Datacard® CP80™ and CP80™ Plus
Card Printers
Service Manual
May 2007
Part No. 539490-002, Rev C
Liability Statement
This product has been built to the high standards of Datacard Group. Please do
not attempt to operate or repair this equipment without adequate training. Any
use, operation, or repair in contravention of this document is at your own risk.
By acceptance of this system you hereby assume all liability consequent to your
use or misuse of this equipment. Datacard assumes no liability for incidental,
special, or consequential damage of any kind. Equipment specifications,
applications, and options are subject to change at the sole discretion of Datacard
without notice.
Proprietary Notice
All drawings and information herein are the property of DataCard Corporation.
All unauthorized use and reproduction is prohibited.
Trademark Acknowledgments
Datacard is a registered trademark and service mark of DataCard Corporation in
the United States and other countries. CP80 is a trademark of DataCard
Corporation.
All other product names are the property of their respective owners.
Datacard Group
11111 Bren Road West
Minnetonka, MN 55343-9015
952.933.1223
Fax: 952.933.7971
www.datacard.com
© 2006, 2007 DataCard Corporation. All rights reserved.
Printed in the United States of America.
ii
Contents
Chapter 1: Introduction __________________________________________________________ 1-1
Intended Audience_________________________________________________________________1-2
Avoiding Electrostatic Discharge ____________________________________________________1-2
Symbol Conventions________________________________________________________________1-3
Chapter 2: Theory of Operation___________________________________________________ 2-1
Print Engine Functional Block Diagram _______________________________________________2-3
Laminator Functional Block Diagram_________________________________________________2-4
Printer Components ________________________________________________________________2-5
Sensors_______________________________________________________________________2-5
Motors _______________________________________________________________________2-6
Miscellaneous ________________________________________________________________2-7
LCD Service Mode Menu Diagram_____________________________________________2-8
Laminator Components_____________________________________________________________2-9
Sensors_______________________________________________________________________2-9
Motors _______________________________________________________________________2-9
Sequence of Operation____________________________________________________________2-10
Power-on Initialization________________________________________________________2-10
Default Card Printing Sequence ______________________________________________2-10
Lamination Process __________________________________________________________2-12
Graphics Printing __________________________________________________________________ 2-13
Printhead Settings____________________________________________________________2-14
Magnetic Cards___________________________________________________________________2-16
Magnetic Data Principles_____________________________________________________2-16
Encoding Format ____________________________________________________________2-21
Magnetic Stripe Primary Data Standards ____________________________________________2-24
ISO/IEC 7811 (Parts 2 and 6) __________________________________________________2-24
AAMVA DL/ID-2000 __________________________________________________________2-24
Saflok and Ving______________________________________________________________2-24
Multiple Record Format (SDS)_________________________________________________2-25
JIS X 6302 (Type I and Type II Cards)___________________________________________2-25
Magnetic Media Locations___________________________________________________2-26
Data Track Locations_________________________________________________________2-27
Summary of Specifications____________________________________________________2-28
Character Encoding _________________________________________________________2-29
Smart Card Technology____________________________________________________________2-31
Contact Smart Cards ________________________________________________________2-32
Non-Contact Smart Cards____________________________________________________2-33
Types of Cards _________________________________________________________2-33
Communication _______________________________________________________2-34
Signal Modulation______________________________________________________2-34
Signal Modulation Summary Diagram ___________________________________2-35
Reader to Card Communication________________________________________2-36
Card to Reader Communication________________________________________2-36
iii
Chapter 3: Routine Maintenance _________________________________________________ 3-1
Required Tools and Supplies_________________________________________________________3-2
Print Engine Routine Mai ntenance Procedure ________________________________________3-3
Clean the Interior of the Printer ________________________________________________3-3
Mechanical Inspection________________________________________________________3-5
Laminator Routine Maintenance Procedur es_________________________________________3-8
Clean the Interior of the Laminator_____________________________________________3-8
Mechanical Inspection________________________________________________________3-9
Run the Cleaning Cards______________________________________________________3-10
Chapter 4: Troubleshooting_______________________________________________________ 4-1
General Notes______________________________________________________________________4-3
General Troubleshooting Proced ures ________________________________________________4-4
Non-Clearing Repetitive Messages_____________________________________________4-4
Troubleshooting Sensors _______________________________________________________4-5
Troubleshooting Motors (Printer) ________________________________________________4-7
Testing General DC Motors ______________________________________________4-7
Testing the Ribbon and Pick Motors_______________________________________4-8
Testing the Cam Motor __________________________________________________4-8
