Zebra Eltron Card Printer User's Guide

P310Maintenance ManualManual No. 980264-001 Rev. B©2001 Zebra Technologies CorporationCP PARD RINTER RODUCTS

objects. For those who wish to create card graphics from their software applications, theunits ship with both Windows 95/98 and NT drivers. Both drive

Step 4. Adjust the Brightness Adjustment Screw by either loosening or tightening.Remember the amount and direction of adjustment. If loosening, push t

For an adjustment to make the Print Head parallel to the Platen Roller, continue as follows:Step 8. Unlatch and raise the Print Head.Step 9. Slightly

6.4.3 Print Head Peel Bar Position AdjustmentFigure 6-10 shows the two screws that fasten the Peel Bar to the Print Head assembly.Slotted holes allow

6.4.4 Image CenteringCentering establishes x- and y-offset values. The x offset determines when a Print Headlowers and raises, between which printing

Step 4. Either measure or estimate any departure from a centered image, and convertthe result to dots. Note that at 300 dpi, the distance between dots

APPENDIX ATEST SOFTWARETest Software supports factory checks that contribute to a functioning Printer.Because of the intuitive nature of the software,

A.2.1 Launching the Card Printer Test SoftwareWith DOS operating and the prompt set to the volume and folder containing the TestSoftware (e.g., C:\PNT

Selection of Item 3 from the previous screen (and entry of the code requested) produces thefollowing screen:980264-001 Rev. B A-3APPENDIX A

Particularly note the following:•A selection results by typing a list item number followed by <Enter>.•Selection of Exit returns the DOS prompt.

A.2.3 Operating in Terminal ModeThe following screen appears following selection of item 4, Terminal Mode, from thesecond screen. Terminal Mode offers

adjust the feeder for other thicknesses as well. The Card Feed Hopper, has an attachedCard Weight that positions itself on top of a stack of cards in

A.2.4 Typical Sub ListSelection of Item 2, Mechanic Test, from the second screen produces the following screen,which offers related selections. Note t

A.2.5 Sensor Test SelectionThe following screen appears after selection of item 2, Sensors Test, from the previousscreen.980264-001 Rev. B A-7APPENDIX

World Wide Sales and SupportZebra Technologies CorporationEltron Card Printer Products1001 Flynn RoadCamarillo, CA 93012-8706 USAPhone: +1 (805) 579 1

1.2.5 Magnetic Stripe Encoder (Option)Printers equipped with Magnetic Stripe Encoders fully support the encoding of cards withmagnetic stripes. This i

1.4 CAUTIONARY NOTESExercise reasonable care when servicing P310 printers, as follows:Other than prescribed operator maintenance, only qualifiedperson

1.5 PACKAGING CONSIDERATIONSThe factory-supplied shipping carton contains the Printer placed inside a protective ESD(Electrostatic Discharge) bag and

CHAPTER 2INSTALLATION AND OPERATIONThis chapter includes information on the following:• Unpacking• Installation• Controls and Indicators• Card and Rib

2.1 INSTALLATION2.1.1 UnpackingFigure 2-1 shows the carrier-approved packaging materials used for shipping and howthese items fit within inside and ou

2.1.2 Tape and Packing RemovalsFigure 2-2 shows the tape and packing material that requires removal prior to printeroperation.2.1.3 Card Input Hopper

2.1.4 Card Catcher InstallationFigure 2-4 shows the installation of the Card Catcher.2.1.5 Cleaning Roller Cartridge PreparationFigure 2-5 shows how t

2.1.6 Cleaning Roller Tape RemovalFigure 2-6 shows removal of the tape protecting the tacky surface.2.1.7 Cleaning Roller Cartridge InstallationFigure

2.1.8 Location ConcernsUsers should avoid dusty locations. Until ready for use, keep ribbon and card media in theircartons. Select a location that off

980264-001 Rev. B 2-7CHAPTER 2USB Concerns(USB Specification Rev. 2.0)1. USB-Equipped Host Computers have Hubconnection(s) and software that supports

2.1.10 Parallel an Serial Cable DiagramsFigure 2-10 shows the cable wiring.2-8 980264-001 Rev.BCHAPTER 2PRINTERMODULEDB-25Pin No.DB-25Pin No.FemaleDB-

2.2 OPERATION2.2.1 Controls and IndicatorsFigure 2-11 shows the push-button switch and LEDs (light emitting diodes) that appear onthe front of the Pri

2.2.3 Print Head Release and Latch LeversFigure 2-12 shows the Release and Latch levers for the Print Head. Users open the Coverand raise the Print He

