P330i Service Manual

Zebra P330i Card Printer Service Manual
980569-001 Rev. A
Foreword
This manual contains service information for the Zebra P330i Card Printers manufactured by Zebra Technologies Corporation, Camarillo, California.
Copyright Notice
2004, 2005 ZIH Corp. This document contains information proprietary to Zebra Technologies Corporation. This document and the information contained within is Copyrighted by Zebra Technologies Corporation and may not be duplicated in full or in part by any person without written approval from Zebra. While every effort has been made to keep the information contained within current and accurate as of the date of publication, no guarantee is given that the document is error-free or that it is accurate with regard to any specification. Zebra reserves the right to make changes, for the purpose of product improvement, at any time.
Trademarks
P330i is a trademark and Zebra is a registered trademark of Zebra Technologies Corporation. Windows and MS.DOS are registered trademarks of Microsoft Corp. All other trademarks or registered trademarks are marks of their respective holders.
Product Disposal
Product Disposal Information Do not dispose of this product in unsorted municipal waste. This product is recyclable, and should be recycled according to your local standards. For more information, please see our web site at: http://www.zebra.com/environment
980569-001 Rev. A
P330i Card Printer Service Manual
Foreword
Declarations of Conformity
89/336/EEC modified by 92/31/EEC and 93/68/EEC 73/23/EEC modified by 93/68/EEC 1999/5/CE
EMC Directive EMC Directive EMC Directive Low voltage Directive R&TTE Directive
EN 55022 (1998) EN 301489-3 V1.4.1 EN55024 (2001) EN 60950-1 (2001) EN300330-2 V1.1.1
RF Emissions control RF Emissions and Immunity for radio equipment Immunity to Electro-Magnetic Disturbances Product safety Radio Frequency Interferences
For a formal certificate, please contact the Compliance Office at Zebras Camarillo facility. EUROPE: Norway Only: This product is also designed for IT power system with phase to phase voltage 230V. Earth grounding is via the polarized, 3-wire power cord. FI: Laite on liitettv suojamaadoitus koskettimilla varustettuun pistorasiaan SE: Apparaten skall anslutas till jordat uttag NO: Apparatet m tilkoples jordet stikkontakt Model P330i conforms to the following specification: FCC Part 15, Subpart A, Section 15.107(a) and Section 15.109(a) Class B digital device.
Supplemental Information:
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the
ii
980569-001 Rev. A
Foreword
user is encouraged to try to correct the interference by one or more of the following measures: Reorient or relocate the receiving antenna. Increase the separation between the equipment and the receiver. Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. Consult the dealer or an experienced radio/TV technician for help. The user may find the following booklet, prepared by the Federal Communications Commission, helpful: How to identify and resolve Radio/TV Interference Problems. This booklet is available from the U.S. Government printing Office, Washington, D.C. 20402, Stock No. 004-00000345-4. Use of a shielded cable is required to comply within Class B limits of Part 15 of FCC Rules. Pursuant to Part 15.21 of the FCC Rules, any changes or modifications to this equipment not expressly approved by Zebra may cause, harmful interference and void the FCC authorization to operate this equipment.
Industry Canada Notice

This device complies with Industry Canada ICES-003 class B requirements.
980569-001 Rev. A
iii
Foreword
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.
Electrostatic Discharge Caution Warns you of the potential for electrostatic discharge.
Electric Shock Caution Warns you of a potential electric shock situation.
Hot Surface Warns you of a situation where excessive heat could cause a burn.
Caution Advises you that failure to take or avoid a specific action could result in physical harm to you, or could result in physical damage to the hardware.
iv
980569-001 Rev. A
Contents
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i 1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Printer Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Controls, Connectors, and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2 Installation and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.2 Unpacking the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.3 Installing the Print Driver Software and Setting Driver Options . . . . . . . . . . . . . 15 2.4 Loading a Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2.5 Installing the Card Cleaning Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2.6 Setting the Card Thickness Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 2.7 Loading Cards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2.8 Card Output Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2.9 Connecting the Printer to your Computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2.10 Connecting Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 2.11 Printing a Test Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 2.12 Packing the P330i Printer for Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 2.13 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 3 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 3.1 Card Printing Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 3.2 Card Path Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 3.3 Card Movement During Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 3.4 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 3.5 CPU PCBA Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
980569-001 Rev. A
Service Manual
4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 4.1 Power-Up Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 4.2 LCD Panel Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 4.3 Printing a Test Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 4.4 Card Feed or Transport Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 4.5 Print Anomalies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 4.6 Troubleshooting the Ethernet Connection and Adapter . . . . . . . . . . . . . . . . . . . . 56 5 Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 5.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 5.2 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 5.1 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 5.2 Removing the Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 5.3 Removing the Print Engine from the Lower Cover . . . . . . . . . . . . . . . . . . . . . . . 67 5.4 Removing the Connector Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 5.5 Removing the Power Supply Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 5.6 Removing the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 5.7 Removing the Rear Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 5.8 Removing the Cam Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 5.9 Removing the Platen Inertia Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 5.10 Removing the Printhead Pressure Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 5.11 Removing the Film/Bracket Sensor PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 5.12 Removing the Pressure Spring Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 5.13 Removing the Cam Arm Follower Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 5.14 Removing the Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 5.15 Removing the Print Head / Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 88 5.16 Removing the Print Head Lift Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 5.17 Replacing the Print Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 5.18 Replacing the LCD PCBA and/or LCD Cable Assembly . . . . . . . . . . . . . . . . . 111 5.19 Replacing the Encoder Shroud and Exit Pressure Roller . . . . . . . . . . . . . . . . . . 113 5.20 Replacing the Exit Pressure Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 116 5.21 Removing the Balls Retainer Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 5.22 Card Feeder Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 5.23 Power / Filter Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 5.24 Removing the CPU PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 5.25 Removing the I/O Daughterboard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 5.26 Removing the RFID Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 5.27 Replacing the Ribbon O-Ring Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 5.28 Replacing the Ribbon Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 5.29 Removing the Ribbon Motor Pulley and the Ribbon Motor . . . . . . . . . . . . . . . 154 5.30 Replacing the Stepper Motor Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 5.31 Removing the Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 5.32 Removing the RFID PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 5.33 Replacing the Ribbon Color Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 5.34 Replacing the Card Sensor Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 5.35 Removing the Print Head Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
vi Service Manual 980569-001 Rev. A
5.36 5.37 5.38 5.39 5.40
Removing the Print Head Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Separating the Front Frame from the Center Frame . . . . . . . . . . . . . . . . . . . . . . 181 Magnetic Stripe Encoder Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Smart Card Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
6 Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Appendix A Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Appendix B P330i Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Appendix C Worldwide Service & Support . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
980569-001 Rev. A
Service Manual
vii
viii
Service Manual
980569-001 Rev. A
1
General Description
1.1 Printer Description

The Zebra P330i Card Printer is a photo ID card printer. It can print at 300 dpi resolution on 10-60 mil (0.25 - 1.5 mm) ISO CR-80 plastic cards. When equipped with a YMCK (Yellow, Magenta, Cyan, Black) ribbon, it can print full-color images. A wide range of other ribbons, including monochrome ribbons and ribbons that will additionally apply a protective transparant overprint, are also available. The P330i Printer has a USB interface as standard. In addition to the USB port, it can optionally be ordered with a 10/100T Ethernet port. If equipped with the optional Magnetic Encoder, the printer will encode a magnetic stripe on the card. Other options allow encoding of smart cards, which have embedded logic and/or memory circuitry. The following shows the main functional features found on your P330i Printer.
980569-001 Rev. A
General Description
Print Head
Main Cover (shown open)
Print Head Carriage (shown in open position)
Print Head Carriage Latch
Card Feeder Cover (shown open) Card Thickness Control
(Optional) Magnetic Encoding Station
Card Cleaning Cartridge
Panel Button Output Hopper (shown in open position)
Ribbon Take-Up Spindle
Ribbon Supply Spindle
(Optional) Smart Card Contact Station
LCD Display Panel
980569-001 Rev. A
General Description
1.2 Controls, Connectors, and Indicators

The P330i Printer has an LCD Display Panel and a Panel Button on the front and a power connector, power switch, and interface connector(s) on the rear panel. These are shown in the following figures.
Panel Button
LCD Display Panel
10/100base-T Connector *
Ethernet Switch * Ethernet Adapter Status LED *
Power Switch
Network Status / Activity LED * * These are on the optional Ethernet Adapter.
Power Connector USB Connector Optional DB-9 Connector location for Smart Card Contact Station
980569-001 Rev. A
General Description
1.2.1
LCD Panel
The LCD Panel can display the following messages:
Message Operational Mode
INITIALIZING READY DOWNLOADING DATA PRINTING MONO MAG ENCODING CONTACT ENCODING PRINTING CYAN PRINTING YELLOW PRINTING MAGENTA PRINTING BLACK PRINTING OVERLAY DOWNLOADING FW CLEANING PRINTER
Warnings
Scrolling Fixed Fixed Fixed Fixed Fixed Fixed Fixed Fixed Fixed Fixed Fixed Fixed
CLEAN PRINTER REMOVE RIBBON THEN CLOSE HEAD EMPTY FEEDER & PRESS BUTTON LOAD CLEANING CARD IN FEEDER PRESS BUTTON TO CONTINUE FEED LONG CLEANING CARD IN EXIT CLEANING PRINTER ENCODING ERROR (printing stops) INVALID MAGNETIC DATA (encoding stops) REMOVE RIBBON
Scrolling Scrolling Scrolling Scrolling Scrolling Scrolling Scrolling Blinking Scrolling Fixed
Errors (Printer will not operate)
OUT OF RIBBON MECHANICAL ERROR OUT OF CARDS PRINT HEAD OPEN
Blinking Blinking Blinking Blinking
980569-001 Rev. A
General Description
1.2.2
Panel Button
During normal printer operation, if the Panel Button is pressed briefly nothing happens. If the Panel Button is held down for more than three seconds, the printer will start a cleaning cycle and the LCD Panel will prompt the operator to load a cleaning card in the feeder. (If a print operation was in process when the Panel Button was pressed and held down, the print operation will be completed before the printer starts a cleaning cycle.) If the Panel Button is pressed and held down while power is turned on to the printer, the printer will print a test card. This provides a quick check of printer operation completely independently of a computer or network connection. In response to LCD Panel prompting messages, press the Panel Button to continue various operations.
980569-001 Rev. A
General Description
1.2.3
Card Thickness Control

The Card Thickness Control is used to set the P330i printer for use with cards of different thicknesses. Use of the Card Thickness Control is described in Chapter 2.
980569-001 Rev. A
General Description
1.2.4
(Optional) Ethernet Adapter

P330i Printers equipped with the optional Ethernet Adapter have the following additional controls and indicators:
(Recessed) Ethernet Reset Switch
10/100Base RJ45 Ethernet Connector
Ethernet Adapter Status Indicator
Network Status / Activity Indicator
Ethernet Reset Switch If the Ethernet Reset Switch is pressed and held while turning the printer power on, and then released when the Ethernet Adapter Status Indicator turns green, the Ethernet Adapter will be reset to the factory default configuration parameters. While power is on, if the Ethernet Reset Switch is press and held, a configuration card showing the Ethernet Adapters current confuguration settings will be printed. Ethernet Adapter Status Indicator The Ethernet Adapter Status Indicator is a bi-color (red - green) LED, that shows the operational status of the Ethernet Adapter. Network Status/Activity Indicator The Network Status/Activity Indicator is a bi-color (orange - green) LED, that indicates network speed, establishment of a link, and network activity.
Note Detailed information on the use of these indicators is presented in Chapter 4,
Troubleshooting.
980569-001 Rev. A
General Description
980569-001 Rev. A
2
Installation and Setup
2.1 General Information

This section will guide you through the installation and setup of your P330i Card Printer. This consists of the following procedures, which should be performed in the order presented. Unpacking the Printer Installing the Print Driver Software and Setting Driver Options Loading a Ribbon Installing the Card Cleaning Cartridge Setting the Card Thickness Control Loading Cards Connecting the Printer to your Computer Connecting Power Printing a Test Card to verify printer operation
The procedure to be followed for Packing the Printer for Shipment is given at the end of this section. The printer should be placed in a location that allows easy access to all sides. The printer should never be operated while resting on its side or upside down.
980569-001 Rev. A
Electric Shock Caution Limit AC power supplied to the P330i Printer to 110 ~ 230 volts, 60 ~ 50 Hertz. Limit excess current draw to 16 amps or less, using an associated circuit breaker or other such device. Never operate the printer in a location where operator, computer, or printer can get wet. Personal injury could result. The printer must be connected to an earthed electrical power source and properly protected against electrical surges and grounding faults; the electrical reliability of the printer is based on the reliability of the mains power source and with the earth connection. The printers power supply is an internal unit that can only be serviced or replaced by trained and authorized personnel.
2.2 Unpacking the Printer

Your P330i Card Printer ships in a carton and protective anti-static bag. Keep all packaging material in case you need to move or re-ship the printer. Step 1. Inspect the shipping container to ensure that no damage has occurred during shipment. If any damage is apparent, file a claim with the shipper. Step 2. Unlatch and remove the handles on either end of the shipping container, as shown in the figure below.
UP
Step 3. (See the figure on the next page as you perform the following steps.) Lift the upper part of the shipping container off of the lower part (which will still hold the printer and its packing material). Step 4. Remove the packing material around the top of the printer.
10
980569-001 Rev. A
Step 5. Lift the printer out of the carton by holding it with both hands. Step 6. Please ensure that you have a clean and nearly dust free environment for proper operation and storage of the printer. Step 7. Make sure the following items are included with your P330i printer:
980569-001 Rev. A
11
CD-ROM with Driver Wizard and Users Manual
Power Cables (2) USB Cable
Cleaning Kit
If any items are missing, please contact your dealer. To reorder, please refer to Appendix D of this manual. Step 8. Remove packing tape securing the printers Main Cover and Card Feeder Cover. Step 9. Your P330i Printer ships with warning tape where the Card Cleaning Cartridge will be installed, and a pad that protects the print head from possible damage in shipment. To remove the tape and pad, follow the following steps:
a.
Open the printers main cover by lifting at its lower front lip.
12
980569-001 Rev. A
b.
Locate the Print Head protection pad and the Card Cleaning Cartridge location tape (see below).
Remove me
A NST L
Print Head Protection Pad
Card Cleaning Cartridge Location Tape
c.
Release the Print Head Carriage by pushing the Print Head Carriage Latch to the left, and raise the Print Head Carriage. It will remain open at about a 45 angle.
980569-001 Rev. A
13
Print Head Carriage Latch
d.
Remove the print head protection pad. Keep the pad, as well as the other packing material and the shipping carton, in case the printer is shipped or moved. If the original material is lost, a replacement Shipping Kit can be ordered from Zebra; please refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer.
14
980569-001 Rev. A
2.3 Installing the Print Driver Software and Setting Driver Options
Printing with the P330i Printer requires the Windows Printer Driver and your card design/ issuing software or printer command level programming through the printer interface. The P330i Card Printer can be used with any Windows 2000 or Windows XP computer, using the drivers provided on CD with the printer. This section contains information on the printing of a sample card in color (using the 5-panel color ribbon YMCKO and the Windows Printer Driver).
Note If updating the printer driver from a previous version, before installing the updated
printer driver version, always delete the existing version from your computer.
980569-001 Rev. A
15
2.3.1
Installing the P330i Print Driver

To install the P330i Printer Driver automatically on all Operating Systems, use the Zebra Install Wizard.
Note Ensure that you have administrative privileges to perform this installation, or contact
your IT department. The Install Wizard will walk you through the appropriate installation steps. The Wizard will: Delete previous versions of the driver and clean up any necessary Registry entries. You must select Remove from the install options to remove any previous driver versions. Automatically launch when the driver CD is inserted. From the main menu of your documentation CD, select your desired language and then select DRIVERS from the subsequent menu. The Install Wizard will walk you through the appropriate steps.
2.4 Loading a Ribbon

i Series Printers require the use of i Series ribbons for full color printing. The Resin Thermal Transfer and Dye Sublimination ribbons for P330i are specifically designed for your P330i Printer. Step 10. Place the printer power switch in the OFF (0) position. Step 11. If the printers Main Cover is closed:
a.
Open the printers Main Cover; lift it by the lip at the bottom front as shown in the figure below left.
16
980569-001 Rev. A
Electrostatic Discharge Caution DO NOT TOUCH the Print Head or the electronic components on the Print Head Carriage. Discharges of electro-static energy that accumulate on the human body or other surfaces can damage the Print Head or other electronic components used in the printer.
Note Avoid any direct contact with the print head to prevent transfer of oils or
contamination. Outside of normal operation, only the Zebra-approved cleaning materials should come in contact with the print head.
b.
Raise the Print Head Carriage by pressing the release latch to the left (toward the output hopper) and lifting as shown below to about a 45 angle. The Print Head Carriage will stay in that position, as shown at the right below.
Ribbon Take-up Spindle
980569-001 Rev. A
17
Step 12. Locate the Ribbon Supply Spindle and the Ribbon Take-up Spindle (see above). Load ribbon onto the supply spindle (under the print head carriage) flange side in, and load the empty core (with tape attached) onto the take-up spindle. Make sure the ribbon comes off the top of the supply spindle and feeds to the top of the take-up spindle.
Take-up Spool
Flange
Supply Spool
Hot Surface Do not touch the print head if the printer has been in service within the last 10 minutes. It could be very hot and cause a burn.
Electrostatic Discharge Caution A static discharge is possible if you touch any exposed metal parts. Use of an anti-static wrist strap or comparable anti-static protection is required.
18
980569-001 Rev. A
Step 13. Gently press the print head carriage down until it is fully lowered, as shown below. Very little force is neccessary to perform this step.
Note During normal operation (with power connected and turned on), the ribbon would
automatically synchronize when the Print Head is restored to its fully-down position. The ribbon would be identified and the corresponding parameters sent to the driver. Since power is not connected at this point in the Installation and Setup Procedure, nothing will happen when the Print Head Carriage is closed. The ribbon will synchronize when power is turned on.
980569-001 Rev. A
19
2.5 Installing the Card Cleaning Cartridge