Testing the Printhead Fan________________________________________________4-9
Testing Transport and Duplex Motors______________________________________4-9
Troubleshooting Motors (Laminator)____________________________________________4-9
Troubleshooting Other Devices ________________________________________________4-9
Testing the Smart Card Solenoid__________________________________________4-9
Testing the Duplex Clutch_______________________________________________4-10
Diagnosing the Duplex Interface Board__________________________________4-11
Diagnosing the Ribbon RFID Antenna____________________________________4-11
Performance Problems_____________________________________________________________4-12
Printer Initialization Errors______________________________________________________4-12
Card Jams at Card Input_____________________________________________________4-13
Card Jams in Printing Area ___________________________________________________4-14
Ribbon Break Errors___________________________________________________________4-15
Card Jams Between Upper and Lower Duplex_________________________________4-15
Laminate Problems __________________________________________________________4-16
Error Codes _______________________________________________________________________4-18
Error Code Prefixes___________________________________________________________4-18
General Notes_______________________________________________________________4-18
Driver API (AP) _______________________________________________________________4-19
Printer Driver Errors (DR)_______________________________________________________4-20
Input Errors (IS) _______________________________________________________________4-22
Duplex Module Errors (DM) ___________________________________________________4-22
System Errors (SY) ____________________________________________________________4-23
Magnetic Stripe Errors (MS) ___________________________________________________4-25
Laminator Errors (OP)_________________________________________________________4-30
Print Errors (PR)_______________________________________________________________4-34
Smart Card Errors (SC)________________________________________________________4-36
Chapter 5: Adjustments __________________________________________________________ 5-1
iv
General Notes______________________________________________________________________5-3
Installing Printer Diagnostics _________________________________________________________5-4
Using Printer Diagnostics ____________________________________________________________5-6
Parts of the Diagnostics Window _______________________________________________5-6
Menu Options ________________________________________________________________5-7
Changing Printer Values_______________________________________________________5-9
Viewing and Saving Values_____________________________________________5-10
Working With Scripts ____________________________________________________5-11
Setting Printer Value Parameters______________________________________________5-12
Printer ID_______________________________________________________________5-12
Card Registration Offset ________________________________________________5-12
Card Strip Offset _______________________________________________________5-13
Ribbon Type ___________________________________________________________5-13
Ribbon Offset __________________________________________________________5-13
Vertical Offset _________________________________________________________5-13
Transport Speed________________________________________________________5-14
YMC, K, T, & F Strobe Duty ______________________________________________5-14
YMC, K, T, and F Power and Base Power _________________________________5-15
Duplex Infeed Offset ___________________________________________________5-15
Duplex Home Offset____________________________________________________5-16
Duplex Print Return Offset_______________________________________________5-16
Duplex Handoff Offset__________________________________________________5-16
Smart Card Registration Offset __________________________________________5-16
Image Clipping Leading and Trailing ____________________________________5-17
Setting Printer Options________________________________________________________5-18
Viewing Printer Status ________________________________________________________5-19
Testing Motors _______________________________________________________________5-20
Testing Motor Functions ______________________________________________________5-21
Setting Up Step Tests for the Printer____________________________________________5-22
Running a Magnetic Stripe Test Card__________________________________________5-23
Configuring the Magnetic Stripe Module ______________________________________5-24
Configuring Custom Track Formats____________________________________________5-26
Running Magnetic Stripe Diagnostics__________________________________________5-27
Testing the Smart Card Option________________________________________________5-28
Setting Laminator Values _____________________________________________________5-30
Laminator Parameter Dependencies____________________________________5-31
Temperature___________________________________________________________5-32
Patch Size _____________________________________________________________5-32
Foil Advance Offset ____________________________________________________5-33
Card Registration Offset ________________________________________________5-34
Debow Enable_________________________________________________________5-34
Roller Down Distance___________________________________________________5-35
Transport Apply Speed _________________________________________________5-35
Foil Control 1(Foil Strip Distance)_________________________________________5-36
Foil Control 2 (Foil Apply Speed Ratio) ___________________________________5-36
Foil Control 3 (Foil Registration Speed) ___________________________________5-37
Duplex Handoff Offset__________________________________________________5-37
Duplex Home Offset____________________________________________________5-37
Duplex Flipped Offset __________________________________________________5-37
Duplex Reject Offset ___________________________________________________5-38
Duplex Debow Offset___________________________________________________5-38