2.2.4 Ribbon LoadingFigure 2-13 shows the loading of ribbons. Note that by keeping the Power ON duringRibbon Loads, a suspended operation resumes auto

2.2.5 Card Gate AdjustmentFigure 2-14 shows the Card Gate Adjustment Lever with arrows that show the directionsof travel.Step 1. Set the Card Gate Thi

2.2.6 Loading Card Input HopperFigure 2-15 shows the Card Input Hopper actions necessary to replenish cards.Step 1. Press down on Release Tab, and rot

2.2.7 Starting the Cleaning CycleAs noted in Section 2.2, the right two panel LEDs flash when the time for a Cleaning Cyclearrives. Until performed, n

CHAPTER 3THEORY OF OPERATIONThis chapter includes three major topics:• Color Fundamentals• Card Path Elements• Circuit Descriptions3.1 COLOR FUNDAMENT

FOREWORDThis manual contains service and repair information for P310 Card Printers manufacturedby Zebra Technology Corporation, Camarillo, California.

Saturated colors are colors in their purest state. This means they contain no white (as inpastels) or black (contrast reduction) components. A so-call

Offset printing and Dye Sublimation can produce a substantial range of colors within justone dot. Color Monitors produce their range of colors using a

Not all images require high dot densities. The need for high dot density decreases as theviewing distance increases. For example, a large roadside sig

color of the print media. In monitors, maximum intensities (maximum additions) result inwhite, and minimum intensities produce black. Because light re

green, and blue CRT phosphors. Moreover, devices with a brightness control allow a widerange of image intensities. Active Matrix Displays generate ima

3.2 PRINTINGColor imaging requires three passes of Card media underneath the Print Head. Cardmedia shuttles back and forth across the print head durin

3.3 CARD PATH ELEMENTSThe upper part of Figure 3-1 points out the rollers that transport Cards. The lower partidentifies the sensors that detect the v

980264-001 Rev. B 3-9CHAPTER 3Card FeedRollerCleaningRollerTransportand PlatenRollersRibbonTa k e U pCardPathDaughterBoardMagneticEncoder(Option)Cam F

3.4 CIRCUIT DESCRIPTIONSAs shown in Figure 3-2, P310 Printers have the following circuits:•Print Head Circuiry•Motor Control Circuitry•Status Circuitr

980264-001 Rev. B 3-11CHAPTER 3Serial PortDriverSmart CardContactStation(Option)EncoderBoard(Option)Read/WriteHeadsParameterStatusFLASHRAMStepperMotor

This information is not intended as a license to practice or infringe on the patents of thiscompany or others. Zebra Technology Corporation reserves t

3.4.1 Print Head CircuitryFigure 3-3 shows the Print Head circuitry. Note that one part lies on the CPU board, andanother part lies on the Print Head

980264-001 Rev. B 3-13CHAPTER 3U15QAQHCKSH-LD/U14QAQHCKSH-LD/U12QAQHCKSH-LD/U13QAQHCKSH-LD/QQDCLRCKQQDCLRCKQ1Q4Q5Q14CLKCLRCTNGNDDATA4DATA2STROBESTROBE

3.4.2 Motor Control CircuitryFigure 3-4 shows the Motor Control Circuitry. Stepper Motor inputs PHASE 1 throughPHASE 4 determine the direction of rota

980264-001 Rev. B 3-15CHAPTER 3PHASE 1PHASE 2PHASE 3PHASE 4J10StepperMotorU28Q1~8COCQ1~2COCQ3~8RESETCS MOT (CS7/)D16~23D24~31D16~31D24~311A11A22A11A22

3.4.3 Status CircuitryFigure 3-5 shows the Status circuitry. This circuitry allows the Micro Controller to monitorall the operational status of the ba

980264-001 Rev. B 3-17CHAPTER 3SD0SD1SCLKCS/RS/SHDNU22CLKOCD1D2D3D4D5D6D7D8Q1Q2Q3Q4Q5Q6Q7Q8CLKOCD1D2D3D4D5D6D7D8Q1Q2Q3Q4Q5Q6Q7Q8RFILMTSYNCHROCOULEURPU

3.4.4 Serial and Parallel Port CircuitryFigure 3-6 shows the Parallel and Serial Port circuitry. Note that a Serial Host Port isoptional. When used, t

980264-001 Rev. B 3-19CHAPTER 3VccJ887654321Vdd+24VC1+C1-T1 INR2 OUTT2 INR1 OUTC2+C2-T1 OUTR2 INT2 OUTR1 INU- U+U18Vcc100nf1k54321J5EXT2TXD1RXD1TXD2RX