The Card Cleaning Cartridge cleans the cards entering the printer. The Card Cleaning Cartridge consists of a Cartridge Frame and an Adhesive Roller, which are packed together. Step 1. Remove the Cartridge Frame and the Adhesive Roller from their packaging. Insert the Adhesive Roller into the Cartridge Frame, as shown below. To avoid contamination, always hold the frame and the roller by the ends. .
Step 2. Peel the protective wrapper from the Adhesive Roller.
Step 3. If the printers main cover is closed, open it. Locate the area where the Card Cleaning Cartridge will be installed (initially, this area was covered by a warning tape).
Card Cleaning Cartridge Mounting Location
20
980569-001 Rev. A
Step 4. Locate the slot at the rear of the Card Cleaning Cartridge mounting location; see below.
Card Cleaning Cartridge Positioning Slot
Step 5. Hold the Card Cleaning Cartridge by the extended handle (so the large arrow on the top is pointing away from you). With the cartridge at about a 30 angle (pointing downward), insert the lip of the cartridge into the slot, until the cartridge seats against the back wall. Then press the front of the cartridge down until it seats all the way down and latches with an audible click. See below.
Slot
980569-001 Rev. A
21
Card Cleaning Cartridge in final position
Step 6. Close the printers Main Cover.
2.6 Setting the Card Thickness Control

The Card Thickness Control is set by the user to adjust the gap as cards enter the printer, to prevent double-feeds (which could cause a jam) or mis-feeds.
Note Set the Card Thickness Control before loading cards.
Step 1. Open the Card Feeder cover. The cover is hinged; lift it by the lip at the right front corner.
Note To reduce contamination and ensure better print quality, minimize the time the Card Feeder cover is open.
22
980569-001 Rev. A
Step 2. The Card Thickness Control Lever is at the front of the left-side opening of the Card Feeder area.
Step 3. There are four detents to set the position of the Card Thickness Control. Slide the Card Thickness Control to the position corresponding to the following:
Detent Position Highest 3rd position 2nd position Lowest
Card Thickness 50 mil (1.27 mm) to 60 mil (1.52 mm) 30 mil (0.76 mm) to 50 mil (1.27 mm) 20 mil (0.51 mm) to 40 mil (1.02 mm) 10 mil (0.25 mm) to 20 mil (0.51 mm)
Note The overlap in settings above accomodates variations in environmental conditions
(especially humidity) and cards from different manufacturers. In general, start at the lowest position and move the lever up until cards feed reliably.
980569-001 Rev. A
23
Note 60 mil (1.524 mm) cards may have a significant variation (over 10%) in the actual thickness of the cards; do not use these cards unless each card has been measured to have a thickness less than 66 mil (1.676 mm).
2.7 Loading Cards

This section shows how to load plastic cards into the P330i Printer. The P330i can use cards with a range of thickness from 10 mil (0.25 mm) to 60 mil (1.5 mm).
Note Do not mix cards of different thicknesses!
The P330i Printer can also load and print cards fed individually. Information on this is given in the next chapter.
Note DO NOT bend cards or touch print surfaces as this can reduce print quality. The
surface of the cards must remain clean and dust free. Always store cards in an enclosed container. Ideally, use cards as soon as possible.
Note For cards with magnetic stripe, refer to Appendix A for loading instructions.
The plastic cards generally come in decks of 100 cards; the Card Feeder can hold a full deck of 100 30-mil cards. Cards sometimes will stick together; this can cause mis-feeding or doublefeeding. To avoid this, separate the cards before loading, as described in steps 2 through 4 below. Step 1. If the Card Feeder cover is closed, open it. The cover is hinged; lift it by the lip at the right front corner.
Note To reduce contamination and ensure better print quality, minimize the time the Card
Feeder cover is open.
24
980569-001 Rev. A
Caution Do not touch print surfaces of the cards; this can reduce print quality
Step 2. Remove all wrapping from the card deck. Step 3. Holding the card deck by the sides, hold it vertically against a flat surface such as a desktop. If the deck is too thick for your hand to hold it comfortably, use about half a deck at a time.
Step 4. Push the stack back and forth to an angle of about 45 from vertical, so as to separate all of the cards.
Note Static charges and edge burrs from the card die-cutting process can render individual cards stuck together with significant adhesion force. These cards must be physically separated from each other before inserting into the feeder; if not separated, feeding or printing problems may occur.
980569-001 Rev. A
25
Step 5. Restore the card stack to its original squared-off condition, and place the cards in the input hopper.
Step 6. Note that there will be a gap in the card stack, with several cards lying flat and the cards above angled upward, as shown in the exaggerated drawing below. This is normal and ensures proper feeding.
Note Do not try to eliminate the gap by pressing down on the card stack in the input hopper;
this can cause misfeeds.
2.8 Card Output Hopper

The card output hopper is normally extended to receive the printed cards. The printer may be operated with the card output hopper in its closed position; in this case the cards will not be collected in the output hopper. Step 1. Pull the card output hopper out to place it in its functional position.
Note The output hopper is a very snug fit to prevent it from moving during shipping or
operation; firm force is required to change its position.
26
980569-001 Rev. A
Step 2. When not using the printer, slide the card output hopper back into its closed position to protect the printer from dust and protect the output hopper from damage. Step 3. The output hopper can be completely removed from the printer if necessary by inserting a thin, blunt object (such as a pencil) up through the hole in the bottom of the printer enclosure and pressing (up) to release the hopper while simultaneously pulling the hopper out. To re-install the output hopper, simply slide the output hopper in until it locks in place.
2.9 Connecting the Printer to your Computer

The P330i Printer includes a standard USB interface. As an option, the printer can be ordered with a 10/100base-T Ethernet Adapter (in addition to the USB interface). The Ethernet Adapter can also be ordered as an add-on option and installed in the field by a Zebra factory certified technician. Step 1. If using the USB interface, use the supplied USB cable to connect between the USB connector on the printer and a USB port on the computer, as shown below. (Note that the figure below shows the optional Ethernet Adapter directly above the USB Connector; this may not be present on your printer.)
980569-001 Rev. A
27
Power Switch
(Optional) Ethernet Connector
Power Connector
USB Connector
Step 2. If your printer includes the optional Ethernet Adapter as well as the standard USB connection, use either the supplied USB cable or a standard Ethernet cable to connect the printer to a corresponding port on the computer or network.
Important Do not use both USB and Ethernet connections at the same time!
Important Intermittent or unpredictable operation may occur from unsecured connectors. If
damaged, the power cable must be replaced by an exact equivalent.
2.10 Connecting Power

The P330i Printer includes an internal AC power supply that accepts nominal input voltage in the range from 110 to 230 volts at 50 to 60 Hertz. The power source must be grounded. Depending on specific model number, your P330i Printer will include one or two power cords; use the one that is appropriate for the AC power source connection at your location. If neither has an appropriate connector, AC power cords may be purchased locally; make sure it is a three-wire (grounded) cord.
28
980569-001 Rev. A
Power Switch
Power Connector
Step 1. Place the Printers power switch in the OFF ( O ) position. Step 2. Depending on your local AC voltage, plug the appropriate power cord into the printers power connector and a grounded AC power source connection.
Caution If the power cord appears damaged in any way, or if the power cord will not securely plug into the Printers power connector or the AC power source connection, STOP! Use of a damaged or incorrect power cord could cause equipment damage, result in an electrical fire, or possibly cause injury.
Step 3. To turn the Printer on, set the Printers power switch to the ON ( | ) position.
980569-001 Rev. A
29
2.11 Printing a Test Card

With ribbon and cards loaded, your P330i Printer is ready to print. To check the operation of the printer, you should print a test card. (Printing a test card does not require that the printer be connected to your computer or network, but power must be applied.) Step 1. Set the printers power switch (on the back of the printer) to the OFF ( O ) position. Step 2. While pressing the Printers front panel button (next to the LCD display panel), switch the printer ON ( | ). Step 3. Hold the panel button until the LCD display panel reads SELF TEST. Step 4. Release the panel button, and the test card will print. This is an example of the test card:
PLASTIC CARD PRINTER

PRINTER: P330iM
Serial N: XXXXX Firmware: XXXXXXX
300 dpi TEST CARD

Head resistance: XXXX Offset: XXXX-XXXX EC:XX Printing counter: XXXXX
2.12 Packing the P330i Printer for Shipment

If the P330i Printer is to be shipped, it is important to use the original packing and shipping material to prevent damage to the Printer. If the original material is lost, a replacement Shipping Kit can be ordered from Zebra; please refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer.
Note The specifics of the shipment and the printers condition may influence which of the
following steps are followed; common sense should prevail. Step 1. Remove cards in the card feeder:
30
980569-001 Rev. A
a.
While the printer still has power applied and is turned on, and is still connected to the host computer, remove cards from the card feeder. The last card may be difficult to remove. If so, use the Eject Card command available through the driver on the host computer to eject the last card that is staged in the feeder.
Caution Do not physically pull the last card out of the feeder staging area. This could damage the printer and void the warranty, as well as damage the card.
Close the Card Feeder Cover. Step 2. If the printer still has power applied and is turned on, and is still connected to the host computer, set the printers power switch (on the back of the printer) to the OFF ( O ) position, and disconnect the interface and power cables to the printer.
b.
Step 3. Open the Main Cover. Open the Print Head Carriage and remove the Ribbon. (If you wish to save the ribbon for future use, you may want to put it in a plastic bag for storage.) Step 4. Insert the print head protection pad, and close the Print Head Carriage. Remove the Card Cleaning Cartridge and place it in the upper foam insert. Close the Main Cover. Step 5. Slide the Output Hopper in all the way against the Printer. Step 6. Place the Printer in its protective plastic bag. Step 7. Place the lower foam insert in the lower part of the shipping carton. Step 8. Use both hands to carefully place the Printer into the recess in the lower foam insert. Step 9. Place the upper foam insert onto the Printer and gently press it down so it makes a snug fit on the Printer; the top of the upper foam insert should be even with the upper edge of the lower part of the shipping carton. Step 10. Slide the upper part of the shipping carton down over the lower part. Step 11. Insert and close the handles/latches.
980569-001 Rev. A
31
2.13 Operation
Printing with the P330i Card Printer is similar to printing with any other printer in a Windows environment. The Printer Driver Software is installed on your computer (see Chapter 2). The P330i Printer is connected to the power source and the computer (see Chapter 2). The P330i Printer is selected by either the Operating System or the appropriate application software program. Printer Properties are set (the factory default values will be appropriate for many applications). Card printing is directed by the appropriate application software program.
32
980569-001 Rev. A
2.13.1
Setting Printer Properties

Printer Properties can be set either at the Operating System level or within the application software program used for printing cards.
Note In the following description of setting Printer Properties, only those properties and options that are suitable for being set by the User are described. The User should not make selections or set parameters unless they are specifically described in this section
Preferences settings can configure the P330i Card Printer for Landscape (wide) or Portrait (tall) printing orientation, and allow the user to verify that the desired ribbon is installed in the printer. (Monochrome ribbons are selected via the drop-down menu.) Detailed instructions on setting printer parameters is presented in Appendix A. If the P330i Printer includes the optional magnetic card stripe encoder, encoding parameters and coercivity can be set. Printer cleaning can be initiated from the Tools window (printer cleaning can also be initiated at the printer; see Chapter 4). Also from the Tools window, the Test Card can be selected from several pre-loaded styles. Single Feed Options allows Disabling or Enabling Single Feed Support. If Disable Single Feed Support is selected, when the P330i Card Printer runs out of cards in the feeder, the LCD display will read OUT OF CARDS. To continue, press the panel button. If Enable Single Feed Support is selected, when the P330i Card Printer runs out of cards in the feeder it will wait until a card is inserted in the single-card slot or cards are loaded in the feeder, and then will automatically continue.
980569-001 Rev. A
33
2.13.2
Printing a Sample Card

Sample card designs are installed with the printer driver. Sample cards require Microsoft Word or Microsoft Paint application software. The cards are accessed via the Start menu. Select Start, select Programs, select Zebra Card Printers, and select a sample card, or follow the directions below to design a card. Follow these steps to design and print your first card: Step 1. Launch Microsoft Word Software. Depending on your computer configuration this may be done by double-clicking an icon on your desktop, or by clicking the Windows Start icon, selecting Programs, and navigating to Microsoft Word Step 2. Go to the File menu and choose Page Setup. Step 3. Select the Paper Size tab, choose Card. Under orientation, select Landscape. Step 4. Select the Margins tab, and set the Top, Bottom, Left, and Right margins to 0 (zero). Step 5. Click OK to close the Page Setup window. Step 6. The card appears on the screen. Step 7. Design a card with both black and colored text and with colored pictures (see example below).
us! http://www.zebracard.com
Note For cards thinner than 20 mils (0.51 mm), the card design must be limited to (1) no more than two 30 mm x 30 mm areas of full color, (2) black information (text and barcode, for example) must cover no more than 50% of the card area, and (3) there must be at least a 5mm unprinted border along all edges. For cards thicker than 40 mils (1.02 mm), the card design must have at least a 5mm unprinted border along all edges. For cards with thickness between 20 mils (0.51 mm) and 40 mils (1.02 mm), these restrictions do not apply; full color printing is permitted edge to edge in both directions.
Step 8. Once you are ready to print, go to the File menu and select Print.
34
980569-001 Rev. A
Step 9. If the printer was not selected as the default printer, go to the File menu, select Print Setup and choose Zebra P330i Card Printer from the printer names list. Then Close the Print Setup dialog box. Step 10. The printer will feed in a card and start printing (the data download time will vary depending on the complexity of the card design and the processing speed of your computer). Step 11. Once the printing job is complete, the card is ejected from the printer.
2.13.3
Feeding One Card at a Time

A Manual Feed Slot is available below the Card Input Hopper for feeding single cards. The Card Input Hopper must be empty for single-card feeding to work properly. Step 1. Open the Card Feeder cover. Verify that there are no cards in the feeder, then close the Card Feeder cover. Step 2. Insert a single card into the slot below the Card Feeder. Do not feed more than one card at a time.
Note If single-card feeding will be the normal mode of operation, you may select that mode through the driver software. In single-card feed mode, the card will not be printed until the print job has been sent to the printer and the card to be printed has been inserted into the single-card feed slot.
980569-001 Rev. A
35
36
980569-001 Rev. A
3
Theory of Operation
This chapter includes five major topics: Card Printing Basics Card Path Elements Card Movement During Printing Block Diagram CPU PCBA Connections
3.1 Card Printing Basics

This section provides an overview description of how images are printed on plastic cards by the Zebra P330i Card Printer.
Print Head
The Print Head is a thin-film device that consists of a row of individually addressable heating elements. Each heating element is approximately 0.0033 inch (0.08 mm) wide, giving a print resolution of 300 dots per inch.
Heating Elements
980569-001 Rev. A
37
Theory of Operation
There are a total of 672 heating elements. Since the width of the plastic card is 2.125 inches (54 mm), 638 elements provide full-width coverage. The extra 34 elements (17 on either side of the cards nominal width) are present to support programmable image centering and full bleed imaging even if a card is slightly oversize. The Print Head Assembly mounts in the Print Head Carriage Assembly. The Print Head Carriage assembly can be raised for ribbon installation.
Print Head Assembly Print Head
Print Head Carriage Assembly (Shown Raised)
Ribbon Take-Up Spindle
Platen Roller
Print Head Assembly Tilt Adjustment Range
The Print Head Assembly and Print Head Carriage Assembly hold the Print Head at a right angle to the cards long surface, while allowing the tilt angle of the Print Head to be adjusted to give optimum print quality.
38 P330i Card Printer Service Manual 980569-001 Rev. A
Theory of Operation
3.1.1
Printing Technologies and Ribbons