Duplex Horizontal Infeed Offset _________________________________________5-38
v
Duplex Vertical Infeed Offset ___________________________________________5-38
MFG Card Registration Baseline_________________________________________5-39
MFG Temperature Baseline _____________________________________________5-39
MFG Patch Registration Baseline ________________________________________5-39
Viewing Laminator Sensors and Enabling Heaters ______________________________5-40
Testing Laminator Motors _____________________________________________________5-41
Network Option Adjustments _______________________________________________________5-42
Software Adjustment Procedures ___________________________________________________5-46
Saving and Restoring a Printer Configuration __________________________________5-46
Start Sentinel Position_________________________________________________________5-49
Card Registration Offset Adjustment __________________________________________5-50
Ribbon Offset Adjustment ____________________________________________________5-51
Updating the Printer Firmware ________________________________________________5-52
Upper Duplex Rotational Adjustment__________________________________________5-53
Lower Duplex Rotational Adjustment__________________________________________5-54
Chapter 6: Removal and Replacement ___________________________________________ 6-1
General Notes______________________________________________________________________6-4
Symbols ______________________________________________________________________6-4
Required Tools________________________________________________________________6-4
Screw Torque Specifications ___________________________________________________6-5
Print Engine Front Wire Routing Diagram________________________________________6-6
Print Engine Duplex and Printhead Wire Routing Diagram________________________6-7
Laminator Front Wire Routing Diagram _________________________________________6-8
Laminator Rear Wire Routing Diagram__________________________________________6-9
Power Supply Wire Routing Diagram __________________________________________6-10
Print Engine Cable Connection Diagram ______________________________________6-11
Laminator Cable Connection Diagram________________________________________6-12
Enclosure Components ____________________________________________________________6-13
Swingarm Cover_____________________________________________________________6-13
Main Enclosure ______________________________________________________________6-15
Input Hopper ________________________________________________________________6-17
LCD Display _________________________________________________________________6-19
Output Hopper ______________________________________________________________6-22
Swingarm Assembly________________________________________________________________6-23
Printhead Fan _______________________________________________________________6-24
Printhead Spring _____________________________________________________________6-25
Upper Printer Sensors_______________________________________________________________6-26
Card Input Sensor____________________________________________________________6-26
Swingarm Sensor_____________________________________________________________6-27
Ribbon Motion Sensor ________________________________________________________6-28
Ribbon Index Sensor _________________________________________________________6-29
Cam Sensor _________________________________________________________________6-30
Card Hopper Empty Sensor___________________________________________________6-31
Upper Printer Motors _______________________________________________________________6-32
Transport Motor______________________________________________________________6-32
Pick Motor___________________________________________________________________6-33
vi
Cam Motor__________________________________________________________________6-35
Ribbon Motor and Gear______________________________________________________6-36
Upper Printer Assembly_____________________________________________________________6-38
Transport Assembly___________________________________________________________6-40
Main Control Board __________________________________________________________6-43
Transport Timing Belt _________________________________________________________6-47
Belt Tensioner Pulley and Tension Spring _______________________________________6-48
Drive and Idler Pulleys________________________________________________________6-49
Cleaning Rocker Assembly ___________________________________________________6-50
Front Rocker Assembly _______________________________________________________6-51
Rear Rocker Assembly________________________________________________________6-52
Ribbon Guide _______________________________________________________________6-53
Pick Roller ___________________________________________________________________6-55
Cleaning Drive Roller_________________________________________________________6-57
Front Drive Roller_____________________________________________________________6-59
Rear Drive Roller _____________________________________________________________6-61
Platen Roller_________________________________________________________________6-64
Printhead Cam ______________________________________________________________6-65
Printhead Lifter ______________________________________________________________6-66
Front Card Guide ____________________________________________________________6-67
Rear Card Guide ____________________________________________________________6-68
RFID Antenna________________________________________________________________6-70
Upper Duplex Module _____________________________________________________________6-71
Duplex Entry Sensor __________________________________________________________6-73
Duplex Home Sensor _________________________________________________________6-75
Duplex Interface Board_______________________________________________________6-76
Duplex Entry Rocker__________________________________________________________6-77
Duplex Motor________________________________________________________________6-78
Magnetic Clutch/Spring Clutch/Duplex Rol lers_________________________________6-80
Magnetic Stripe Option ____________________________________________________________6-84
