrape deposits from the print head. Permanent damage to the print head will result. Step 1. Place the printer power switch in the ON ( | ) position.
Preventive Maintenance Platen Care and Cleaning 6.3 Platen Care and Cleaning Important • Regular cleaning of the Platen helps maintain performance. The Platen plays an important part in the printing process, providing a rigid supporting surface for the card as it passes under the print head. Because flatness is important, the Platen is surface ground to close tolerances.
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APPENDIX A Part Numbers The Part Number of a particular Printer is shown on a label affixed to the bottom of the printer; that Part Number identifies the specific configuration for that printer. 980006-001 Rev.
Part Numbers This chart shows the configurations that are available.
Appendix B Magnetic Encoder Media Loading Orientation Caution • ONLY USE cards that comply with ISO 7810 & 7811 standards for magnetic stripe cards. The magnetic stripe must be flush to the surface of the card to work properly. Never use cards which have taped-on magnetic stripes. When loading cards with magnetic stripes into the card feeder, please ensure that the magnetic stripe is face up, facing the front of the printer. Magnetic Stripe 980006-001 Rev.
Magnetic Encoder Magnetic Card Stripe Encoding Magnetic Card Stripe Encoding This section contains information on the additional operations of the P630i or P640i Printer with Magnetic Card Stripe Encoder.The magnetic encoder uses high coercivity.
Appendix C Smart Card Contactless Encoder Introduction Smart cards can have a built-in microprocessor and/or memory chip. The printer may be equipped with an optional contactless station for programming Smart Cards. Smart card contactless encoders utilize a short-range radio signal. Use of the encoder is entirely under control of the third-party application program -- no operator action is required. All other printer operations remain the same as the standard model.
Smart Card Contactless Encoder Printing Contactless Smart Cards Printing Contactless Smart Cards When designing material to be printed on Contactless Smart Cards, be sure the printing will not be on the smart chip area (i.e., the printing on either side of the card must not be on top of or underneath the smart chip area). By looking at an un-printed card very carefully, it is possible to see the chip location (as in the figure on the left below).
Appendix D Smart Card Contact Station Introduction Smart Cards have a built-in microcomputer and/or memory chip, which is used to store fingerprints, voice recognition patterns, medical records, or other types of data. The printer may be equipped with an optional contact station for programming Smart Cards (ISO 7816). This printer model responds to commands that position the card at the contact station, where the printer connects to the contacts on the Smart Card.
Smart Card Contact Station Laminating Contact Smart Cards Laminating Contact Smart Cards The laminating patch on the top surface of a smart card has a rectangular aperture to expose the card’s electrical contacts. In all other respects the laminating process for smart cards is the same as for ordinary cards. The special laminate for the top cassette is punched with a repeated pattern. Loading procedure for smart card laminate is exactly the same as for standard laminate as shown in Chapter 2.
Appendix E Printer Security ID/Key The optional ID/Key is a physical security key that is programmed for each specific P630i or P640i printer. It is intended to prevent unauthorized use of that printer. ID Key The ID/Key has a non-alterable memory containing a unique 64-bit serial number that is compared prior to each print job with a serial number stored in the printer’s Non-Volatile Random Access Memory (NVRAM). If the serial numbers fail to match, or if no ID/Key is detected, the printer is disabled.
Printer Security Printer Parameters in the Driver Printer Parameters in the Driver ID/Code The ID/Code, or password, synchronizes the driver with the printer. This prevents use of the printer with a PC not having the same ID/Code. The initial ID/Code is assigned at the factory during manufacture. The factory assigned code is located on a sticker on the underside of the ID/Key. To change this code, select Start > Printers (or Printers and Faxes).
Printer Security Printer Parameters in the Driver Password Protection Password protection is not the same as ID/Code. Password protection blocks access to various low level printer adjustment screens. To enable password protection, select Start > Printers (or Printers and Faxes). Right click Zebra P630i, or Zebra P640i, then select Properties > Device Settings > Control > Advanced Utilities. In the Password Protection section, check Use Password; and enter a password of your choice. 980006-001 Rev.
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APPENDIX F Printer Pooling Setting Up the Printers Individually • For illustration, we will establish a pool of three printers • Note • In the P640i, many of the configuration variables are stored in the printer itself, unlike the typical printer as defined by Microsoft. All pooled P640i printers must be set up similarly. Step 1. Install and setup the three printers.
Printer Pooling Creating the Pool Creating the Pool Step 1. Go to Start > Printers and Faxes > Add a Printer Step 2. Click Next on the Add Printer Wizard welcome screen. Step 3. Select Local Printer. Make sure that Automatically Detect My Plug and Play Printer is unchecked, then click Next. Step 4. Select Use the following port, and choose the port that the first printer is on. In this illustration, this will be ATLUSB001. Step 5.
Printer Pooling Using the Printer Pool Using the Printer Pool • Send print jobs to the pool, not to an individual printer • When the first printer has taken as many jobs as it can handle (that being two jobs - one to be printed immediately, the other waiting), the following jobs “spill over” to the second printer, and then to the third printer. Note that if you are only printing two jobs, they would both go to the first printer. Pooling is a spill-over methodology. It does not balance printer usage.