There are two types of printing technology used in the Printer: Dye Sublimation and Thermal Transfer. The technology to use is determined by the type of dyeor ink on the ribbon. Monochrome Ribbons have a single color ink on the length of the ribbon. The Printer is programmed to use Thermal Transfer printing for monochrome ribbons. Multi-Panel Ribbons have a repeating sequence of panels of different dye. RFID Multi-Panel Ribbons have an RFID tag on the supply spool; the RFID code identifies the ribbon typr and panel count. (Note that the lack of an RFID tag will be interpreted by the Printer as being a Monochrome Ribbon.) Printing with a Multi-Panel Ribbon requires multiple passes of the card under the Print Head, once per panel. For full-color printing, a YMCKO Multi-Panel Ribbon is generally used. A YMCKO ribbon will have successive panels as follows: Color Yellow (Y) Magenta (M) Cyan (C) Black Resin (K) Varnish Overlay (O) Technology Dye Sublimation Dye Sublimation Dye Sublimation Thermal Transfer Thermal Transfer Function / Usage Full-Color Printing and Dye Sublimation Black Printing Full-Color Printing and Dye Sublimation Black Printing Full-Color Printing and Dye Sublimation Black Printing K Resin Black Printing U. V. Protective Coating
Dye Sublimation Printing Process
Thermal Transfer Printing Process Black (K) Resin Varnish for Overlay (O) (YMCKO Pattern Repeats)
Yellow (Y) Dye
Magenta (M) Dye
Cyan (C) Dye
Ribbon Movement From Supply Spool
Other ribbons are available for the P330i Card Printer; see the Supplies List on the Driver and Documentation CD that came with your printer, or go to the Zebra Card Printer Solutions website at http://www.zebracard.com.
980569-001 Rev. A
39
Theory of Operation
The ribbon synchronizes to its starting position whenever the Print Head is opened and then closed. For a YMCKO ribbon, the starting position will be with the leading edge of a Yellow Panel at the Print Head location. The following figure shows how the ribbon and card move relative to each other during printing.
Print Head at Fixed Position
1.
Ribbon Moves Yellow Panel into Position at Print Head
2.
Card is Fed to Printing Position Under the Print Head
3.
Card and Ribbon Move Together as Yellow Panel is Printed
4.
Card and Ribbon Stop at End of Yellow Panel
5.
Ribbon is Stationary; Card is Moved Back to Printing Position
6.
Card and Ribbon Move Together as Magenta Panel is Printed
40
980569-001 Rev. A
Theory of Operation
Dye Sublimation Printing

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

In Thermal Transfer, voltage is either applied or not applied to each Print Head printing element. If voltage is applied, the ink at that location is transferred to the surface of the card. Each pixel is either printed (i.e., the ink transferred to the card) or not; there are no intermediate levels. Thermal Transfer printing with a resin ribbon is used for printing bar codes, since contrast between the light and dark areas is the highest and the edges are the sharpest.
Print Head Ribbon Carrier Layer Ribbon Ink Layer Card Ink Transfered to Surface of Card Platen Roller
980569-001 Rev. A
41
Theory of Operation
3.2 Card Path Elements

The figure below shows the rollers that transport Cards as they make their way through the P330i printer. The rollers keep the card on a horizontal path, reducing the chance of a card edge catching on anything.
Cleaning Roller
Card Path
Transport and Platen Rollers
Card Feed Rollers
The figure below shows the sensors that track card and ribbon position and movement.
Ribbon Sync. Sensor
Head Open Sensor
Smart Card Sensor (if equipped)
Single Card Feed Sensor (on enclosure) Magnetic Encoder Sensor (if equipped) Ribbon Color Sensor Cam Sensor (PCBA) Card Entry Sensor Feeder Sensor
42
980569-001 Rev. A
Theory of Operation
3.3 Card Movement During Printing

The P330i printer moves a card through a specific sequence of movements as it encodes and prints the card.
(Optional) Magnetic Stripe Encoding Station
Cleaning Cartridge
Card Exit
Card Input Hopper
Output Hopper
Print Head
(Optional) Smart Card Contact Station
Single Card Feed Slot
The card is fed from the bottom of the stack in the Card Input Hopper, or in through the Single Card Feed Slot. The card moved along in contact with the exposed sticky area of the Cleaning Cartridge; this cleans dust or dirt particles from the (upper) card surface. If the printer includes an optional Smart Card Encoder (either contact-style or contactless), the smart card is encoded. If encoding fails, the card is moved directly to the card exit, without printing. This is done to avoid wasting time and ribbon panels on a defective card.
980569-001 Rev. A
43
Theory of Operation
If the printer includes an optional Magnetic Stripe Encoder, the card is moved past the print head to the magnetic encoder, and the stripe is encoded. Note that the card goes past the print station without being printed at this time. After magnetic encoding, the card is moved back to just before the print head. As with smart-card encoding, if magnetic encoding fails, the card is moved directly to the card exit, without printing.
The leading edge of the card is moved under the Print Head, and the print head is lowered. When the printer was turned on, the ribbon was automatically synchronized, bringing the leading edge of the yellow ribbon panel under the print head. Lowering the print head reduces space between the print head, the ribbon, and the card, reducing spread of the printed spot and giving sharper images. As the card and ribbon move along, each element of the print head is energized to one of 32 levels (from completely off to maximum heat), which melts a corresponding amount of yellow dye onto that particular spot on the card. If using a resin ribbon (used when printing a bar code on a card), the head elements are energized to either on or off. The on level actually transfers the spot of resin under the print head element to the card. This results in the sharpest possible images; for bar codes you want the sharpest edges and highest contrast between dark and unprinted areas.
After this yellow pass is completed, the print head is raised, the card is moved back, and printing continues with the Magenta ribbon panel, then the Cyan panel, then the Black (K) panel if present, then an Overlay panel. When using a monochrome ribbon, the card makes a single pass under the print head.
When printing is completed, the card is moved (past the magnetic encoder, if present) to the Card Exit, where it falls into the Output Hopper.
44
980569-001 Rev. A
Theory of Operation
3.4 Block Diagram

Most of the circuitry in the P330i is on the CPU PCBA. Since the CPU PCBA is not a serviceable unit, circuit analysis to the component level is pointless. Below is a block diagram of the functional circuits of the P330i Printer; the block diagram also shows how signals are passed to and from the CPU PCBA to the rest of the printer.
P330i CPU PCBA

Motor Drivers Ribbon and Card Transport Motors
(Ethernet Option Components)

Ethernet Port Ethernet Printserver Board Ethernet Extension Board Ethernet Connection Circuitry Memory for CPU A/D Circuitry for Optical Sensors
I/O Daughterboard
Optical Sensors
USB Port
USB Circuitry CPU
Sensor Calibration Circuitry Printhead Circuitry
RFID Tag in Ribbon Core
Printhead
RFID Transponder
Ribbon RFID Circuitry
Clock
LCD Display and Panel Button Circuitry
LCD Display Panel Panel Button
(Mag Encoder Option Components)

AC Voltage Power Supply 24 VDC Power Control Magnetic Encoder Circuitry Magnetic Encoder
(Smart Card Option Components)

Smart Card Encoder Circuitry Contact or Contactless Smart Card Encoder
980569-001 Rev. A
45
Theory of Operation
3.5 CPU PCBA Connections

Most of the circuitry in the P330i is on the CPU PCBA. Since the CPU PCBA is not a serviceable unit, circuit analysis to the component level is pointless; but a basic understanding of how the CPU PCBA connects to the rest of the printer helps to better understand the P330i printer.
J11 (Ribbon RFID)
J7 (Smart Card)
J1 (Mag Encoder Head)
J8 (Auxiliary RS-232; factory use only)
J6 (USB Port) J2 (Mates with Ethernet Extension Board)
J10 (LCD Panel)
J13 (Motors and Sensors Connects to I/O Daughterboard) J12 (+24 VDC Input from Power Supply)
J4 (Not Used)
J3 (Out of Cards Sensor)
J9 (Print Head, Head Lock, Head Temp. Sensor)
46
980569-001 Rev. A
4
Troubleshooting
The objective of troubleshooting is to relate a problem to an associated assembly or system function, in order to most efficiently isolate and repair the problem. Typically this involves determining the failure symptom and then checking one or more possible causes of the failure. Only a symptom-related list of possibilities appears. In general, for a given failure symptom one or more possible causes are listed, with suggested corrective action to take. These causes should be checked and corrective actions taken in the order given; they are listed in order of likelihood and complexity. When the suggestions presented fail to lead to a repair, a CPU Board replacement, if not prescribed, should nevertheless be tried. A check for broken or disconnected cables and any loss of power should also take place along with checks for obvious mechanical damage. The Test Software described in Appendix A includes selections to exercise most printer functions. Beyond this, Zebra Card Printer Solutions offers Technical Support and factory repair as options.
980569-001 Rev. A
47
Troubleshooting
4.1 Power-Up Failures

Some problems are evident as soon as power is applied to the printer. The following table will help in diagnosing these problems. Symptom When power is turned on, nothing at all happens (no sound, LCD panel stays dark). Possible Cause 1. No power to printer. Corrective Action 1. Check AC power source, verify power cord is plugged into printer, try a different power cord. 2. Check EMI filtering components. 3. If Fuse in Power Supply is blown, replace it. If replacement fuse blows, replace Power Supply. 4. Replace Power Supply. 1. Verify cable from CPU PCBA to LCD Panel securely plugged in at both ends. 2. Replace LCD Panel. 3. Replace CPU PCBA. 1. Replace CPU PCBA.
2. Defective EMI filtering components. 3. Check Fuse in Power Supply.
4. Defective Power Supply. When power is turned on, sounds are heard inside printer and ribbon advances, but LCD Panel stays dark. 1. Cable from CPU PCBA to LCD Panel unplugged at either end. 2. Defective LCD Panel. 3. Defective CPU PCBA. When power is turned on, sounds are heard inside printer, LCD Panel lights up and INITIALIZING message scrolls, but LCD Panel message does not change to a steady READY message within about 30 seconds. 1. Defective CPU PCBA.
4.2 LCD Panel Messages

The LCD Panel on the front of the printer continuously displays messages as to what operation the printer is performing as well as certain fault messages. The following table lists possible causes and solutions to the fault messages.
48
980569-001 Rev. A
Troubleshooting
Problem / Description The LCD Panel displays OUT OF CARDS message.
Cause / Solution 1. Check for cards in the card feeder. If no cards present, load cards. 2. Check that Card Thickness Control lever is properly adjusted (see Loading Cards in Chapter 2). 3. Press the Panel Button for 1 second. The printing job will restart. 1. Check ribbon. Replace if defective or entirely used. Ribbon will automatically synchronize and printing will restart with a new card. 1. Check that Print Head Carriage is closed and latched. If not, close and latch it. 1. Check that you are using the correct card type (see Technical Specifications). 2. Check that Card Thickness Control lever is properly adjusted (see Loading Cards in Chapter 2). 3. If two cards are fed into the printer at the same time: Open cover and remove Card Cleaning Cartridge, empty the Card Feeder, and pull the jammed cards out. Replace the Card Cleaning Cartridge. Separate the cards as shown in Loading Cards in Chapter 2, and replace. 4. Check that ribbon is loaded correctly. 1. Check that you are using the correct magnetic card type (for low or high coercivity encoding). 2. Verify command syntax. 3. Contact Zebra technical support. 1. Clean the printer (see Chapter 4).
The LCD Panel displays OUT OF RIBBON message.
The LCD Panel displays PRINT HEAD OPEN message. The LCD Panel displays MECHANICAL ERROR message.
The LCD Panel displays ENCODING ERROR message.
The LCD Panel displays CLEAN PRINTER message.
980569-001 Rev. A
49
Troubleshooting
4.3 Printing a Test Card

Printing a Test Card is an efficient way to determine if there is a card transport problem or a printing problem.
Print a Test Card (See Section 2.11)
Test Card Emerges from Printer?
No
Check Problems Associated With Card Transport. See Section 4.4.
Yes
P75i
Test Card OK?
No
Check Problems Associated With Print Anomalies. See Section 4.5.
Yes
No Problem With Basic Printing.
50
980569-001 Rev. A
Troubleshooting
4.4 Card Feed or Transport Failures

Troubleshooting of card feed or transport failures generally involves seeing where the failure occurs or what type of failure it is. That determination leads to checking certain assemblies or components. Symptom Cards dont feed at all. Possible Cause 1. Card Thickness Control is improperly adjusted. 2. Defective Feeder Sensor. 3. Dirty or torn/missing Card Feeder Belt. 4. Defective Card Feed Roller. 5. Broken Card Feed Drive Belt. 6. Defective Card Feed Motor. Multiple card jam. 1. Card Thickness Control is improperly adjusted. 2. Cards are sticking together. Corrective Actions 1. Set Card Thickness Control correctly (see section 2.6). 2. Replace Feeder Sensor. 3. Clean or replace Card Feeder Belt. 4. Replace Card Feed Roller. 5. Replace Card Feed Drive Belt. 6. Replace Card Feed Motor. 1. Set Card Thickness Control correctly (see section 2.6). 2. Be sure to separate the cards when loading them into the Card Feeder, as described in section 2.7. 1. Set Card Thickness Control correctly (see section 2.6). 1. Clean or replace Clean Drive Roller. 2. Replace 63T x 4mm Stepper Motor Belt. 3. Replace Stepper Motor.
Partial Card Feed. Card stalls near Cleaning Cartridge.
1. Card Thickness Control is improperly adjusted. 1. Dirty or defective Clean Drive Roller. 2. Defective 63T x 4mm Stepper Motor Belt. 3. Defective Stepper Motor.
980569-001 Rev. A
51
Troubleshooting
Symptom Card stalls at Platen (i.e., under the Print Head).
Possible Cause 1. Dirty or defective Print Head Platen Roller. 2. Defective 56T x 1/8 Timing Belt.
Corrective Actions 1. Clean or replace Print Head Platen Roller. 2. Replace 56T x 1/8 Timing Belt. 1. Replace 104T x 1/8 Timing Belt. 2. Clean Exit Pressure Roller or replace Exit Pressure Roller Assembly. 3. Clean or replace Exit Card Drive Roller.
Card doesnt exit printer
1. Defective 104T x 1/8 Timing Belt. 2. Dirty or defective Exit Pressure Roller. 3. Dirty or defective Exit Card Drive Roller.
4.5 Print Anomalies