Magnetic Stripe Circuit Board_________________________________________________6-84
Magnetic Stripe Registration Sensor ___________________________________________6-85
Magnetic Stripe Head________________________________________________________6-86
Magnetic Stripe Rocker Assembly_____________________________________________6-88
Smart Card Option ________________________________________________________________6-89
Smart Card Interface Board __________________________________________________6-89
Solenoid Assembly/Solenoi d Link______________________________________________6-90
Smart Card Contact _________________________________________________________6-92
Contactless Smart Card Coupler______________________________________________6-95
Laminator Transport Assembly ______________________________________________________6-97
Power Supplies ______________________________________________________________6-98
Upper Laminator Transport Rollers_____________________________________________6-99
Lower Laminator Transport Rollers ____________________________________________6-101
Intermediate Transport Rollers and Card Guide _______________________________ 6-103
Upper Platen Roller__________________________________________________________6-105
Lower Platen Roller__________________________________________________________6-106
Rear Cooling Fan ___________________________________________________________6-107
vii
Hand Guard________________________________________________________________6-108
Laminator RFID Antennas____________________________________________________6-111
Laminator Sensors ________________________________________________________________6-112
Duplex Exit Sensor___________________________________________________________6-112
Card Exit Sensor_____________________________________________________________6-113
Card Registration Sensor ____________________________________________________6-114
Upper Foil Index Sensor______________________________________________________6-115
Lower Foil Index Sensor______________________________________________________6-116
Foil Motion Sensors__________________________________________________________6-117
Heater Home Sensor ________________________________________________________6-118
Laminator Motors_________________________________________________________________6-120
Card Transport Motor _______________________________________________________6-120
Foil Advance Motors ________________________________________________________6-122
Heater Lift Motors ___________________________________________________________6-123
Major Subassemblies______________________________________________________________6-124
Upper Heater Assembly _____________________________________________________6-124
Lower Heater Assembly _____________________________________________________6-125
Upper Foil Drive Assembly ___________________________________________________6-126
Lower Foil Drive Assembly____________________________________________________6-128
Heating Element/Heated Roller/Thermocouple _______________________________6-129
viii
Revision Log
Datacard CP80 and CP80 Plus Card Printers Service Manual
Revision Date Description of Changes
A March 2006 First release of this document.
B June 2006 Updated for RoHS compliance.
C May 2007 Updated for release of CP80 Plus.
Regulatory Compliance
Notice for USA (FCC Notice)
This equipment generates, uses, and can radiate radio frequency energy. If it is
not installed and used in accordance with this instruction manual, it may
interfere with radio communications. This equipment has been tested and found
to be within the limits for Class A computing devices, pursuant to Title 47 CFR
Part 15 Subpart B of FCC rules, designed to provide reasonable protection
against radio interference in a commercial environment. Operation of this
equipment in a residential environment may possibly cause interference. In the
event of interference, the users, at their own expense, will be required to take
whatever measures are necessary to correct the problem.
Notice for Canada
This digital apparatus does not exceed the Class A limits for radio noise for
digital apparatus set out in the Radio Interference Regulations of the Canadian
Department of Communications.
Le présent appareil numérique n'émet pas de bruits radioélectriques dépassant
les limites applicables aux appareils numériques de la classe A prescrites dans le
Règlement sur le brouillage radioélectrique édicté par le ministère des
Communications du Canada.
ix
Safety Issues
All Datacard products are built to strict safety and reliability specifications in
accordance with UL60950-1 and CUL requirements; therefore, safety issues
pertaining to operation and repair of Datacard equipment are primarily
environmental and human interface.
The following basic safety tips are given to ensure safe installation, operation,
and maintenance of Datacard equipment and are not to be considered as
comprehensive on all matters of safety.
Safe Environment
Connect equipment to a grounded facility power source. Do not defeat or
•
bypass the ground lead.
• Place the equipment on a stable surface (table), and ensure floors in work
area are dry and non-slip. Insulated rubber floor mats are preferred.
• Know the location of equipment branch circuit interrupters or circuit
breakers and how to turn them on and off in case of emergency.
• Know the location of fire extinguishers and how to use them. Use only ABC
type extinguishers on electrical fires.
• Know local procedures for first aid and emergency assistance at the customer
facility.
• Use adequate lighting at the equipment.
• Maintain the recommended range of temperature and humidity in
equipment area.
• Do not use this product in an environment containing volatile or flammable
compounds.
Safe Human Interface
• Use proper lifting techniques when moving or installing the equipment.
• Use standard electrostatic discharge (ESD) precautions when working on or
near electrical circuits.
• Do not defeat or disconnect safety interlocks.
• Observe standard safety precautions when servicing the system.
WARNING: To avoid a possible electric shock, always unplug the system
before servicing.
x
Chapter 1: Introduction
This chapter provides an introduction to the Datacard® CP80 and
CP80 Plus card printers and how they function.