3.4.5 USB Port Circuitry (Optional)Figure 3-7 shows the USB circuitry. This circuitry resides on a separate board that attachesto the same connector t

3.4.6 Magnetic Stripe Encoder Circuitry (Option)Figure 3-8 shows the Magnetic Strip Encoder elements, consisting of the board,Read/Write heads and ass

vTable of ContentsCHAPTER 1 GENERAL DESCRIPTIONPRINTER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Opt

3.4.7 Smart Card Circuitry (Option)Figure 3-9 shows the Smart Card circuitry. Note that J05 interfaces with the Main CircuitBoard of the printer, and

980264-001 Rev. B 3-23CHAPTER 3C8C7C6C5C1C2C3C4C4C3C2C1C5C6C7C8Top View with ContactsFacing DownVccRSTCLKRFUGNDVppI/ORFUC1C2C3C4C5C6C7C8C1C2C3C4C5C6C7

3.4.8 Operator Panel CircuitryFigure 3-103 shows the circuit elements contained on the Operator Panel Board. TheMicro Controller supplies or receives

CHAPTER 4TROUBLESHOOTINGTypically, troubleshooting begins with an attempt to relate a problem to an associatedcomponent or system function. In this ph

4.1 DIAGNOSING BASIC PRINTER PROBLEMSFigure 4-1 shows a diagnostic flow diagram designed to reproduce problems related tocard images and card transpor

Problems Associated with Print AnomaliesSymptom Possible CausesReferencesAdjustmentor CleaningReplace-mentNo ImageNon Eltron Ribbon Installed Upside D

4.2 DIAGNOSING COMPUTER INTERFACE PROBLEMSFigure 4-2 shows a flow diagram that checks the interface to the computer. For additionalinformation, see:•C

CHAPTER 5REPLACEMENT PROCEDURESThis chapter consists of part replacement procedures for those items either found orsuspected of malfunctioning. These

5.1 REQUIRED TOOLSThe following tools and fixtures are the basic items required for repair and adjustment:Item No. Tool Description1 Number 1 Phillips

5.2 PART REPLACEMENTSThe following sections describe the requirements for removing both major assemblies and,where applicable, components on those ass

viMotor Control Circuitry · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3-14Status Circuitry · · · · · · ·

5.2.2 Front Case RemovalRefer to Figure 5-2, and proceed as follows:Step 1. Remove the Rear Case (see Section 5.2.1).Step 2. Remove the Card Input Car

5.2.3 Bottom Plate RemovalFigure 5-3 shows the screws and connectors associated with removal of the Bottom Plate.Proceed as follows:Step 1. Disconnect

5.2.4 Power Supply ReplacementFigure 5-4 shows the Bottom Plate and Power Supply with the shield removed.Step 1. Remove the Front and Back Case member

5.2.5 Card Feeder Part RemovalsFigure 5-5 shows the fasteners associated with Card Feeder parts. Replaceable itemsinclude the Belt, Roller, Motor, or

5.2.6 Print Head ReplacementReplacement Print Heads arrive in ESD-safe plastic bags. Upon removal, servicing personnelshould exercise extreme care to

980264-001 Rev. B 5-9CHAPTER 5Step 2. As shown in Figure 5-7, loosen the screw holding the Ground Lug, and pullthe Lug free.Figure 5-7. Print Head Gro

Step 3. As shown in Figure 5-8, unhook the ring holding the lower part of the PrintHead Assembly, and slide the unit away from its mounting. Note that

Step 4. Disconnect the two cable connectors from the Print Head Assembly shown inFigure 5-9. Note that until pushed away, a spring tab prevents remova

Step 6. Note the Resistance label on the new Print Head, and install a new PrintHead by reversing the steps used during removal. Before tightening the

5.2.7 Fan RemovalTwo self-tapping screws secure both the Fan and the associated Fan Guard. Refer toFigure 5-11, and proceed as follows:Step 1. Remove

viiTable of FiguresFigure 1-1. Major Elements . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Figure 2-1. Packaging Mater

5.2.8 Ribbon Sensor RemovalThe four wires of the Ribbon Sensor connect to the Daughter Board. Refer to Figure 5-12, andproceed as follows:Step 1. Remo

5.2.9 Front Belt RemovalsFigure 5-13 shows the Front Belts. These belts transport cards downstream from the PlatenRoller. Proceed as follows:Step 1. R

5.2.10 CPU and Encoder Board ReplacementsSee Appendix A for CPU Board tests. Note that removal of the underlying plate does notrequire removal of thes

5.2.11 Rear Plate RemovalAccess to the Daughter Board and the associated motor and sensor connectors, and theirrelated component replacements, require

5.2.12 Daughter Board RemovalNote that this board contains the Print Head Up-Down Sensors and connectors for theremaining sensors and all motors. Acce

5.2.13 Flag and Head Latch Sensor Board Replacement.Refer to Figure 5-17, and proceed as follows:Step 1. Remove the Rear Case Member (see Section 5.2.