A careful examination of the cards that are printed will lead to efficient troubleshooting of printing problems. Keep in mind that cleanliness and the card stock are two factors that strongly affect print quality.
Note For optimum print quality, always keep the Main Cover and the Card Feeder Cover of
the printer closed,
52
980569-001 Rev. A
Troubleshooting
Symptom No Image.
Possible Cause 1. Ribbon is not an i-Series Ribbon. 2. Ribbon incorrectly installed. 3. Cards may not meet specifications. 4. Print Head elements may be scratched or burnt. 5. Print Head not being positioned correctly.
Corrective Action 1. Always use i-Series Ribbons in the P330i printer. 2. Check that ribbon is installed correctly (see section 2.4). 3. Use a different supply of cards. 4. Replace Print Head. 5. Replace CPU PCBA. Replace Print Head Up/Down Motor. Check Print Head Position Sensors, replace if defective.
Faint Image.
1. Dirty Print Head. 2. Low Print Head Voltage.
1. Clean Print Head. 2. Replace CPU PCBA.
Artifacts. Horizontal Lines.
1. Particles on Feed or Transport Rollers. 1. Dirty or damaged Print Head element. 1. Clean the Print Head (see Chapter 4). If horizontal lines are still present, replace the Printhead Assembly. 1. Replace CPU PCBA. 1. Align Printhead Assembly (see Printhead Replacement Procedure). Replace Printhead Assembly.
Multiple Evenly-Spaced Horizontal Lines. Wavy horizontal lines (these will be especially noticeable in solid blocks of color).
1. Print Head Registers on CPU PCBA 1. Printhead Assembly out of alignment.
Vertical Lines. Sticking Ribbon. Washout. Sheared Ribbon 1. Peel Bar on Print Head Assembly out of adjustment. 1. Peel Bar on Print Head Assembly out of adjustment. 1. X-Offset value incorrect. 1. Adjust Peel Bar or replace Print Head Assembly. 1. Adjust Peel Bar or replace Print Head Assembly. 1. Adjust X-Offset value.
980569-001 Rev. A
53
Troubleshooting
Symptom Image Off-Center 1. Excessive border at trailing edge of card. 2. Excessive border at leading edge of card. 3. Excessive border at card edge nearer front of printer. 4. Excessive border at card edge nearer back of printer. CYMK Not Aligned. Abrupt Color Change. Small spots appear on the printed card with a non-printed area or a different color.
Possible Cause 1. X-Offset value too low. 2. X-Offset value too high. 3. Y-Offset value too low. 4. Y-Offset value too high.
Corrective Action 1. Increase X-Offset value. 2. Decrease X-Offset value. 3. Increase Y-Offset value. 4. Decrease Y-Offset value.
1. Contamination on the card surface. 2. Dust inside the printer and/or dirty Cleaning Cartridge.
1. Check that cards are stored in a dust free environment. 2. Clean the printer (see Chapter 4). 3. Replace Cleaning Cartridge (see Chapter 4).
There are non-printing horizontal lines (white) on the card surfaces.
1. Ribbon not correctly positioned.
1. Ensure that the ribbon is properly rolled onto the ribbon spindles and that there are no wrinkles in the ribbon. 2. Replace ribbon.
3. Print Head is dirty. 4. Print Head elements are damaged (e.g., scratched or burnt).
3. Clean the Print Head 4. Replace Print Head Assembly.
54
980569-001 Rev. A
Troubleshooting
Symptom Printing shows very pale, very dark, or inconsistent results
Possible Cause 1. Defective ribbon. 2. Cards may not meet specifications. 3. Contrast and/or Intensity may be set to incorrect values. 4. Head Settings are too low / high. 5. Dust or embedded contamination on elements of the Print Head.
Corrective Action 1. Change ribbon and print again. 2. Use a different supply of cards. 3. Adjust Contrast and/or Intensity values in software. 4. Adjust Head Settings higher / lower. 5. Clean the Print Head (see Chapter 4). If contamination cannot be removed, replace the Printhead Assembly. 1. Check that the ribbon is properly rolled onto the spindles. . Replace ribbon and print again. 2. Open the Print Head Carriage, then close it. This will cause the ribbon to re-synchronize. 3. Use a different supply of cards. 4. Clean the Printer. Replace the Cleaning Cartridge. 1. Use only i Series ribbons for full color printing. 1. Use different format for graphics. Use higher-resolution graphics.
Printing shows blurry printed image.
1. Ribbon cartridge may not be correctly positioned.
2. Ribbon may not be synchronized on the correct color panel position. 3. Cards may not meet specifications. 4. Dust or embedded contamination inside the printer and/or dirty Cleaning Cartridge. Only one panel of a color ribbon prints. Text prints ok but graphics have image distortion, blotches of color, color dots or grid. 1. Using the wrong type of ribbon. 1. Graphics incompatibility.
980569-001 Rev. A
55
Troubleshooting
4.6 Troubleshooting the Ethernet Connection and Adapter

4.6.1 Resetting to Factory Defaults
To reset the Ethernet Adapter configuration parameters to the factory defaults, press the Ethernet Switch and hold it in while turning the printer power on. Keep the Panel Button pressed until the Status Indicator light turns green, then release the Ethernet Switch. To print a configuration card, press and hold the Ethernet Switch until a card starts to print.
Ethernet Reset Button
Network Status / Activity Indicator
56
980569-001 Rev. A
Troubleshooting
4.6.2

A bi-color Status Indicator displays the operational status of the Ethernet Adapter. The following conditions might occur: During normal operation, the LED is solid green for more than 30 seconds. This indicates all the hardware is functioning properly and the Ethernet Adapter has detected the presence of the network. It does not mean the Ethernet Adapter has an IP address or is attached to a printer queue. If the LED is rapidly flashing green (9 times/sec), the Ethernet Adapter has not detected the presence of a network cable. To solve the problem: Verify that the network cable is appropriate for the network and has an RJ-45 connector. Turn the printer power off (O). Remove the network cable from the Ethernet Adapter. Plug the network cable back in until you hear a positive click. Check the other end of the cable in the same manner. Turn the printer power on; if the Ethernet Adapter still does not detect a cable, continue. Connect the Ethernet Adapter to a known good network connection. If the Ethernet Adapter is still unable to detect the network cable, contact Technical Support for assistance.
Important Cables with a rating higher than CAT-6 have not been tested.
If the LED is slowly flashing green (1 time/sec), the Ethernet Adapter is trying to print a job. If the job does not print, check the following: Verify that the printer has media and ribbon. If the printer is showing any errors, it is unlikely that the Ethernet Adapter can send data to the printer. The LED continues to blink until the printer malfunction is resolved or until the printer is turned off (O). Flashing red indicates the Power On Self Test (POST) is in progress. If the LED is solid red for more than 30 seconds, the Ethernet Adapter has failed the POST. A failed POST can be caused by any of the following: The printer attached to the Ethernet Adapter device is malfunctioning. Turn the printer power off, wait 10 seconds, then turn the printer back on ( | ). If the Ethernet Adapter still fails the POST, the Ethernet Adapter has a hardware problem that can be fixed only by replacing or returning the unit. Contact Technical Support for repair or replacement information. If the LED is alternately flashing red and green for longer than 2 minutes, the Ethernet Adapter is in firmware-download mode. This means it is waiting for new firmware data to be sent before it continues normal functioning. Perform the following:
980569-001 Rev. A
57
Troubleshooting
If the Ethernet Adapter was purposely put into firmware-download mode, finish the download with the proper update utility. Contact the Zebra web site at http://www.zebra.com to download this utility. Contact Technical Support for help recovering this unit.
58
980569-001 Rev. A
Troubleshooting
4.6.3
Network Status/Activity Indicator

A bi-color Status/Activity LED indicates network speed, established link, and network activity. If the LED is off, no link was established. If the LED is solid green, a 100Base link is established. If the LED is flashing green, a 100Base link is established and network activity has been detected. If the LED is solid orange, a 10Base link is established. If the LED is flashing orange, a 10Base link was established and network activity has been detected. Network activity detected by this LED does not mean the activity is data for the print server. The activity is all activity on the network as seen by the Ethernet Adapter.
980569-001 Rev. A
59
Troubleshooting
60
980569-001 Rev. A
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.
Electric Shock Caution Before performing any of the procedures in this chapter, set the printer power to OFF (O) and disconnect the power cord.
still
Caution Before beginning any of the procedures that follow, read completely through the procedure. If you do not have the specified tools, or if any step(s) seem beyond your skill or experience level, do not attempt the procedure. You may cause additional damage to the printer.
Note Some of the photographs in this section may show printers with different
configuration or options than your particular printer. They may also show additional parts removed in addition to removals for the process being described. Please disregard these differences; the information pertaining to the replacement process being described will still apply to your printer.
980569-001 Rev. A
61
5.2 Required Tools

This section lists the tools required for the replacement procedures described in this chapter. Naturally, not all tools are required for a particular procedure; specific tools are called out in each step as appropriate.
Important When removing any of the nylon or plastic pulleys or gears, the use of a gear puller is strongly recommended. If a gear puller is not available, use pliers and/or a flat-blade screwdriver to pry the gear or pulley off its shaft. In either case, remove any loctite residue from the shaft and the gear/pulley. Inspect the old gear/pulley very carefully. If any teeth have burrs, are missing, or are damaged, or if the center hole is distorted or enlarged, the gear/pulley must be replaced rather than the old one re-installed.
1. Flat-Blade Screwdrivers, from 1/16 inch (2 mm) to 1/4 inch (6.5 mm) 2. Numbers 0, 1, and 2 Phillips Screwdrivers 3. Torx T10 and T15 drivers 4. Small Gear Puller (strongly recommended) 5. Small Crescent Wrench or locking pliers 6. Fine-Point, Offset Fine-Point, and Needle-Nose pliers 7. Small Diagonal Cutters or other cutter for cutting cable ties 8. 1.5 mm and 2.0 mm hex keys 9. 5.5 mm hex driver (this can also be used for securing push nuts) 10. Small and Medium Spring Hook Tools 11. Soldering Iron with fine pointed tip
Note Unless specifically stated, all screws noted in this document use the Torx T10 driver.
blah
62
980569-001 Rev. A
5.1 Removal Sequence

This figure shows the recommended removal sequence. For example, to remove the CPU PCBA, you would remove the Top Cover (procedure given in section 5.2 on pg 64), remove the Print Engine from the Lower Cover (section 5.3 on pg 67), remove the Connector Plate (section 5.4 on pg 68), and then remove the CPU PCBA (section 5.24 on pg 142).
Start Here Complete P330i Printer
5.18 LCD PCBA (pg 111)
5.2 Top Cover (pg 64) 5.3 Remove Print Engine from Lower Cover (pg 67) 5.4 Connector Plate (pg 68) 5.5 Power Supply Cover (pg 71) 5.6 Power Supply (pg 73) 5.7 Rear Plate (save bearings and wavy washers) (pg 75) 5.8 Cam Lever (pg 78) 5.9 Platen Inertia Roller (pg 79) 5.10 Printhead Pressure Spring (pg 80) 5.11 Film/Bracket Sensor PCBA (pg 81) 5.12 Pressure Spring Plate (pg 82) 5.13 Cam Arm Follower Assy (pg 83) 5.14 Clutch Assembly (pg 84) 5.15 Print Head / Carriage Assembly (pg 88) 5.16 Print Head Lift Cam (pg 92)
5.17 Print Head Assembly (pg 94)
5.23 Power and Filter Components (pg 141)
5.18 LCD Cable Assy (pg 111
5.24 CPU PCBA (pg 142)
5.19 Encoder Shroud & Exit Pressure Roller (pg 113) 5.20 Exit Pressure Roller Assy (pg 116)
5.21 Balls Retainer Plate, Springs, Balls (pg 125)
5.34 Card Sensor Cable Assy (pg 166)
5.22.2 Card Feeder Drive Belt, Card Feeder Motor (pg 129)
5.22.3 Card Feeder Assy, ESD Brush, Card Feeder Belt, Card Feeder Rollers (pg 134)
5.25 I/O Daughterboard (pg 145)
5.26 RFID Cable (pg 147)
5.27 Ribbon O-Ring Drive Belt (pg 149) 5.28 Ribbon Pulley Assy, Ribbon Take-Up Spindle (pg 151)
5.30 Stepper Motor Drive Belt (pg 156) 5.31 Stepper Motor (pg 157)
5.29 Ribbon Motor Pulley, Ribbon Motor (pg 154)
5.32 RFID PCBA (pg 160)
5.33 Ribbon Color Sensor (pg 162)
5.22.1 Card Sensor Cable Assy (pg 127)
Remove Print Head Assembly if not already removed (94)
Remove I/O Daughterboard if not already removed (pg 145)
5.36 Print Head Lift Motor (pg 180)
5.35 Print Head Cable Assy (includes Sensor & Fan) (pg 171
5.37 Replace Parts that Require Separating the Front Frame from the Center Frame (pg 181)
5.38 Magnetic Stripe Encoder Option (pg 186)
5.39 Smart Card Options (pg 188)
980569-001 Rev. A
63
5.2 Removing the Top Cover

Step 1. Turn the printer power off, and disconnect the power cord. If an interface cable (USB or ethernet) is plugged into the printer, disconnect it. Remove any plastic cards from the Card Input Hopper. Step 2. Turn the printer over, and rest it upside-down on a work surface. Step 3. Press a screwdriver or similar tool into the Hopper Release Hole and slide the Card Output Hopper out of the printer. Step 4. Remove five screws securing the top cover from underneath. Four of them are at the Card Input Hopper end of the printer, as shown below.
Hopper Release Hole
Top Cover Attachment Screws
Step 5. The fifth Top Cover attachment screw is located above the card output opening (this is why the Card Output Hopper was removed). See below.
64
980569-001 Rev. A
Top Cover Attachment Screw
Step 6. Turn the printer over, so it is right-side up. Remove two screws into the upper part of the back of the printer.
Remove These Screws
Step 7. Remove one remaining screw attaching the top cover.
980569-001 Rev. A
65
Remove This Screw
Step 8. Carefully remove the top cover. Be careful to avoid damaging the cable to the LCD Panel PCBA or the wires to the card sensor.
Top Cover
66
980569-001 Rev. A
5.3 Removing the Print Engine from the Lower Cover

Step 1. Remove two screws from the back of the lower cover to release the print engine.
Remove These 2 Screws
Step 2. Remove the print engine from the lower cover.
980569-001 Rev. A
67
5.4 Removing the Connector Plate

Step 1. Remove the two Phillips-head screws shown in the figure below.
Remove These 2 Phillips-head Screws
Step 2. Disconnect the ground lug as shown below.
Ground Lug
68
980569-001 Rev. A
Step 3. Remove the screws attaching the print engine to the Connector Plate as shown in the two pictures below.
Remove This Screw
Remove This Screw
980569-001 Rev. A
69
Step 4. Swing the Connector Plate away from the Print Engine as shown below. If your printer includes the Contact Station Smart Card Option, disconnect wires to the Smart Solenoid PCBA as you swing the Connector Plate.
Smart Solenoid PCBA (Part of Contact Station Smart Card Option)
Connector Plate
Step 5. Then detach the wires at the Power Switch that go to the Power Supply, freeing the Connector Plate from the Print Engine.
70
980569-001 Rev. A
5.5 Removing the Power Supply Cover
Power Supply Cover
Step 1. Remove four screws holding the Power Supply Cover in place, as shown in the next two pictures, and remove the Power Supply.
Remove These Two Screws
980569-001 Rev. A
71
Remove These Two Torx T-10 Screws, then Remove the Power Supply Cover.
72
980569-001 Rev. A
5.6 Removing the Power Supply

Step 1. Unplug the two connectors shown in the picture below. The mating part of each connector has a tab/latch that must be moved out of the way to allow removal of the connector; this is easier with the use of a small flat-blade screwdriver.
Power Supply
Unplug These Connectors
Step 2. Remove four Torx T-10 screws shown in the picture below, and remove the Power Supply.
980569-001 Rev. A
73
74
980569-001 Rev. A
5.7 Removing the Rear Plate

The Rear Plate is removed to provide access to the I/O Daughterboard and many other mechanical and electrical components of the printer.
Note In the pictures that follow, the Power Supply has been removed from the Rear Plate. The Rear Plate can be removed without removing the Power Supply, but it is suggested that you remove the Power Supply Cover so the wires to the Power Supply can be disconnected.
Step 1. This step only applies for printers that include a Magnetic Stripe Encoder. Using a small flat-blade screwdriver, pry open the Cable Clip that secures the Magnetic Encoder cable.
(These wires are present only if your printer has a Magnetic Stripe Encoder Option.)
2. Then unplug this connector from the CPU PCBA.
1. Use small flat-blade screwdriver to pry the Cable Clip open, being VERY careful to not crush any of the wires.
980569-001 Rev. A
75
Remove these 3 screws, and lift the Rear Plate back from the Print Engine.
As you remove the Rear Plate, pass this cable through the rectangular cutout.
Important When you remove the Rear Plate, take careful note of the Wavy Washers and
Bearings as shown in the picture below. They are held in place by the Rear Plate; when the Rear Plate is removed they can fall off their shafts. It is suggested that you remove them and store them until the Rear Plate is to be replaced. When you replace them, make sure each Bearings flange side is inward and that the Wavy Washer is centered and seated on the Bearings body.
76
980569-001 Rev. A
980569-001 Rev. A
77
5.8 Removing the Cam Lever
Upper Cam
Print Head Lift Cam
Cam Lever
Platen Inertia Roller
Step 1. Remove the Cam Lever The upper (smaller) hole in the Cam Lever fits over a peg in the Upper Cam; the lower (larger) hole fits over the raised cam of the Printhead Lift Cam. (The Cam Lever is not attached at either end; it is held in place by the Rear Plate.)
78
980569-001 Rev. A
5.9 Removing the Platen Inertia Roller
Platen Inertia Roller
Step 1. The Platen Inertia Roller is secured to the Step Motor shaft with a small setscrew. Since access to the setscrew is limited, turn the Platen Inertia Roller so the setscrew is accessible, and use an L-shaped 2-mm hex key to loosen the setscrew; then slide the Platen Inertia Roller off the shaft.
Shaft That Held Platen Inertia Roller
980569-001 Rev. A
79
5.10 Removing the Printhead Pressure Spring

Step 1. With a heavy Spring Hook or similar tool, free the Printhead Pressure Spring from the Pressure Spring Plate, as shown below. The Printhead Pressure Spring is under a lot of tension, it will snap off the Pressure Spring Plate when freed.
Printhead Pressure Spring
Spring Hook Tool
Pressure Spring Plate
Step 2. Then remove the Printhead Pressure Spring from the Cam Arm Follower Assembly.
Cam Arm Follower Assembly
80
980569-001 Rev. A
5.11 Removing the Film/Bracket Sensor PCBA