Intended Audience______________________________________________________________ 1-2
Avoiding Electrostatic Discharge _________________________________________________ 1-2
Symbol Conventions_____________________________________________________________ 1-3
CP80 and CP80 Plus Service Manual 1-1
Intended Audience
This manual is intended for use by authorized representatives of Datacard who
are responsible for the maintenance, service, and repair of the CP80 and CP80
Plus card printers.
The service representatives must complete an authorized Datacard training
course prior to servicing the printers.
Avoiding Electrostatic Discharge
While working around control boards and other sensitive components, use
proper equipment and procedures to reduce the possibility of damaging the
components. This section describes the procedure for protecting against damage
due to electrostatic discharge.
CAUTION: Static electricity can destroy components on a circuit board. Use
the following precautions when handling the board, its components, or tools
in contact with the board or its components.
Tools Required:
Static-grounding kit (Part Number: TUL006-006) containing:
• Static-grounding mat
• Mat-grounding cable
• Static-grounding wrist strap
Procedure:
1. Wear appropriate clothing. Avoid wool and synthetic fabrics.
2. Remove movable carpet and rugs.
3. Apply the grounding strap to a wrist. Ensure that there is no clothing
4. Connect one end of the grounding cable to the wrist strap.
5. Using the grounding plug, connect the other end of the grounding cable to
6. Clear a work area, lay the static-grounding mat on the work area, and
7. Always set unshielded static-sensitive materials on the grounded anti-static
• Wrist strap grounding cable
• Grounding plug
between the strap and skin and that the strap is snug enough to maintain
contact with the skin.
the earth ground of a facility AC outlet.
connect the movable end of the long grounding cable to the mat.
mat. Whenever possible, place components into static-shielded bags.
8. When bringing two objects into contact (tool to circuit board or board to mat),
first simultaneously touch both objects with fingers.
1-2 Introduction
Symbol Conventions
The appearance and purpose of the symbols used in this manual are presented
below.
This symbol is used to designate a procedure that
involves electrostatic discharge sensitive components.
ESD procedures should be used.
CAUTION: This symbol indicates a strong cautionary
message to avoid serious damage to the printer.
WARNING: This symbol indicates a strong warning
message to prevent personal injury to the technician.
This symbol indicates a spring hazard. Safety glasses
should be worn when completing the procedure.
This symbol indicates a reminder message or other
additional information for the technician.
Graphic callouts with a colored background provide
incidental information about the graphic itself.
Graphic leaders with a colored background indicate a
direction of movement or similar information.
CP80 and CP80 Plus Service Manual 1-3
1-4 Introduction
Chapter 2: Theory of
Operation
This chapter provides the theory of operation for the CP80 and CP80
Plus card printers.
Print Engine Functional Block Diagram ____________________________________________ 2-3
Laminator Functional Block Diagram______________________________________________ 2-4
Printer Components______________________________________________________________ 2-5
Sensors_______________________________________________________________________________2-5
Motors _______________________________________________________________________________2-6
Miscellaneous ________________________________________________________________________2-7
LCD Service Mode Menu Diagram_____________________________________________________2-8
Laminator Components __________________________________________________________ 2-9
Sensors_______________________________________________________________________________2-9
Motors _______________________________________________________________________________2-9
Sequence of Operation_________________________________________________________ 2-10
Power-on Initialization________________________________________________________________2-10
Default Card Printing Sequence ______________________________________________________2-10
Lamination Process __________________________________________________________________2-12
Graphics Printing _______________________________________________________________ 2-13
Printhead Settings ___________________________________________________________________2-14
Magnetic Cards ________________________________________________________________ 2-16
Magnetic Data Principles ____________________________________________________________2-16
Encoding Format ____________________________________________________________________2-21
Magnetic Stripe Primary Data Standards _________________________________________ 2-24
ISO/IEC 7811 (Parts 2 and 6) __________________________________________________________2-24
AAMVA DL/ID-2000 __________________________________________________________________2-24
Saflok and Ving______________________________________________________________________2-24
Multiple Record Format (SDS)_________________________________________________________2-25
JIS X 6302 (Type I and Type II Cards)___________________________________________________2-25
Magnetic Media Locations___________________________________________________________2-26
Data Track Locations ________________________________________________________________2-27
CP80 and CP80 Plus Service Manual 2-1
Summary of Specifications ___________________________________________________________2-28
Character Encoding_________________________________________________________________2-29
Smart Card Technology_________________________________________________________ 2-31
Contact Smart Cards ________________________________________________________________2-32
Non-Contact Smart Cards____________________________________________________________2-33
Types of Cards ___________________________________________________________________2-33
Communication _________________________________________________________________2-34
Signal Modulation________________________________________________________________2-34
Signal Modulation Summary Diagram _____________________________________________2-35
Reader to Card Communication__________________________________________________2-36
Card to Reader Communication__________________________________________________2-36
2-2 Theory of Operation
Print Engine Functional Block Diagram
CP80 and CP80 Plus Service Manual 2-3
Laminator Functional Block Diagram
2-4 Theory of Operation
Printer Components
Sensors
All of the optical sensors in the CP80 and CP80 Plus printers are of the open
collector type, and are configured to be active-low with a pull-up resistor on the
output. When the sensor is not active (or not connected at all) the control board
sees a high voltage (5V) at the Signal input. When the sensor is active, it shorts
Signal to Ground. The diagram below is a simplified representation of an
interruption sensor.