5.2.14 Rear Belt and O-Ring RemovalFigure 5-18 shows the three timing belts that extend stepper motor drive to the Platen andtwo rollers that drive ca

5.2.15 Smart Card Interface Board Replacement (Option)Units equipped for Smart Card Docking have the following components:•Smart Card Interface PWB•Sm

For Smart Card Solenoid removal, proceed as follows:Step 1. Remove the Rear Case (see Section 5.2.1), the Front Case (see Section5.2.2), and the Botto

For Smart Card Contact Station removal, refer to Figure 5-21, and proceed as follows:Step 1. Remove the Rear Case (see Section 5.2.1).Step 2. Remove b

viiiFigure 4-1. Problems Duplicated by a Test Print. . . . . . . . . . . . . . . 4-2Figure 4-2. Interface Diagnostic Flow.. . . . .

5.2.16 Encoder Head ReplacementTwo Encoder Head configurations exist—the standard below-the-card-pathconfiguration and the above-the-card-path configu

For Below the Card Path Configurations:Step 1. Remove the Front Case (see Section 5.2.2), and the Encoder Board (seeSection 5.2.10).Step 2. Remove the

Step 4. Snap the Front Pressure Roller free of the rod by applying pressure to theright side while holding the left side stationary (see Figure 5-25).

Step 6. Remove the two screws holding the Encoder Head Assembly. Then, whilefeeding the associated cables through the Rear Plate cutout, Remove the En

Step 7. Install the new Encoder Head, and replace the overlying parts previouslyremoved. Feed cables through plastic frame, and to the Encoder Board (

Step 2. Unplug the connector for the the motor being replaced from the DaughterBoard.Step 3. Remove the belt and cam or pulley from the motor being re

5.2.18 Ribbon Supply Spindle and Clutch ReplacementsFigure 5-30 shows the Ribbon Supply Spindle and associated Clutch Assembly. Replacementoptions inc

980264-001 Rev. B 5-31CHAPTER 5Figure 5-30. Supply Spindle Assembly

5.2.19 Ribbon Take Up Spindle ReplacementsFigure 5-31 shows the Ribbon Take Up Spindle. Replacement options include any of the partsthat appear in the

980264-001 Rev. B 5-33CHAPTER 5Figure 5-31. Ribbon Take Up Spindle

CHAPTER 1GENERAL DESCRIPTION1.1 PRINTER DESCRIPTIONEltron® Model P310 printers offer low cost solutions to those that need to print, encodemagnetic st

5-34 980264-001 Rev.BCHAPTER 5

CHAPTER 6MAINTENANCE AND ADJUSTMENTSThis chapter contains procedures for Cleaning and Adjustments. A more thoroughcleaning than the Cleaning Card proc

6.1 CLEANING MATERIALSFigure 6-1 shows a Cleaning Kit swab.6.2 CLEANINGThis Section describes a manual cleaning of the Print Head and Card Transport R

Step 3. Select a suitable fiber-free cleaning media. For ordinary foam-tipped swabsmoisten with alcohol, For Eltron-supplied swabs, bend the foam tip

6.2.2 Cleaning the Print HeadRefer to Figure 6-3, and proceed as follows:Step 1. Turn off power, and allow about five minutes for a cool down.Step 2.

6.3 OBTAINING AND INSTALLING FIRMWARE UPDATESP310 Firmware resides in Flash Memory. Those needing an update or reload can get thelatest version of the

6.4.1 Stepper Belt TensionThree screws fasten the Stepper Motor to the rear chassis casting. For belt tensioningpurposes, two of the screws hold the m

Step 3. Attach the Belt Tensioning Fixture between the Stepper and Platen pulleys(see Figure 6-5). Note that two cutouts on the fixture attach to the

6-8 980264-001 Rev.BCHAPTER 6Figure 6-6. Stepper Belt Tensioning.

6.4.2 Print Head Tilt AdjustmentsPrint Head Tilt adjustments serve to position the imaging elements with reference to thePlaten Roller. Two alignments