Step 1. Open the Aluminum Cable Tie to free the Film/Bracket Sensor PCBAs cable.
Film/Bracket Sensor PCBA Aluminum Cable Tie
Step 2. Follow the Film/Bracket Sensor PCBAs cable to where it plugs into the I/O Daughterboard. Unplug it. Then work it out from behind the RFID Cable Assembly. Step 3. Remove the screw securing the Film/Bracket Sensor PCBA to the Print Engine Center Frame, and remove the Film/Bracket Sensor PCBA.
RFID Cable Assembly
Screw that Secures the Film/ Bracket Sensor PCBA
Film/Bracket Sensor PCBAs Cable
980569-001 Rev. A
81
5.12 Removing the Pressure Spring Plate

Step 1. After removing the Film/Bracket Sensor PCBA, remove the screw securing the Pressure Spring Plate to the Print Engine Center Frame, and remove the Pressure Spring Plate
Pressure Spring Plate
Mounting Screw
82
980569-001 Rev. A
5.13 Removing the Cam Arm Follower Assembly

Step 1. Remove the two Torx T15 screws that hold the Cam Arm Follower Assembly in place, as shown below. The upper one screws into the threaded end of the Print Head U-Support Assembly; it can be removed easily.
Torx T15 Screws
Cam Arm Follower Assembly
Step 2. The lower T15 screw goes into the threaded end of the Printhead Bracket Shaft; to remove this one it will be necessary to prevent the Printhead Bracket Shaft from turning. The best way to do this is to hold the shaft in place with a medium flat-head screwdriver from the front of the Print Engine, as shown in the next picture.
Printhead Bracket Shaft
980569-001 Rev. A
83
5.14 Removing the Clutch Assembly

Important Do not attempt to take the Clutch Assembly apart! If the Clutch Assembly is damaged, it is replaced as a unit.
Clutch Assembly
84
980569-001 Rev. A
Step 1. Hold the Ribbon Supply Spindle, and use a Number 1 Phillips screwdriver to remove the screw securing the Ribbon Supply Spindle to the Clutch Assembly Shaft, as shown in the next picture. If necessary to prevent the shaft from turning, use a small crescent wrench on the flat of the Clutch Assembly Shaft to prevent the shaft from turning, as shown in the second picture.
Remove PhillipsHead Screw
Prevent the Clutch Assembly Shaft from turning
980569-001 Rev. A
85
Step 2. Remove the Ribbon Supply Spindle from the Clutch Assembly Shaft by pulling and turning the spindle.
Step 3. Now pull the Clutch Assembly straight out from the rear of the Print Engine. If the Clutch Assembly is to be re-installed, be careful to avoid bending the Flag Disk.
Flag Disk
86
980569-001 Rev. A
When replacing or re-installing the Clutch Assembly, make sure the hole in the tab on the Clutch Assembly fits over the raised pin through the RFID PCBA, as shown below.
Clutch Assembly Tab Raised Pin Through RFID PCBA
980569-001 Rev. A
87
5.15 Removing the Print Head / Carriage Assembly

Step 1. Note that when the Clutch Assembly is removed, the entire Print Head / Carriage Assembly can be removed from the Print Engine (the shaft which had held the Clutch Assembly will be sticking through the Center Frame, and the Printhead Bracket Assembly will rest against the Front Frame, as shown in the next two pictures).
Shaft which had held the Clutch Assembly Printhead Bracket/Fan Cable Assembly
88
980569-001 Rev. A
Hole that the Printhead Bracket Shaft normally passes through
Step 2. As you remove the Print Head / Bracket Assembly, gently pull the Print Head Cable Assembly through the opening in the Center Frame.
Print Head Cable Assembly (Normally Plugs into CPU PCBA)
980569-001 Rev. A
89
Caution Dont touch the Print Head Elements, shown in the picture below.
90
980569-001 Rev. A
Print Head Elements
980569-001 Rev. A
91
5.16 Removing the Print Head Lift Cam

Step 1. Rotate the Print Head Lift Cam clockwise until the Setscrew lines up with the cut out in the Center Frame, as shown in the second picture below. The best way to rotate the Cam is to place both index fingers on the inner surface (toward the front of the printer) and both thumbs on the outer surface (nearest you). Do not try to rotate the Cam in a counter-clockwise direction; this could damage the Print Head Lift Motor.
Setscrew Rotate Clockwise Only
Cut Out in Center Frame
Print Head Lift Cam
92
980569-001 Rev. A
Setscrew
Step 2. Use a Number 0 Phillips Screwdriver to loosen the Print Head Lift Cam Setscrew. Then pull the Print Head Lift Cam off the Motor shaft.
Important When re-installing the Print Head Lift Cam, do not over-tighten the Setscrew; it
should only be snug against the shaft.
980569-001 Rev. A
93
5.17 Replacing the Print Head Assembly
Electrostatic Discharge Caution The Print Head is extremely susceptible to Electrostatic Discharge (ESD) damage. Do not touch the bottom surface of the Print Head. The replacement must be performed at a static-free work station, an anti-static wrist strap must be worn and properly terminated, or other appropriate protection must be used.
Important This procedure describes replacing the Print Head Assembly. The Print Head
Assembly is supplied with components in correct alignment with each other. These alignments are critical to proper operation of the printer. Do not deviate from the procedure given here, do not loosen or tighten any screws except those specifically noted in this procedure, and do not attempt to adjust any part of the Print Head Assembly.
5.17.1
Replacement Procedure
Step 1. Turn the printer power off, and disconnect the power cord. Step 2. Open the printers main (translucent blue) cover. Then remove the cover by pressing inward and twisting at the pivot points.
Step 3. Press the Print Head Carriage Latch to the left, and open (raise) the Print Head Carriage.
94
980569-001 Rev. A
Step 4. Remove the ribbon by pulling both the supply and take-up spools straight out.
Step 5. Using the Torx T10 driver, remove the retaining screw on the front side of the Print Head Carriage.
980569-001 Rev. A
95
Step 6. While removing the retaining screw, the Print Head Adjustment Screw may slip out of the notch in the front of the Print Head Carriage. Whether it has slipped or not, use a medium flat-blade screwdriver to remove the Print Head Adjustment Screw and its associated washer and spring.
Print Head Adjustment Screw
Washer
Spring
Step 7. Looking at the Print Head Carriage from the rear of the printer, note that the Print Head Assembly Shaft has a notch just inside the slotted end. That notch will be riding in a reduced-size cutout in the Print Head Carriage Frame, as shown below.
Cutout in the Print Head Carriage Frame
End of Print Head Assembly Shaft
96
980569-001 Rev. A
Step 8. Gently rock the Print Head Assembly back and forth (the Print Head Assembly Shaft will be the pivot) until the end of the Print Head Assembly Shaft lines up with the circular opening in the Print Head Carriage Frame.
End of Print Head Assembly Shaft
Step 9. Slide the Print Head Assembly Shaft out of the Print Head Carriage. It can be slid out toward the front or the rear of the printer; you may need to press on the end of the Shaft, and it may be a snug fit.
Print Head Assembly Shaft
980569-001 Rev. A
97
Step 10. Disconnect the Ground Lug Spade Connector, as shown in the picture below (this is more easily done by using needle-nose pliers). Gently use a small flat-blade screwdriver to pry the Print Head Cable Connector up and unplug it.
Print Head Cable Connector
Ground Lug Spade Connector
Step 11. Rock the Print Head back and forth while gently separating the sides of the Print Head Carriage until the Print Head can be slid free from the Print Head Carriage.
98
980569-001 Rev. A
Step 12. Remove the replacement Print Head Assembly from its protective packaging.
Caution When handling the Print Head Assembly, be careful to avoid touching the active surface of the Print Head. The Print Head is extremely susceptible to damage from static discharge. Also, oil from your fingers can cause poor print quality and/or shorter Print Head life.
Active Surface of Print Head
Step 13. Slide the Print Head Assembly Shaft through the holes in the Print Head Assembly Frame as shown.
Slotted and Notched End of Print Head Assembly Shaft Goes Through This Hole
980569-001 Rev. A
99
Step 14. The Print Head Assembly Shaft should stick through both sides of the Print Head Assembly Frame.
Step 15. Turn the Print Head Assembly Shaft so the threaded hole in the center is accessible through the center cutout in the Print Head Assembly Frame. Start the Print Head Adjustment Screw (with its associated Spring and Washer in place) into the threaded hole in the center of the Print Head Assembly Shaft. Run it in two or three turns; it must stay engaged in the Shaft during the steps that follow.
100
980569-001 Rev. A
Step 16. Position the Print Head Assembly as shown below. Gently separate the sides of the Print Head Carriage while rocking the Print Head Assembly back and forth and slide it into approximate position within the Print Head Carriage. See the following pictures. You want the Print Head Assembly Shaft to (first) engage the circular cutout in the back side of the Print Head Carriage, and then (at the same time) engage the large cutout in the front of the Print Head Carriage.
Keep the Print Head Assembly Screw Below the Notch in the Print Head Carriage as You Rock the Print Head Assembly Into Place
980569-001 Rev. A
101
Print Head Assembly is in Proper Position when the End of the Shaft Sticks Through the Circular Cutout
Step 17. When the Print Head Assembly Shaft is in position at the circular cutout (above), press the Shaft toward the back of the printer (i.e., so it sticks out about 1/16 inch or 2mm); this will make it easier to rock the front end of the shaft into position, as shown below. Then press the Shaft (forward) so it is approximately centered within the Print Head Carriage.
End of Print Head Assembly Shaft Sticks Through this Large Cutout
102
980569-001 Rev. A
Step 18. Plug in the Print Head Cable Connector, and use a small flat-blade screwdriver to press the connector evenly and firmly into place. Connect the Ground Lug Spade Connector (this is more easily done by using needle-nose pliers).
Step 19. See the following pictures. With your fingertips or a small flat-blade screwdriver, slightly compress the Print Head Adjustment Screw Spring and slide the Washer down; now pivot the Print Head Adjustment Screw upward so it is within the notch in the front of the Print Head Carriage (and the Washer and Spring are inside the Carriage, as shown in the second picture.
980569-001 Rev. A
103
Step 20. With a medium flat-blade screwdriver, turn the Print Head Adjustment Screw clockwise. (Dont let the screw head slip out of the notch in the Print Head Carriage.) Note that as the Screw is turned, the Print Head Assembly pivots about the Print Head Assembly Shaft.
104
980569-001 Rev. A
As the Print Head Adjustment Screw is driven clockwise, the Print Head Assembly Shaft Moves Into the Narrower Part of the Cutout
Print Head Shaft in Position, roughly centered laterally and within the middle curved slot.
980569-001 Rev. A
105
Step 21. Drive the Print Head Adjustment Screw in (clockwise) until the single raised bump on the Print Head just makes contact with the front end of the curved slot in the Print Head Carriage.
Single Raised Bump at Front of Curved Slot
Step 22. Turn the screw out (counter-clockwise) exactly four and one-half turns. The (upper) single raised bump will be somewhere within the arc of the curved slot. (The Print Head will rotate on its shaft and the two lower raised bumps; ignore their positions as long as they are within their respective curved slots.)
Single Raised Bump Somewhere Within Curved Slot
106
980569-001 Rev. A
Step 23. Insert and tighten the Torx head retaining screw.
Step 24. Re-install the ribbon; lower the Print Head Carriage until it clicks into place; reinstall the printer cover. Connect the power cord, and turn the printer power on.
980569-001 Rev. A
107
5.17.2
Enter the Print Head Resistance

Before proceeding to the Final Adjustment, the resistance value of the replacement must be entered, since the resistance will affect the physical adjustment. Step 1. From the Windows Start button or from the Printers or Printers and FAXes Control Panel, select the P330i printer. Right click to bring up Properties, select Device Settings, and select Tools / Properties. This will bring up the Tools window, as shown below.
Step 2. As shown above, in the Command to send to printer area, enter !R followed by a space followed by the resistance value of the replacement print head. (The resistance value will be shown on the replacement print head.) Then click the Execute button, then close the Tools window.
108
980569-001 Rev. A
5.17.3
Print Head Final Adjustment

Print Head final adjustment involves printing a card, inspecting it, and if necessary adjusting the Print Head Adjustment Screw. This sequence is repeated until the card print quality is acceptable. Step 1. From the Windows Start button or from the Printers or Printers and FAXes Control Panel, select the P330i printer. Right click to bring up Properties, select Device Settings, and select Tools / Properties. This will bring up the Tools window, as shown below.
Step 2. If your printer has a color ribbon, enter IM in the Command to send to printer area, then click the Execute button. A card like the following one will be printed.
Step 3. If your printer has a monochrome ribbon, enter IMB in the Command to send to printer area, then click the Execute button. A gray (ideally) or moire-pattern card like the following one will be printed.
980569-001 Rev. A P330i Card Printer Service Manual 109
Step 4. If the card print quality is acceptable, no additional adjustment is necessary. If the card print quality is not acceptable, loosen the Torx head retaining screw and turn the Print Head Adjustment Screw one-quarter turn clockwise or counterclockwise. Print another card.
a. b.
If the print quality is better, turn the Print Head Adjustment Screw one-eighth turn in the same direction.
If the print quality is worse, turn the Print Head Adjustment Screw one-half turn in the other direction. Step 5. Continue making smaller adjustments in either direction until the print quality is optimized. Then tighten the Torx head retaining screw.
110
980569-001 Rev. A
5.18 Replacing the LCD PCBA and/or LCD Cable Assembly

Note To replace the LCD PCBA, detach the Top Cover and proceed as follows. If the LCD
Cable Assembly is to be replaced, the Print Engine must be removed from the Lower Cover. Step 1. Unplug the LCD Cable Assembly from the LCD PCBA. It may help to use a small flat-blade screwdriver to gently pry the cable connector out of the PCBA connector; if you do this be very careful to avoid damaging either connector or bending any pins.
Unplug LCD Cable Assembly
Step 2. If replacing the LCD Cable Assembly, unplug it from J10 on the CPU PCBA.
LCD Cable Assembly
Plugs into J10 on CPU PCBA.
980569-001 Rev. A
111
Step 3. While lifting on the right-hand end of the LCD PCBA, use a small flat-blade screwdriver to gently pry the support clip to the right as shown below. Use just enough force to free the PCBA; too much force could damage or break the support clip.
Support Clip
Step 4. When installing the LCB PCBA, place it in position on the Top Cover and press to snap it into place.
112
980569-001 Rev. A
5.19 Replacing the Encoder Shroud and Exit Pressure Roller

Note This procedure covers replacing the Exit Pressure Roller only, not the complete Exit
Pressure Roller Assembly (which also includes the Pivot Shaft and Spring). For instructions on replacing the complete Exit Pressure Roller Assembly, see the next procedure. The instructions given in this procedure also apply in general terms to the other Pressure Rollers. Step 1. Remove the protective Encoder Shroud that protects the Magnetic Encoder Sensor and Head (if present). (Note that the Shroud is present whether or not there is a Magnetic Encoder.) Press the two removal tabs toward the rear of the printer, and lift the shroud by the lift tab.
Lift Tab
Protective Shroud
Removal Tabs
980569-001 Rev. A
113
Step 2. With the shroud removed, note the position of the Exit Pressure Roller.
Exit Pressure Roller Assembly Spring Exit Pressure Roller
Exit Pressure Roller Assembly Pivot Shaft
Step 3. Lift the legs of the Exit Pressure Roller so they disengage from the Pivot Shaft.
114
980569-001 Rev. A
Step 4. Push the Exit Pressure Roller outward, then pull it the rest of the way out from under the Pressure Spring.
Pressure Spring
Step 5. When the Exit Pressure Roller has been removed, the Pressure Spring on the Pivot Shaft will look like the picture below.
980569-001 Rev. A
115
5.20 Replacing the Exit Pressure Roller Assembly