Name Function
Card Input
Printhead Cam
Swingarm
Open
Ribbon Index
Ribbon Motion
The card input sensor is an interruption sensor that detects the presence of
a card at the entrance of the printer and registers the trailing edge of the
card for printing.
As the printhead cam rotates, a flag on the cam interrupts the beam of the
cam sensor. This allows the printer to know the position of the printhead
lifters.
The swingarm open sensor detects when the swingarm is open. The sensor
itself detects when the swingarm is closed, but the signal is inverted
elsewhere in the system.
The ribbon index sensor is used to determine the position of the print ribbon
panels. The sensor bounces a beam off the reflective sticker on the
printhead. When the index mark or K-panel on the ribbon p a sses between
the sensor and the reflector, the beam is broken (not reflected). The Y, M,
C, and T panels do not interrupt the beam.
The ribbon motion sensor is a two-channel optical interruption sensor that
detects slots on the ribbon encoder wheel. The encoder wheel is located
on the ribbon cartridge. Internally the sensor body contains a pair of
standard interruption sensors.
Magnetic
Stripe
Registration
CP80 and CP80 Plus Service Manual 2-5
This is a reflective sensor that locates the leading edge of the card for
magnetic stripe encoding. When no card is present, the sensor beam
reflects off a plate on the magnetic stripe rocker. When a card passes
between the sensor and the reflector, the beam is broken (not reflected).
The sensor itself is active when no card is present, but the signal is inverted
elsewhere in the system.
Name Function
Card Input
Magnetic
Stripe Optical
Encoder
Duplex Entry
Duplex Home
Input Hopper
Empty Sensor
Option
Motors
The card input sensor is an interruption sensor that detects the presence of
a card at the entrance of the printer and registers the trailing edge of the
card for printing.
This encoder monitors the rotation of the idler roller in the magnetic stripe
module. It provides positional feedback to the module to ensure proper
magnetic encoding.
The duplex e ntry senso r i s an optical inter ruption se n s or that dete cts the
presence of a card as it enters and leaves the duplex module.
The duplex home sensor determines the ro tational position of the duplex
flipper. The flipper has three flags that pass through the sensor.
This reflective sensor detects when the card hopper has no cards left. It
functions only when special software is created to use it.
The printer engine has up to five motors depending on the configuration. The
three DC motors are all similar, with an integral reduction geartrain and 24-volt
operation. The speed of the motors is controlled by pulse width modulation.
While the motors are reversible, some are wired to operate in one direction only.
The duplex step motor operates at 24 volts, but the transport step motor operates
at 40 volts.
Name Function
Pick Motor
Transport Motor
Cam Motor
Ribbon Motor
Duplex Motor
The pick motor drives the pick roller to bring a card into the
system. The motor is wired for unidirectional operation and cannot
be reversed by the control board. One wire is connected to
ground and the other wire is the control. This motor is driven by a
single channel in the motor driver.
The transport motor drives the platen roller through a gear, which
also drives the main transport belt. This is a 2-phase (4-wire), 40-volt
stepper motor.
The cam motor rotates the printhead cam, which operates the
printhead lifters. The lifters raise and lower the printhead into
position for printing or permitting a card to pass beneath.
The ribbon motor drives the gear train of the ribbon cartridge to
advance the ribbon during printing. The motor is wired for
unidirectional operation and cannot be reversed by the control
board. One wire is connected to ground and the other wire is the
control. This motor is driven by a single channel in the motor driver.
The duplex motor drives a gear on the duplex clutch. The clutch
permits a single motor to operate the rollers, or to rotate the entire
flipper assembly (this is discussed in more detail on page
is a 2-phase (4-wire), 24-volt stepper motor.