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APPENDIX G Spares List Introduction The following tables list the Spare Parts Kits available for the Zebra P630i & P640i Card Printer. Before ordering, be sure to check the Partner Zone on www.zebracard.com for the latest spare parts kits listing. The Spares List is arranged in the following categories: • Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284 • Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spares List Assemblies 284 Kit # Description 105927G-231 KIT,ASSY,FLIP STATION COMPLETE 105927G-284 KIT,ASSY,CARD EJECT ARM 105927G-285 KIT,ASSY,CLEAN STATION 105927G-239 KIT,POWER SUPPLY/BRKT Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Spares List 980006-001 Rev.
Spares List 286 Kit # Description 105927G-443 KIT, WEIGHT HOPPER 105927G-240 KIT,P6XX REPLACEMENT KEY 105927G-446 KIT,ASSY,DONGLE,P640 105927G-287 KIT,KNOB,MANUAL DRIVE Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Spares List Enclosures 980006-001 Rev.
Spares List 288 Kit # Description 105927G-294 KIT,PANEL,END,ENCLOSURE 105927G-292 KIT,COVER,REAR,ENCLOSURE 105927G-227 KIT,DOOR,LOAD,CARD 105927G-229 KIT,ASSY,DOOR,MAIN ACCESS Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Spares List 980006-001 Rev.
Spares List Transport 290 Kit # Description 105927G-277 KIT,BELT,TIMNG,MXL,3/8W,150 OT 105927G-278 KIT,BELT,TIMING,MXL,3/8W,140T 105927G-260 KIT,C/A,SENSOR,CARRIAGE HOME 105927G-258 KIT,C/A,SENSR,CRD HOPPR EXIT 105927G-298 KIT,SWITCH, NEAR HOPPER Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Spares List 980006-001 Rev.
Spares List Cleaning Station 292 Kit # Description 105927G-088 KIT,SENSOR, CLEANING ENCODER 105927G-230 KIT,BEARING,SLEEVE W/GROOVE (SET OF 5) 105927G-221 KIT,ROLLER,CLEAN,P640I Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Spares List Printing Station 980006-001 Rev. A Kit # Description 105927G-244 KIT,MOTOR, HEAD LIFT 105927G-241 KIT,MOTOR,PRINT RIBBON,P640I 105927G-247 KIT,O-RING,.
Spares List 294 Kit # Description 105927G-348 KIT,COLOR SENSOR ASSY 105927G-458 KIT,ARBOR RBN SPINDLE P6XX Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Spares List Flip Station 980006-001 Rev.
Spares List 296 Kit # Description 105927G-441 KIT,SPRING,FLIP GUIDE,P640I (SET OF 5) 105927G-243 KIT,MOTOR,FLIP STATION 105927G-266 KIT,PCBA,SENSR,FLIP STATN Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Spares List Laminator Kit # Description 105927G-276 105927G-275 980006-001 Rev.
Spares List 298 Kit # Description 105927G-259 KIT,C/A,SENSOR,CARD LAM EXIT 105927G-264 KIT,LAM CASSETTE,UPPER 105927G-265 KIT,LAM CASSETTE,LOWER 105927G-305 KIT,BELT,TIMING,LAMINATOR 105927G-120 KIT,PCBA,SNSR,LAM Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Spares List 980006-001 Rev.
Spares List Kit # Description 105927G-442 KIT,LAM GUIDE EDGE 105927G-249 105927G-249 KIT,GUIDE,FLEX,PLASTIC,3.954IN 105927G-251 105927G-250 300 105927G-251 KIT,GUIDE,MEDIA,UPPER 105927G-250 KIT,GUIDE,MEDIA,LOWER Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Spares List Miscellaneous 980006-001 Rev.
Spares List 302 Kit # Description 105927G-206 KIT C/A, AC CABLE TO PWR SUPPLY 105927G-432 KIT C/A, AC CABLE TO MAIN PCBA TBD KIT, RFID ANTENNA Zebra P630i & P640i Card Printer Service Manual 980006-001 Rev.
Spares List Shipping Carton 980006-001 Rev.
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Appendix H Worldwide Support For Technical Support or Repair Services, contact the appropriate facility listed below. North America - Technical Support Zebra Technologies Card Printer Solutions 1001 Flynn Road Camarillo, CA 93012-8706 USA Phone: email: +1 800 511 9909 techsupport@zebra.com North America - Repair Services Before returning any equipment to Zebra Technologies Corporation for in-warranty or out-ofwarranty repair, contact Repair Services for a Return Materials Authorization (RMA) number.
Worldwide Support Europe, Middle East, and Africa - Technical Support Zebra Technologies Card Printer Solutions Zebra House, Unit 14, The Valley Centre Gordon Road, High Wycombe Buckinghamshire HP13 6EQ, UK Phone: e-mail: + 44 (0) 8702 411527 cardts@zebra.com Europe, Middle East, and Africa - Repair Services Before returning any equipment to Zebra Technologies Corporation for in-warranty or out-ofwarranty repair, contact Repair Services for a Return Materials Authorization (RMA) number.
Worldwide Support Asia Pacific - Technical Support and Repair Services Before returning any equipment to Zebra Technologies Corporation for in-warranty or out-ofwarranty repair, contact Repair Services for a Return Materials Authorization (RMA) number. Repack the equipment in the original packing material, and mark the RMA number clearly on the outside.
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