Note This procedure covers replacing the complete Exit Pressure Roller Assembly (which also includes the Pivot Shaft and Spring). For instructions on just replacing the Exit Pressure Roller, see the previous procedure. The instructions given in this procedure also apply in general terms to the other Pressure Roller Assemblies.
Important Do not even attempt this procedure if you do not have a thin spring hook tool
like the one shown below (shown next to a Pressure Roller for size reference).
Note This procedure can also be perfomed with the Exit Pressure Roller already removed,
as described in the previous procedure. The pictures and steps are so similar that differences will be readily apparent.
116
980569-001 Rev. A
Step 1. Note the location of the components of the Exit Pressure Roller Assembly shown in the following pictures.
Exit Pressure Roller Assembly Spring Exit Pressure Roller
Exit Pressure Roller Assembly Pivot Shaft
Exit Pressure Roller
(See Next Picture)
Pivot Shaft
980569-001 Rev. A
117
Step 2. Remove the screw that covers and secures the end of the Pivot Shaft, shown in the picture below.
Screw Head Securing End of Pivot Shaft
Step 3. In the next picture, you can see the end of the Pivot Shaft after the securing screw has been removed.
End of Pivot Shaft
118
980569-001 Rev. A
Step 4. With fine-point pliers, grab the Pivot Shaft between the legs of the Pressure Roller and slide it out of the Front Frame. It will be a snug fit; it may help to simultaneously rotate the Pivot Shaft and slide it out. (If the Pressure Roller has already been removed, grab the Pivot Shaft anywhere along its length and slide it out.)
Caution As the Pivot Shaft is freed from the bearing in the Front Frame, keep in mind that the Exit Pressure Roller Spring is under tension.
Step 5. If you will be replacing the Exit Pressure Roller Assembly, be sure to keep the three parts as shown in the picture below.
Pivot Shaft
Pressure Roller Spring
980569-001 Rev. A
119
Step 6. Feed the Pivot Shaft through the hole in the Front Frame.
Step 7. As you feed the Pivot Shaft inward, place the Spring on the Shaft as shown below. The two ends and the large central portion all come from the bottom of the Spring, and the two legs of the Spring must be facing as shown.
120
980569-001 Rev. A
Step 8. Continue feeding the Pivot Shaft until it is engaged in its bearing on the Center Frame.
Step 9. With fine-nose pliers, bring the leg of the Spring over the Pivot Shaft as shown in the next two pictures. This may be somewhat easier if you slide the Spring away from the Center Frame about 1/8 inch (4 mm).
980569-001 Rev. A
121
Step 10. Reach in under the Pivot Shaft with the spring hook tool and grab the end of the spring. Then let go with the pliers.
Step 11. Pull the end of the Spring under the Pivot Shaft (again, this may be easier if you slide the spring away from the Center Frame). Continue pulling the end of the Spring around the Pivot Shaft until the Springs leg can rest in the detent of the ridge as shown below. There is a small hole in the side of the frame next to the detent; the very end of the Springs Leg should be pressed into that hole.
Detent of Ridge
122
980569-001 Rev. A
Step 12. Then follow the same steps with the end of the Spring closer to the Front Frame, as shown in the following series of pictures.
980569-001 Rev. A
123
Lift End of Spring onto Flat Area
Step 13. Then replace the Exit Pressure Roller as described in the previous procedure.
124
980569-001 Rev. A
5.21 Removing the Balls Retainer Plate

The Balls Retainer Plate is located below the Ribbon Supply Spindle. It covers the access hole for the pivot shaft of a pressure roller assembly. It also holds a pair of springs in place, which in turn provide spring pressure to a pair of Delrin Balls that precisely position the card within the card path.
Important When the Balls Retainer Plate is removed, be careful to not lose the springs and/
or balls that it holds in place. Step 1. The Balls Retainer Plate is held in place below the ribbon supply spindle by a flathead Phillips screw. Using a Number 0 Phillips screwdriver, remove the screw and remove the Balls Retainer Plate.
Balls Retainer Plate
980569-001 Rev. A
125
Step 2. The next picture shows the Balls Retainer Plate removed.
Pivot Shaft Access
Springs (Delrin Balls not visible)
Step 3. The following picture is a magnified view of the springs and Delrin Balls. Actual size of the Balls is 5 mm (about 1/5 inch).
126
980569-001 Rev. A
5.22 Card Feeder Components

This section describes replacing various components of and associated with the Card Feeder. Some of these procedures involve detaching and disassembling the Card Feeder Assembly, others do not.
5.22.1
Replacing the Card Sensor Cable Assembly

The Card Sensor Cable Assembly can be replaced with or without disassembling the Card Feeder Assembly; it can even be replaced without detaching the Card Feeder Assembly from the Print Engine. Step 1. The Card Sensor Cable Assembly in turn plugs into a Cable Assembly that goes to the I/O Daughterboard. Unplug the connector. Step 2. The Card Sensor Cable Assembly snaps into a recess in the side of the Card Feeder Assembly frame, as shown in the picture below.
(Card Feeder Assembly shown detached from the Print Engine)
Card Sensor Cable Assembly
Unplug this connector from the Cable Assembly that goes to the I/O Daughterboard.
980569-001 Rev. A
127
Step 3. To remove the Card Sensor Cable Assembly, hold the four wires close to the sensor and push up while lifting away from the Card Feeder frame, as shown in the next picture.
128
980569-001 Rev. A
5.22.2
Replacing the Card Feeder Drive Belt and/or Card Feeder Motor
The Card Feeder Drive Belt and/or Card Feeder Motor can be replaced with or without disassembling the Card Feeder Assembly; either or both can even be replaced without detaching the Card Feeder Assembly from the Print Engine; the procedure for detaching the Card Feeder Assembly is given in paragraph 5.24.3. (The pictures in this section show the Card Feeder Assembly disassembled.)
(Card Feeder Assembly shown detached from the Print Engine)
Card Feeder Drive Belt
Step 1. In the following picture, note the location of the push nut on the Roller Shaft.
980569-001 Rev. A
129
Push Nut
Step 2. With a small flat-blade screwdriver, gently pry the pushnut off the shaft.
Step 3. This will allow you to slip the Timing Belt off the Pulleys.
130
980569-001 Rev. A
After removing the Card Feeder Drive Belt, the Card Feeder Motor can be replaced. Step 4. There is a very small E-Ring that secures the Feeder Pulley to the Motor shaft (see below). With a small flat-blade screwdriver, push this E-Ring around the shaft until the center of the E-Ring is at the flat of the shaft (this will give maximum access to the E-Ring). Then, with a very small flat-blade screwdriver, free the E-Ring from the groove of the Motor shaft.
980569-001 Rev. A
131
Step 5. With the E-Ring removed, lift the Feeder Pulley and two spacer washers from the Card Feeder Motor shaft.
132
980569-001 Rev. A
Step 6. Then remove three screws as shown below to free the Card Feeder Motor. (If the Card Feeder Assembly has not been disassembled, remove the Card Feeder Motor by reaching up through the open bottom of the Card Feeder Assembly.
980569-001 Rev. A
133
5.22.3
Detaching and Disassembling the Card Feeder Assembly

Step 1. The Card Feeder Assembly is attached to the Print Engine by two screws, as shown in the picture below.
Remove This Screw on Front
Remove This Screw on Back
Step 2. Unplug the spade lug on the green ground wire at the location shown in the next picture.
Detach Green Wire at the Spade Lug on This End
134
980569-001 Rev. A
Step 3. Slide a medium flat-blade screwdriver into the gap below the left side of the ESD Brush as shown in the picture below. Then turn the screwdriver clockwise to push the left side of the ESD brush upward, as shown in the next picture.
980569-001 Rev. A
135
Step 4. Lift the left end of the ESD Brush just enough to clear the protective lip of the frame.
Protective Lip
Caution Handle the ESD Brush carefully to avoid bending or otherwise damaging it.
Step 5. Gently bring the left end of the ESD Brush in front of the protective lip, so it is approximately in its original horizontal orientation.
136
980569-001 Rev. A
Step 6. Gently push the ESD Brush to the right, so the elongated hole at the right end can disengage from the post on the frame, and remove the ESD Brush.
Important If the ESD Brush appears damaged in any way, replace it.
Step 7. Remove four screws inside the counterbores as shown in the picture below.
980569-001 Rev. A
137
Step 8. Use a small flat-blade screwdriver to gently pry the two parts of the Card Feeder Assembly frame apart. (It will probably be necessary to go around the entire seam several times to gradually separate the parts.)
Step 9. With the Card Feeder Assembly Frame apart, the Card Feeder belt can be removed off its rollers (turning the rollers back and forth will make this somewhat easier). (Note that the picture also shows the Card Feeder Motor in place.) After the Card Feeder Belt is removed, the Card Feeder Rollers can be removed if desired. (If the Roller over the Card Feeder Motor is to be removed, remove the gear from its shaft.)
Card Feeder Belt
Card Feeder Rollers
138
980569-001 Rev. A
Step 10. Reassembling the Card Feeder Assembly is shown in the following series of pictures. First, hold the two sides of the Frame together as shown, and place the Feeder Gate Lever in position. Note that the Feeder Gate Lever must be placed so the hole in the arm fits over the raised pin on the frame.
Feeder Gate Lever
Hole in Feeder Gate Lever fits over Raised Pin on Feeder Frame
Step 11. Place the Ruber Gate over the raised pins on the frame as shown in the next picture.
Rubber Gate Fits Over Raised Pins
980569-001 Rev. A
139
Step 12. Place the Feeder Gate Plate in approximate position. Make sure the slot in the Feeder Gate Plate engages the raised pin on the Feeder Gate Lever, then press the Feeder Gate Plate inward on each side to snap it into the groove on each side of the frame.
Feeder Gate Plate
Make Sure Slot in Feeder Gate Plate Engages Pin on Feeder Gate Lever, then Snap Feeder Gate Plate into place.
Step 13. Replace the screws into the counterbores that were removed in step 7. Step 14. Reinstall the ESD Brush, or install a new one.
140
980569-001 Rev. A
5.23 Power / Filter Components

Step 1. The Power / Filter Components are mounted on the Connector Plate, and are shown in the picture below. The two unused lugs on the left side of the Power Switch connect to the Power Supply.
AC Power Connector
Power Switch
EMI Ferrite Cable Assembly
EMI Filter
980569-001 Rev. A
141
5.24 Removing the CPU PCBA

The CPU PCBA can be removed whether you remove the Connector Plate (as described in section 5.4) or not. If you do not remove the Connector Plate, be careful to avoid damaging components on the Connector Plate or wires to/from it. Step 1. The CPU PCBA rests on slides below the Rear Plate, as shown below. Note that the CPU PCBA is not secured by any mounting hardware; it is simply held in place by the wires to/from it (and, when the Print Engine is in place on the Lower Cover, by the Lower Cover itself).
CPU PCBA
Step 2. Slide the CPU PCBA straight out, carefully unplugging connectors as you slide the board out, as shown in the next three pictures.
142
980569-001 Rev. A
To Card Feeder Sensor
This Cable goes to the LCD Screen
Use a Small Flat-blade Screwdriver to Remove the Restraining Clip on this connector
RFID Cable
980569-001 Rev. A
143
Step 3. The next figure shows for reference the primary functions of the various connectors on the CPU PCBA.
J11 (Ribbon RFID) J7 (Smart Card) J1 (Mag Encoder Head) J8 (Auxiliary RS-232; factory use only)
J6 (USB Port) J2 (Mates with Ethernet Extension Board)
J10 (LCD Panel)
J13 (Motors and Sensors Connects to I/O Daughterboard) J12 (+24 VDC Input from Power Supply)
J4 (Not Used)
J3 (Out of Cards Sensor)
J9 (Print Head, Head Lock, Head Temp. Sensor)
Step 4. When sliding the CPU PCBA back into position, make sure it is between the guides on either side. Re-attach connectors as you slide the board in.
Slide CPU PCBA Between Guides On Either Side
144
980569-001 Rev. A
5.25 Removing the I/O Daughterboard

Step 1. When the Rear Plate is removed (see section 5.7), the I/O Daughterboard is visible. It is directly above the CPU PCBA, but it is hidden (and held in position) by the very bottom of the Rear Plate.
I/O Daughterboard
CPU PCBA (Shown with Ethernet Adapter)
(Rear Plate Removed)
I/O Daughterboard
980569-001 Rev. A
145
Step 2. Unplug as many of the connectors to the I/O Daughterboard as you can reach before starting to slide it out; unplug other connectors as they become accessible.
Step 3. The following figure shows the connectors on the I/O Daughterboard.
Color Sensor 1 J04
Color Sensor 2 J09
DC DC Motor Motor J06 J08
Stepper Motor J01
J05
Synchro Film Sensor Position Bracket Sensor
J07 DC Motor
J02 Synchro Card Sensor
J03 (To J13 on CPU PCBA)
146
980569-001 Rev. A
5.26 Removing the RFID Cable

The RFID Cable connects the RFID PCBA to the CPU PCBA.
RFID PCBA
RFID Cable
CPU PCBA
980569-001 Rev. A
147
Step 1. Use a small flat-blade screwdriver to remove the restraining clip on the connector at each end of the RFID Cable. Open the Aluminum Cable Ties that hold the RFID Cable in place on the Center Frame. Remove the RFID Cable.
Retaining Clip (on connector at each end of RFID Cable)
Aluminum Cable Ties
148
980569-001 Rev. A
5.27 Replacing the Ribbon O-Ring Drive Belt
Ribbon O-Ring Drive Belt
Step 1. Remove the Ribbon O-Ring Drive Belt by slipping it off the Ribbon Motor Pulley and the Ribbon Pulley. Step 2. To install the Ribbon O-Ring Drive Belt, seat it in the groove of the Ribbon Pulley, pass it around both sides of the Upper Cam, and roll it into the groove of the Ribbon Motor Pulley.
980569-001 Rev. A
149
Important Make sure that the Ribbon O-Ring Drive Belt passes on the inside of the shield,
as shown in the picture below.
Ribbon Pulley Upper Cam
Ribbon Motor Pulley
Shield CORRECT -- Ribbon O-Ring Drive Belt Inside Shield
INCORRECT -- Ribbon O-Ring Drive Belt Outside Shield
150
980569-001 Rev. A
5.28 Replacing the Ribbon Pulley Assembly

Step 1. The Ribbon Pulley Assembly Shaft is secured by a screw in the middle of the Ribbon Take-Up Spindle.
Ribbon Pulley Assembly
980569-001 Rev. A
151
Step 2. While holding the Ribbon Take-Up Spindle, use a No. 1 Phillips screwdriver to remove the screw attaching the Ribbon Take-Up Spindle to the Ribbon Pulley Assembly Shaft, and slide the Spindle off the shaft (it may be a snug fit).
152
980569-001 Rev. A
Step 3. Slide the Ribbon Pulley Assembly (which includes the shaft) out of the bearing in the center frame.
980569-001 Rev. A
153
5.29 Removing the Ribbon Motor Pulley and the Ribbon Motor
Step 1. The Ribbon Motor Pulley is secured to the Ribbon Motor Shaft with a setscrew. Use a 1.5 mm hex key to loosen the setscrew, and remove the Ribbon Motor Pulley.
Ribbon Motor Pulley
Ribbon Motor Shaft
154
980569-001 Rev. A
Step 2. Cut the Cable Tie holding the bundle of Cables at the I/O Daughterboard
Cut This Cable Tie
These wires go to the Ribbon Motor
Step 3. Unplug the Connector for the Ribbon Motor from the I/O Daughterboard.
Step 4. The Ribbon Motor is held in position by three Torx T10 screws. Remove them.
Ribbon Motor Mounting Screws
980569-001 Rev. A
155
Step 5. Now reach up into the lower cavity between the Center Frame and the Front Frame and remove the Ribbon Motor.
5.30 Replacing the Stepper Motor Drive Belt

The Stepper Motor Drive Belt should be very snug so it will not slip off the Stepper Motor Drive Pulley during printer operation. Also, if the belt is too loose, vertical lines may appear on cards printed. A limited amount of tensioning adjustment can be made as follows. Step 1. Loosen the three 5.5 mm hex nuts securing the Stepper Motor to its Mounting Plate. Step 2. Reach up into the space between the Front Frame and the Center Frame, and move the Stepper Motor (the holes in the Center Frame are slightly enlarged, permitting some movement). Step 3. Tighten the three 5.5 mm hex nuts. Step 4. When pressing with a finger against the mid-point of the Stepper Motor Drive Belt, there should be less than 1/8 inch (3 mm) deflection.
156
980569-001 Rev. A
Stepper Motor Drive Belt
Stepper Motor Mounting Plate
Stepper Motor Drive Pulley
5.31 Removing the Stepper Motor

Step 1. Remove the Stepper Motor Drive Belt.
980569-001 Rev. A
157
Step 2. Remove the Stepper Motor Pulley. (If the old Stepper Motor will be re-installed and there is no apparent damage to the Stepper Motor Pulley, the Stepper Motor Pulley does not need to be removed.) Step 3. Remove the three 5.5 mm hex nuts securing the Stepper Motor to its Mounting Plate.
5.5 mm Hex Nuts
Stepper Motor Mounting Plate
Step 4. Reach up into the space between the Front Frame and the Center Frame, and remove the Stepper Motor.
158
980569-001 Rev. A
980569-001 Rev. A
159
5.32 Removing the RFID PCBA

Step 1. If the RFID Cable is still plugged into the RFID PCBA, use a small flat-blade screwdriver or fine-point plierst remove the retaining clip on the RFID Cable connector, as shown in the picture below. Unplug the RFID Cable.
Note that this pin on the Center Frame passes through a hole on the RFID PCBA.
Retaining Clip
RFID Cable
Step 2. With a Number 1 Philips screwdriver, remove two screws as shown in the next picture.
RFID PCBA Mounting Screws
160
980569-001 Rev. A
Step 3. Remove the RFID PCBA.
980569-001 Rev. A
161
5.33 Replacing the Ribbon Color Sensor