2-7). This
2-6 Theory of Operation
Miscellaneous
Name Function
Smart Card Solenoid
Duplex Clutch
RFID Antenna
The smart card solenoid retracts the smart card rocker downward so
the contacts touch the card. When relaxed, a return spring lifts the
rocker and contacts away from the card.
The duplex clutch controls whether the duplex motor operates the
drive rollers or rotates the whole flipper assembly. The clutch contains
two concentric axes that are free to rotate ind ependently when the
clutch is relaxed. When the clutch is active, a magnetic field pulls the
two axes to gether and f riction fo rces the tw o to rotate in u n ison.
Because the clutch is engaged magnetically, the rotation of either axis
is independent of the body of the clutch.
Operation: The duplex motor rotates the outer axis (large gear), which
is coupled to the two duplex drive rollers. The flipper assembly is
coupled to the inner axis. When the clutch is relaxed, the outer axis
(gear) rotates independently from the flipper assembly, and this
causes the drive rollers to rotate. When the clutch is engaged, the
whole flipper assembly rotates in unison with the large gear, which
keeps the drive rollers from rotating.
The RFID antenna circuit board is a simple loop antenna that
communicates with the supplies ID chip in the ribbon supply spool. The
bi-directional communication method is similar to
(see page 2-33) using load-modulation, although the specific
Cards
details may vary.
Non-Contact Smart
Duplex Interface
Board
Magnetic Stripe
Daughter Board
Smart Card
Daughter Board
The duplex interface board contains a step motor driver for the duplex
motor and a 24-volt driver circuit for the clutch. The sensor signals are
passed through directly from the main control board.
There are two types of magnetic stripe daughter boards: 3-track and
single track. The circuit board controls the magnetic stripe head and
provides an interface for the optical encoder. The optical encoder
data is passed back to the main control board without modification.
The smart card daughter board provides a communication interface
between the application computer and the smart card. Most of the
communication aspects and the data transfer are controlled by an
external software application that is transpar e nt to the pri nter. The
daughter board also provides a connection to control the smart card
solenoid.
CP80 and CP80 Plus Service Manual 2-7
LCD Service Mode Menu Diagram
2-8 Theory of Operation
Laminator Components
Sensors
Name Function
Interstage
Duplex Exit
Duplex Home
Card
Registration
Card Exit
Foil Motion
Foil Index
Heater Home
This sensor is located between the upper and lower duplex assemblies
and detects a card as it passes from the upper duplex to the lower
duplex.
The duplex exit sensor is an optical interruption sensor that detects the
presence of a card as it leaves the duplex module. Thi s sensor also
registers the card for the first laminator.
The duplex home sensor determines the ro tational position of the duplex
flipper. The flipper has three flags that pass through the sensor.
This sensor is located between the first and second laminators, and
registers the card for the second laminator.
This sensor is located just before the output hopper and detects when a
card leaves the printer.
Each laminator has a foil motion sensor. This is a reflective sensor that
detects the teeth on an encoder wheel within the supply cassette.
Each laminator has a foil index sensor. This is a reflective sensor that
detects index marks on the supply spool. It also detects a smart card
cutout (if present) in the foil.
Each heated roller assembly has a heater home sensor. This interruption
sensor detects a flag on the heater lift cam to determine the vertical
position of the heated roller.
Thermocouple
Motors
Name Function
Transport Motor
Heater Lift
Motors
Foil Advance
Motors
Duplex Motor
Each heated roller has a thermocouple for determining temperature. A
thermocouple is made from two dissimilar metals connected together. As
temperature increases, the voltage be tween the two metals increases.
The transport motor drives the upper (L1) platen roller through a gear,
which also drives the main transport belt. This is a 2-phase (4-wire), 24-volt
stepper motor.
Each heater assembly has a heater lift motor. The DC motor operates an
eccentric cam shaft to raise and lower the heated roller.
Each foil supply cassette is driven by a stepper motor through a geartrain.
The final gear has a square hole in the center to engage the capstan
roller in the supply cassette.
The duplex motor drives a gear on the duplex clutch. The clutch permits a
single motor to operate the rollers, or to rotate the entire flipper assembly
(this is discussed in more detail on page
2-7).
CP80 and CP80 Plus Service Manual 2-9
Sequence of Operation
Power-on Initialization
1. When the printer is turned on, it begins its initialization routine.
2. As the main control board initializes itself, the status light on the front of the
printer will be steady amber.
3. After the control board is initialized, the status indicator will cycle through
red, amber, and green.
4. While the control board examines and initializes external components, the
indicator will flash green.