The Ribbon Color Sensor is located under the Ribbon Supply Spindle, as shown below. Note that the Ribbon Color Sensor cannot be removed until items have been removed from the Center Frame through the RFID PCBA.
Ribbon Color Sensor
162
980569-001 Rev. A
Step 1. See the two pictures below. With a small flat-blade screwdriver, gently pry up toward the front of the Ribbon Color Sensor until it pops free of the Print Engine.
980569-001 Rev. A
163
Step 2. The wires from the Ribbon Color Sensor are held in place on the Center Frame by two aluminum Cable Ties, as shown in the next picture. The wires are also routed through two guides, and secured in the guides by glue.
Guides with glue holding the wires in place
Aluminum Cable Ties
Step 3. Open the Cable Ties. Scrape the glue off the surface of the guides, being careful to avoid nicking or crimping the wires. Free the wires from the guides. Step 4. Unplug the wires from the Ribbon Color Sensor from the I/O Daughterboard. The connectors are behind the Ribbon Lift Cam.
Ribbon Lift Cam
164
980569-001 Rev. A
Step 5. Unplug the wires from the Ribbon Color Sensor from the I/O Daughterboard. The connectors are behind the Ribbon Lift Cam. Step 6. The Ribbon Color Sensor can now be removed by passing its wires through the rectangular cutout in the Center Frame.
980569-001 Rev. A
165
5.34 Replacing the Card Sensor Cable Assembly

Important The Torx T10 driver used in this procedure must have a blade at least 4 inches
(100 mm) long to reach through the access hole to the Card Sensor Mounting Screw. Step 1. The Card Sensor is located just inside the support for the Print Head Carriage, as shown in the picture below. The picture also shows the location of the Mounting Screw; the Mounting Screw location is also shown in the following picture. .
Card Sensor
Card Sensor Mounting Screw
Step 2. Looking up from under the Print Engine, note the routing of the wires in the Card Sensor Cable Assembly. When replacing or re-installing the Card Sensor, the wires must be routed the same way. If it has not already been done, unplug the Card Sensor Cable Assembly from the I/O Daughterboard. The picture also shows the location of the Card Sensor Mounting Screw.
3. All Four Wires then pass under this post.
1. Red and Green Wires come out on this side, and stay below the White and Black Wires.
2. White and Black Wires come out on this side, then bend over the Card Sensor and route over the Red and Green Wires.
166
980569-001 Rev. A
Step 3. See the following picture. If necessary, turn the Print Head Lift Cam and deflect the belt as shown to clear the Card Sensor Mounting Screw Access Hole. With a longbladed Torx T10 driver, go straight through the Access Hole until the Torx head engages the head of the Mounting Screw. Remove the Mounting Screw (the Card Sensor will remain in place).
Card Sensor Mounting Screw Access Hole
Print Head Lift Cam
Step 4. The following picture (from underneath) shows the Torx T10 driver bit in the Card Sensor Mounting Screw.
980569-001 Rev. A
167
Step 5. Using a Number 0 Phillips screwdriver, remove the Balls Retainer Plate and the springs and Delrin Balls it holds in place (more detailed information is given in section 5.21). Be careful to not lose the springs and/or balls.
Balls Retainer Plate
Step 6. The next picture shows the Balls Retainer Plate, springs, and balls removed. The Card Sensor Cable Assembly is barely visible.
Card Sensor Cable Assembly
168
980569-001 Rev. A
Step 7. Using a small flat-blade screwdriver, gently pry the Card Sensor toward the back of the Print Engine, as shown in the next picture. Be very careful to avoid crimping or breaking any of the wires. Pushing the wires upward (from underneath) will make prying the Card Sensor easier.
Use Small Flat-Blade Screwdriver Here...
... To Pry the Card Sensor This Way.
Step 8. The following picture shows the Card Sensor pried toward the back of the Print Engine.
980569-001 Rev. A
169
Step 9. Use a small flat-blade screwdriver to gently pry the Card Sensor upward, while rocking it back and forth until the Card Sensor clears the card path, as shown in the next picture.
Rock the Card Sensor back and forth while gently lifting / prying it upward.
Step 10. Lift the Card Sensor free of the Print Engine. Be careful to avoid damaging any of the wires. Continue lifting until the connector clears the hole in the card path.
170
980569-001 Rev. A
5.35 Removing the Print Head Cable Assembly

The Print Head Cable Assembly includes the Print Head Fan and the Ribbon Sync Sensor.
Caution During this procedure, be careful to avoid touching the Print Head Elements.
Step 1. If you have not already done so, remove the Print Head Assembly from the Printhead Bracket Assembly (steps are given in detail in section 5.19, but are repeated here in simplified form for convenience).
a.
With a medium flat-blade screwdriver, remove the Print Head Adjustment Screw (and its washer and spring).
980569-001 Rev. A
171
b.
With a Torx T10 driver, remove the retaining screw on the front side of the Print Head Carriage. (You may need to use a flat-blade screwdriver on the other end of the Print Head Assembly Shaft to remove the retaining screw.)
c.
Remove the Print Head Assembly Shaft.
172
980569-001 Rev. A
d.
Unplug the Print Head Cable (you may need to use a small flat-blade screwdriver to pry the plug apart from the connector). Disconnect the Ground Lug Spade Connector.
Ground Lug Spade Connector
Print Head Cable Connector
980569-001 Rev. A
173
e.
Rock the Print Head Assembly back and forth while gently separating the sides of the Print Head Carriage until the Print Head Assembly can be slid free of the Print Head Carriage.
Step 2. Cut the Cable Tie and remove the screw that holds the Ribbon Sync Sensor in place, as shown in the picture below.
Cable Tie
Screw Attaching Ribbon Sync Sensor
174
980569-001 Rev. A
Step 3. Push the Print Head Cable Connector, the Ground Lug, and the Ribbon Sync Sensor out of the way so you can see the four latches (two on each side) that hold the Print Head Fan in place, as shown in the next two pictures.
Fan Motor Attachment Latches
980569-001 Rev. A
175
Step 4. Through the cutouts in the Print Head Bracket, note the four Fan Motor mounting holes (even though they are not used to mount the Fan Motor).
Fan Motor Mounting Holes
Step 5. While in turn pressing the four Fan Motor Attachment Latches away from the Fan Motor, use a Number 2 Phillips Screwdriver (the blade is too big to go through the Fan Motor Mounting Holes) to press against the Fan Motor Mounting Holes). You may need to go around the four latches and holes more than once, but eventually the Fan Motor will be freed by all four Latches.
176
980569-001 Rev. A
Step 6. Then the Fan Motor can be pulled clear of the Attachment Latches.
Step 7. Remove two screws, shown in the next picture, that attach the Print Head Pivot Bracket to the Print Head Carriage.
Remove These Screws
980569-001 Rev. A
177
Step 8. Press and hold the Print Head Carriage Latch; twist and gently pull the Print Head Pivot Bracket until it separates from the Print Head Carriage.
2. Separate Head Pivot Bracket from the Print Head Carriage
1. Press and Hold Print Head Carriage Latch
Step 9. Work the Print Head Cable Assembly through the cut-outs in the Print Head Carriage. Bend the cable so the connector is roughly parallel to the cable to get it through the cut-outs.
178
980569-001 Rev. A
980569-001 Rev. A
179
5.36 Removing the Print Head Lift Motor

Step 1. The I/O Daughterboard and the Print Head Lift Cam must be removed to access the Print Head Lift Motor Mounting Screws. With a Number 0 Phillips screwdriver, remove three Mounting Screws as shown in the picture below.
Print Head Lift Motor Mounting Screws
Step 2. Reach up into the space between the Front Frame and the Center Frame, and remove the Print Head Lift Motor.
180
980569-001 Rev. A
5.37 Separating the Front Frame from the Center Frame

There are only a limited number of parts that would require separating the Front Frame from the Center Frame. These are: The Clean Drive Roller The Card Drive Roller The Platen Drive Roller The Exit Drive Roller The three Transport Rollers past the Platen The Card Pressure Plate attached to the Front Frame The Magnetic Encoder Station Roller attached to the Front Frame (Roller is present whether the printer includes the Magnetic Stripe Encoder Option or not)
Separating the Front Frame from the Center Frame constitutes a significant dismantling of the printer! The suggested procedure follows; procedures that are described in greater detail have references to the appropriate sectiion. Step 1. Remove the Top Cover (5.2) Step 2. Remove the LCD PCBA (5.18) Step 3. Remove the Print Engine from the Lower Cover (5.3) Step 4. Remove the Card Feeder Assembly (5.22.3) Step 5. Remove the Connector Plate (5.4) Step 6. Remove the CPU PCBA (5.24) Step 7. Remove the Power Supply Cover (5.5) Step 8. Remove the Power Supply (5.6) Step 9. Remove the Rear Plate (5.7) Step 10. Remove the Cam Lever (5.8) Step 11. Remove the Platen Inertia Roller (5.9) Step 12. Remove the I/O Daughterboard (5.25) Step 13. Remove the Printhead Pressure Spring (5.10) Step 14. Remove the Film/Bracket Sensor PCBA (5.11) Step 15. Remove the Pressure Spring Plate (5.12)
980569-001 Rev. A P330i Card Printer Service Manual 181
Step 16. Remove the Cam Arm Follower Assembly (5.13) Step 17. Remove the Clutch Assembly (5.14) Step 18. Remove the Print Head / Carriage Assembly (5.15) Step 19. Remove the Ribbon Color Sensor (5.32) Step 20. Remove the Smart Card Contact PCBA, if present Step 21. Remove the Card Sensor Cable Assembly (5.33) Step 22. Remove the Encoder Shroud and Exit Pressure Roller (5.19); remove all other Pressure Rollers using the same procedure. Step 23. Remove the Balls Retainer Plate, Springs, and Balls (5.21) Step 24. Remove Exit Pressure Roller Assembly (5.20); remove all other Pressure Roller Assemblies using the same procedure. Step 25. Remove the Stepper Motor Drive Belt (5.30.1) Step 26. Remove the ESD Brush at the Card Exit. Use a soldering iron to melt the flattened plastic posts and gently pry off the push nuts. When replacing, use the soldering iron to flatten the plastic posts to secure the push nuts. Step 27. Remove the items shown in the next two pictures in the order shown. Do not remove the Pulleys and Push Nut specified in the second picture.
182
980569-001 Rev. A
5.
Timing Belt
4.
Front Pulley
3.
Timing Belt
7.
Pulley
6.
Push Nut, then Rear Pulley
1.
2.
Pulley
(Do NOT remove Front Pulley, Push Nut, and Rear Pulley)
8.
Timing Belt
9.
Pulley
10. Push Nut
12. Pulley 11. Timing Belt
13. Position Front Frame/Center Frame with Center Frame Flat on work surface, then remove 7 Torx T10 Screws at bottom of these bores and lift the Front Frame straight up off the Center Frame.
980569-001 Rev. A
183
Step 28. Lift the Front Frame straight up off the Center Frame, and note the orientation of the Rollers shown in the next picture. The Rollers simply slip into their bearings in the Center Frame; they are held in place by corresponding bearings in the Front Frame when the Front Frame is attached.
Exit Drive Roller
Platen Drive Roller
Card Drive Roller
Clean Drive Roller
Step 29. The Card Pressure Plate is held in position (inside the Front Frame) by two springs, which provice slight pressure inward to the card in the card path. The Card Bias Guide limits the travel of the Card Pressure Plate
Magnetic Encoder Station Roller
Card Bias Guide
Card Pressure Plate
184
980569-001 Rev. A
Step 30. To remove the Card Pressure Plate, detach the Springs, then remove the Card Bias Plate (it is held by 3 Torx T10 screws).
Magnetic Encoder Station Roller
Card Bias Guide
Card Pressure Plate Springs
Step 31. To remove the Magnetic Encoder Station Roller, remove (in order) the outer Pulley, Push Nut, and inner Pulley shown in the picture below. Then slide the Magnetic Encoder Station Roller on its shaft through the bearing in the Front Frame.
1.
Outer Pulley
2.
Push Nut
3.
Inner Pulley
980569-001 Rev. A
185
5.38 Magnetic Stripe Encoder Option

The Magnetic Stripe Encoder Option consists of a Magnetic Encoder Sensor and Magnetic Encoding Head. These can be located below the card path (regular) or above the card path (reverse encoding). The instructions presented here are general enough that they can be applied to either. Step 1. Remove the protective shroud that protects the Magnetic Encoder Sensor and Head. Press the two removal tabs toward the rear of the printer, and lift the shroud by the lift tab.
Lift Tab
Protective Shroud
Removal Tabs
186
980569-001 Rev. A
Step 2. When the shroud is removed, the Magnetic Encoder Sensor and Magnetic Encoding Head are visible, as shown below.
Regular:
Magnetic Encoding Head Magnetic Encoder Sensor Reverse:
Step 3. The Magnetic Encoding Head and the Magnetic Encoder Sensor are attached with Torx T10 screws. Step 4. If the Rear Plate has not been removed, remove it (see section 5.7). Step 5. The wires for either type of Encoding Head and Encoder Sensor pass through a rectangular cut-out in the Center Frame.
980569-001 Rev. A
187
5.39 Smart Card Options

There are four different Smart Card Options available for the P330i. These can be summarized as follows: Contact Smart Card options use a Solenoid below the Card Path and a Contact PCBA above the Card Path. The Solenoid presses the card upward so the Contact PCBAs pins make electrical contact with the appropriate pads on the smart card. For the Contact Station version, wires from the Contact PCBA connect to a Smart Solenoid PCBA which mounts on the Connector Plate and includes a db9 connector for an external serial interface. For the GEM PLUS version, wires from the Contact PCBA (which includes logic for the GEM PLUS version) connect to the CPU PCBA. Additional logic circuitry on the CPU PCBA allows passing Smart Card signals via the USB connector, along with the normal functions of the USB interface. Contactless Smart Card options use either of two short-range radio technologies (HID or MiFARE) to communicate with the smart card. One component is a combination antenna and PCBA for the specific technology; this is mounted below the Card Path. There is also an Auxiliary PCBA, which is mounted on the bottom of the Center Frame, which provides an interface between the Antenna/PCBA and the CPU PCBA. Removal of most of these items is readily apparent.
5.40 Solenoid Assembly

If your printer includes a Contact Smart Card Option, it will include a Solenoid Assembly, which will be apparent by the two mounting screws shown in the following picture.
Solenoid Assembly Mounting Screws
188
980569-001 Rev. A
Step 1. With a Number 0 Phillips screwdriver, remove the two Solenoid Assembly Mounting Screws. Step 2. Reach up into the space between the Front Frame and the Center Frame, and remove the Solenoid Assembly.
Solenoid Assembly Mounting Holes
Solenoid Assembly
980569-001 Rev. A
189
190
980569-001 Rev. A
6
Preventive Maintenance
Introduction
The Model P330i Printer is designed for operation with minimal maintenance. If the printer is cleaned on a regular basis, as described in this section, it should provide trouble-free operation. There are no periodic measurements, adjustments, or other preventive maintenance procedures required in normal usage.
Cleaning the Printer
Caution PROTECT YOUR FACTORY WARRANTY! The recommended cleaning procedures must be performed to maintain your factory warranty. Other than the recommended cleaning procedures described in this manual, allow only Zebra authorized technicians to service the P330i Printer.
Clean your P330i Printer using Pre-Saturated Cleaning Cards provided. The regular use of these cards will clean and maintain important parts of your printer that cannot be reached, including the Print Head, Transport Rollers, and optional Magnetic Encoder Station.
980569-001 Rev. A
191
Preventive Maintenance Cleaning the Printer
When to Clean the Printer

Clean the printer when either of the following occurs: When the LCD Panel displays the message CLEAN PRINTER. Approximately every 1000 cards when using 5-panel color ribbon, or every 5000 cards when using a monochrome ribbon.
How to Clean the Printer

Note This cleaning procedure uses two cleaning cards. One cleaning card is the size of a regular plastic card, and is referred to as the cleaning card. The other is elongated, with a wider section at one end; it is referred to as the long cleaning card.
Step 1. Leave the Printer power on, or turn it on if it was off. Step 2. Initiate the cleaning process by either of the following methods: At the printer, press and hold the panel button for several seconds, until the LCD Panel displays the message REMOVE RIBBON THEN CLOSE HEAD. From the computer, enter the P330i Printer Tools software, and click on the CLEAN button. The LCD Panel will display the message REMOVE RIBBON THEN CLOSE HEAD. Step 3. Open the Main Cover, release the Print Head Carriage, and remove the ribbon. Then close the Print Head Carriage. (For details, see Chapter 2.) The LCD Panel will display the message EMPTY FEEDER & PRESS BUTTON. Step 4. Open the Card Feeder Cover and remove cards from the Card Feeder. The last card is difficult to remove; leave it in place. Press the Panel Button on the front of the printer. The card remaining in the feeder will be ejected. The LCD Panel will then display the message LOAD CLEANING CARD IN FEEDER. Step 5. Place a pre-saturated Cleaning Card into the Card Feeder. The Cleaning Card will automatically feed into the printer and the cleaning process will start (there is a several second delay after the Cleaning Card feeds before the cleaning movement starts). While the cleaning process is underway, the LCD Panel will display the message CLEANING PRINTER.
192
980569-001 Rev. A
Preventive Maintenance Cleaning the Printer
Step 6. At the conclusion of this part of the cleaning process, the Cleaning Card will be ejected, and the LCD Panel will display the message PRESS BUTTON TO CONTINUE. Step 7. After the user presses the panel button, the LCD Panel will display the message FEED LONG CLEANING CARD IN EXIT. Insert the long end of the long cleaning card into the card exit (directly above the Output Hopper). If the user inserts a regular cleaning card into the card exit, the LCD Panel will display the message INVALID CARD, PRESS BUTTON until the user presses the panel button and inserts the long cleaning card into the card exit.
Note If the user does nothing at this point (i.e., does not insert the long cleaning card), after a timeout the LCD Panel display will change to CLEAN PRINTER. The printer will be able to print, but the LCD Panel will continue to display CLEAN PRINTER.
This limited cleaning does not do a thorough cleaning, but may be performed if no long cleaning cards are available. To restore the display to READY, you will need to perform a complete cleaning process, using both short and long cleaning cards, from step 2 above through step 9 below. Step 8. The long cleaning card will automatically feed into the printer and the printing process will continue. The LCD Panel will again display the message CLEANING PRINTER. Step 9. When the cleaning process is completed, the long cleaning card will be ejected and the LCD Panel will display the message READY, indicating that the printer is ready to resume normal printing operations. Step 10. Discard both cleaning cards after a single use.
980569-001 Rev. A
193
Preventive Maintenance Cleaning the Print Head
Cleaning the Print Head

Note Do not use previously used cleaning cards.
A cleaning using the Cleaning Cards usually suffices. However, a separate Print Head cleaning can remove more stubborn deposits when print anomalies persist. To avoid deposits, only use foam-tipped swabs. Step 1. Place the printer power switch in the OFF ( O ) position. Step 2. Open the Main Cover, release the Print Head Carriage, and remove the ribbon. Leave the Print Head Carriage in its raised position. (For details, see Chapter 2.) Step 3. Clean Print Head by moving an alcohol-moistened swab tip side-to-side across the Print Head elements. Only use moderate force. To re-order swabs, please refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer.
Step 4. The swabs can also be used in a similar manner to clean the optional magnetic encoding head.
Caution Never use a sharp object or any abrasive to scrape deposits from the print head. Permanent damage to the print head will result.
194
980569-001 Rev. A
Preventive Maintenance Card Cleaning Cartridge
Hot Surface Do not touch the print head if the printer has been in service in the last 10 minutes. It could be very hot and cause a burn.

Your P330i Printer includes a Card Cleaning Cartridge. This item cleans the cards entering the printer through the card feeder. To ensure print quality, the cleaning roller requires periodic replacement. New cleaning rollers are included with each ribbon or may be purchased separately. (To reorder, please refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer.) Installation of the Card Cleaning Cartridge is described in Chapter 2 and is not repeated in detail here.
When to Replace the Cleaning Roller

Note Before replacing the Card Cleaning Cartridge or its cleaning roller, clean the Printer
using the Cleaning Cards as described earlier in this chapter. Replace the Cleaning Roller each time you install a new ribbon.
How To Replace the Cleaning Roller

Step 1. Open the main cover and locate the Card Cleaning Cartridge.
Step 2. Gently remove the Card Cleaning Cartridge. Lift the handle end, and then pull it away from the printer.
980569-001 Rev. A
195
Step 3. Remove the cleaning roller from the Card Cleaning Cartridge and discard.
Step 4. Install new cleaning roller into the Card Cleaning Cartridge. To avoid contamination, always hold the cleaning roller by the ends. (For replacement cleaning rollers, please refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer.)
196
980569-001 Rev. A
Step 5. Peel protective wrapper from the cleaning roller by gently pulling on the tape.
Note DO NOT touch the adhesive roller surface that contacts the cards.
Step 6. Replace the Card Cleaning Cartridge into the printer:
Card Cleaning Cartridge in final position
Step 7. Close the printer main cover.
980569-001 Rev. A
197
198
980569-001 Rev. A
APPENDIX A Software
Introduction
This section lists software commands to initiate, check, or adjust various system functions, parameters, and variables. Detailed information on the use of these commands are given in the EPCL Programmers Guide, Zebra document 980415-001, which can be downloaded from the Zebra Card Printer Solutions website at http://www.zebracard.com.
Entering Software Commands

Step 1. From the Windows Start menu or from the Windows Control Panel, navigate to Printer Properties. This will bring up a display like the one below
980569-001 Rev. A
199
Software Entering Software Commands
Step 2. Click on the Device Settings tab, then select Tools, then click on the Properties block that will appear, as shown below.
Step 3. This brings up the Tools display. Type the desired command in the Command to send to printer window, and click the Execute button.
Type the command here ...
... then click the Execute button.
200
980569-001 Rev. A
Software Software Commands
Software Commands
The following listing includes the software commands that apply to the P330i Printer. Complete information about each command, including description, syntax, and parameters, is presented in the EPCL Programmers Guide, Zebra document 980415-001, which can be downloaded from the Zebra Card Printer Solutions website at http://www.zebracard.com. A- - - - - - - - - ATM - - - - - - &B- - - - - - - - +BS - - - - - - - B/vB - - - - - - &C- - - - - - - - +C - - - - - - - - +$C - - - - - - - !CC - - - - - - - %CDER - - - - &CDER - - - - &CDEW- - - - +CDOTS - - - +CH - - - - - - - CHECK - - - - CLEAN - - - - %CLN - - - - - CLNCARD - - +CV - - - - - - - C/vC - - - - - - !D - - - - - - - - &D - - - - - - - D/vD - - - - - - E---------&E- - - - - - - - &E* - - - - - - - +EC - - - - - - - $F - - - - - - - - !FF- - - - - - - - $FP - - - - - - - FS - - - - - - - - F/vF - - - - - - - GS - - - - - - - - G/vG - - - - - - %HEAD - - - - I ---------980569-001 Rev. A
Print Test Card Set Card Feeding Mode Load Magnetic Encoder Track Write Buffer Set Black Synchro Write Bar Code Set Coercivity Adjusts Monochrome Intensity Adjust Color Contrast Get Number of Cards Printed Get Magnetic Encoder Read Settings Set Magnetic Encoder Track Read Encode Parameters Set Magnetic Encoder Track Write Encode Parameters Image Print Quality Compensation Factor Adjust Hologram Intensity Return Checksum Set Cleaning Card Sequence Check Due-for-Cleaning Parameters Set Cleaning Parameters Adjust Clear Varnish Intensity Write Box (Monochrome) Move Print Head Down Change Track Density Draw Diagonal Line (Monochrome/Overlay) Retransmit Last Response Write Single Track Write Track Buffers End of Print Clear Color Image Buffers Set Ribbon Color Sequence Clear Specified Bit-Maps Control Use of Card Feed Sensor Clear Monochrome Image Buffers Download Color Graphic Initialize Monochrome Graphic (B/W) Get Print Head Serial Number Print Monochrome Panel
P330i Card Printer Service Manual 201
IH - - - - - - - - IM - - - - - - - - IMB - - - - - - - IS- - - - - - - - - +ISC - - - - - - +ISC2- - - - - - ISERIES - - - - IV - - - - - - - - J ---------!L - - - - - - - - $L - - - - - - - - &L- - - - - - - - +$L - - - - - - - $LD - - - - - - - L/vL- - - - - - - !M - - - - - - - - MB - - - - - - - MC - - - - - - - MCL - - - - - - ME - - - - - - - MI - - - - - - - - MIB - - - - - - - MM - - - - - - - M/m - - - - - - - MO - - - - - - - MR - - - - - - - MS- - - - - - - - &N - - - - - - - !NL - - - - - - - +O - - - - - - - - +OCL- - - - - - +OS - - - - - - - O/vO - - - - - - +OY- - - - - - - !P- - - - - - - - - +PRF - - - - - - PS - - - - - - - - P/vP - - - - - - - R---------!R - - - - - - - - &R- - - - - - - - >R - - - - - - - - 202
Print Hologram Overlay Print Color Test Card Print Gray Test Card Print Card Panel Set Smart Card Serial Port Data Rate Set Smart Card Serial Port Data Rate (Advanced) i-Series Printer Test Print Clear Varnish Print Multiple Monochrome Cards Check Status of Printer Sensors Draw a Horizontal Line/Rectangle in a Color Buffer Read Single Track Adjust Specified Color Intensity Initialize a Color Buffer to a Specified Intensity Level Draw Horizontal Line (Monochrome/Overlay) Move Print Head Up Return Card To Card Feeder Clear Media Path Move Contactless Exit Card To Output Hopper Move Card Into Print Ready Position Move Card Back To Print Ready Position Move Card Through Printer Multiple Command Move Card To Output Hopper Check for Card Presence Move Card To Smart Card Programmer Select Magnetic Encoding Standard Get Printer Impression and Error Counters Print Offset X-Axis Offset Contactless Smart Card X-axis Offset Load Single Line Bit-map (Monochrome) Print Offset Y-axis Move Card Forward 8 cm Pre-Feed a Card Close to the Print Area Download Color Image Buffer Draw Single Dot (Monochrome/Overlay) Reset Print Head Resistance Reset Magnetic Encoder Read Data From Smart Card Serial Interface
P330i Card Printer Service Manual 980569-001 Rev. A
>RB - - - - - - - >RG - - - - - - - !RIBBON - - - !RIBPN - - - - !RIBLEN - - - +RO - - - - - - - +ROY - - - - - !SA - - - - - - - !SAN - - - - - - SDATA- - - - - %SERIE - - - - &SVM - - - - - &T- - - - - - - - T/vT- - - - - - - V- - - - - - - - - !V - - - - - - - - +V - - - - - - - - !W - - - - - - - - &W - - - - - - - >W - - - - - - - >WB - - - - - - >WG - - - - - - !X - - - - - - - - +X - - - - - - - - !Z - - - - - - - - Z/vZ- - - - - - - .- - - - - - - - - - -
Read Data From Smart Card Serial Interface in ASCII hex Form Contact Internal Gemplus Smart Card Read Command Get ribbon type installed Get ribbon part number Get number of remaining panels on ribbon X-Axis Offset, Relative Y-Axis Offet, Relative Self Adjust Perform pre-calibration baseline testing Force immediate save of parameters Get Printer Serial Number Disable/Enable Magnetic Encoding Verifications Magnetic Encoder Card Eject Draw Text (Monochrome/Overlay) Check Printer Type/Version Return Operational Parameter Black Print Speed Move Card Backward 8 cm Change Encoding Direction Write Data To Smart Card Serial Port Write Data Formatted in ASCII HEX To Smart Card Serial Port Contact Internal Gemplus Smart Card Write Command Check Command Initiator Change Command Initiation Character Re-Synchronize Card Load Bit-map (Monochrome) Clear Error Status Lines
980569-001 Rev. A
203
204
980569-001 Rev. A
APPENDIX B P330i Model Numbers
Specific model numbers include identifiers that specify options using the following lettering conventions:
Part Number P330i-_____-___
Description Base Printer P330i Color Card Printer Smart Card Options None Contact Encoder Contact encoder & HID iCLASS contactless Contact encoder & MIFARE contactless Contact station HID iCLASS contactless MIFARE contactless Magnetic Encoder None Yes (select defaults below) Magnetic Encoder Defaults None Stripe Down, HiCo Stripe Up, HiCo Memory Expansion None Interface USB Only USB and Ethernet
_ _ _ _ _ _ _
_ _ _ _ _ _ _
_ _ _ _ _ _ _
__ __ __ __ __ __ __
0 B C D E F H
_ _ _ _ _ _ _
_ _ _ _ _ _ _
_ _ _ _ _ _ _
_ _ _ _ _ _ _
_ _ _ _ _ _ _
__ __ __ __ __ __ __
_____-_0___-___ _____-_M___-___ _____-__0__-___ _ _ _ _ _ - _ _ 1_ _ _ - _ _ _ _____-__3__-___ _____-___0_-___ _____-____A-___ _____-____C-___
980569-001 Rev. A
205
P330i Model Numbers
_____-_____-I__ _____-_____-U__
Power Cords U. S. and Europe U. K. and Australia Windows Drivers and User Documentation / Training CD
_____-_____-_D0
Windows Drivers and User Documentation / Training included on one CD (Software & Documentation Package) which contains Multi-language documentation.
206
980569-001 Rev. A
APPENDIX C Worldwide Service & Support
Service and Support Locations

North America Region
Zebra Technologies Card Printer Solutions 1001 Flynn Road Camarillo, CA 93012-8706 USA Phone: 800-511-9909 e-mail: techsupport@zebra.com
Europe, Middle Ease, and Africa Region

Zebra Technologies Card Printer Solutions, Europe, Middle East, Africa The Valley Centre, Gordon Road, High Wycombe Buckinghamshire HP13 6EQ, England Phone: + 44 (0) 870 241 1527 (from outside U.K.) Phone: 0870 241 1527 (from isside U.K.) e-mail: cardts@zebra.com
980569-001 Rev. A
207
Worldwide Service & Support Website
Latin America Region

Zebra Technologies Card Printer Solutions, Latin America 9800 NW 41st Street, Suite 220 Doral, FL 33178 USA Phone: + 1 (305) 558 3100 e-mail: techsupport@zebra.com
Asia Pacific Region

Zebra Technologies Asia Pacific, LLC 16 New Industrial Road #05-03 Hudson TechnoCentre Singapore 536204 Phone: + 65 6885 0833 Fax: + 65 6885 0836 e-mail: esoh@zebra.com
Website
www.zebracard.com
208
980569-001 Rev. A

P330i Service Manual

Hochgeladen von

Dokumentinformationen

Originalbeschreibung:

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

P330i Service Manual

Hochgeladen von

Copyright:

Verfügbare Formate

Zebra P330i Card Printer Service Manual

P330i Card Printer Service Manual

89/336/EEC modified by 92/31/EEC and 93/68/EEC 73/23/EEC modified by 93/68/EEC 1999/5/CE

P330i Card Printer Service Manual

Industry Canada Notice

P330i Card Printer Service Manual

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

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

P330i Card Printer Service Manual

5.36 5.37 5.38 5.39 5.40

6 Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

1.1 Printer Description

P330i Card Printer Service Manual

Main Cover (shown open)

Print Head Carriage (shown in open position)

Print Head Carriage Latch

Card Feeder Cover (shown open) Card Thickness Control

(Optional) Magnetic Encoding Station

Card Cleaning Cartridge

Panel Button Output Hopper (shown in open position)

Ribbon Take-Up Spindle

Ribbon Supply Spindle

(Optional) Smart Card Contact Station

LCD Display Panel

P330i Card Printer Service Manual

1.2 Controls, Connectors, and Indicators

LCD Display Panel

Ethernet Switch * Ethernet Adapter Status LED *

P330i Card Printer Service Manual

Errors (Printer will not operate)

OUT OF RIBBON MECHANICAL ERROR OUT OF CARDS PRINT HEAD OPEN

Blinking Blinking Blinking Blinking

P330i Card Printer Service Manual

P330i Card Printer Service Manual

Card Thickness Control

Card Thickness Control

P330i Card Printer Service Manual

(Optional) Ethernet Adapter

10/100Base RJ45 Ethernet Connector

Ethernet Adapter Status Indicator

Network Status / Activity Indicator

P330i Card Printer Service Manual

P330i Card Printer Service Manual

2.1 General Information

P330i Card Printer Service Manual

Installation and Setup

2.2 Unpacking the Printer

P330i Card Printer Service Manual

Installation and Setup

P330i Card Printer Service Manual

Installation and Setup

CD-ROM with Driver Wizard and Users Manual

Card Cleaning Cartridge

Power Cables (2) USB Cable

P330i Card Printer Service Manual

Installation and Setup

Print Head Protection Pad

Card Cleaning Cartridge Location Tape

P330i Card Printer Service Manual

Installation and Setup

Print Head Carriage Latch

P330i Card Printer Service Manual

Installation and Setup