A. The system checks for smart card, magnetic stripe, and duplex modules.
B. The duplex module is initialized, and the rollers are operated for
sufficient time to ensure no cards are present in the module.
C. The printhead cam motor is cycled and homed.
D. The transport is initialized and then operated for sufficient time to ensure
that the card track is clear.
E. The ribbon type is identified. This may or may not result in the ribbon
motor being energized for a short time to detect a ribbon encoder change.
5. When the printer has finished its initialization procedure and is ready to
process cards, the status light will turn green.
Default Card Printing Sequence
1. After the card data has been sent to the printer, it begins the card
personalization process.
2. The card is picked and passes through the cleaning rollers.
3. After the leading edge of the card passes through the cleaning rollers, the
card is detected by the input sensor. The trailing edge of the card is registered
for positioning.
4. The card is first sent to the smart card area.
A. When the card is approaching the location of the smart card contacts, the
solenoid engages and pulls the contacts down.
B. The leading edge of the card makes contact with the smart card sensor
(mechanical switch in the contact block) and the transport stops.
C. The card is programmed by an external application. The printer acts only
as an interface to the card.
D. The external application notifies the printer that smart card interaction is
complete, and control is returned to the printer.
2-10 Theory of Operation
5. The card is then sent back toward the entrance of the printer before being
sent to the magnetic stripe module.
A. The leading edge of the card is registered by the magnetic stripe sensor.
B. The optical encoder measures the distance the card travels during the
encoding process.
C. All tracks of the card are written simultaneously.
D. On the return pass, the card data is verified.
6. The card is then returned to the input sensor and registered for graphics
printing.
A. When the leading edge of the card reaches the platen roller, the printhead
cam engages and lowers the head onto the card.
B. The ribbon motor is engaged. The motor is over-driven, and the spindle
clutch slips as needed to match the speed of the card.
C. After a panel is printed, the printhead is raised and the card is returned to
the input sensor.
D. The ribbon motor advances to the next panel by examining the ribbon
encoder.
E. The process is repeated for the remaining panels.
7. The card is passed to the duplex module.
A. The duplex entry sensor detects the card and determines the position
within the flipper.
B. With the magnetic clutch relaxed, the drive rollers pull the card into the
module.
C. The clutch is engaged and the motor rotates the flipper to the return
position.
D. The clutch is released, and the motor drives the rollers to move the card
back into the printer. (The rollers always move in the forward direction,
but since the flipper assembly is inverted, the card is moved back into the
printer.)
8. The card is re-registered by the input sensor and printing is completed on the
back of the card in the same fashion as the front.
9. After being printed, the card is passed back to the duplex module.
A. The duplex entry sensor detects the card and determines the position
within the flipper.
B. With the magnetic clutch relaxed, the drive rollers pull the card into the
module.
C. The clutch is engaged and the motor rotates the flipper to the vertical
position.
CP80 and CP80 Plus Service Manual 2-11
D. The clutch is released, and the motor drives the rollers to move the card
down into the lower duplex.
10. Using the same procedure, the lower duplex inserts the card into the
laminator transport.
Lamination Process
1. The card is moved toward the laminator position at normal transport speed,
as the laminate foil is registered.
2. Once the card clears the card registration sensor, the speed is slowed down
and the card is moved to the apply area.
3. While both the transport and the foil motor are in hold, the heated roller is
moved to the down position.
4. If necessary, the flipper is moved into the debow position.
5. The foil and transport motors are activated, and the laminate is applied to the
card.
6. When the length of the card has been laminated, the roller is lifted to the
home position.
7. The transport continues to move the card a short distance past the heated
roller.
8. The foil motor increases speed and advances slightly to strip the foil from the
card.
9. If debow is enabled, the card is moved back to the duplex.
A. The duplex flipper had already been placed out of alignment with the
card track.
B. The card is pushed against the duplex flipper, bending the card in the
process.
C. The card is held in this position for a short time.
10. The card is moved to the optional second laminator and the same process is
completed for laminating the other side of the card. The debow process is
completed by the debow roller at the printer exit.
2-12 Theory of Operation
Graphics Printing
The information presented in the following section is not required for servicing
the CP80 and CP80 Plus printers but is presented to augment the customer
engineer’s training and knowledge base.
The printhead is made up of 672 microscopic heating elements. Each of these
thermal elements is made from a printed circuit conductor etched into the
printhead substrate (metallic-like foil). The elements are spaced 0.0035 inch apart,
and represent a single pixel at 300 DPI resolution.
To transfer pigment from the print ribbon to the card, the respective thermal
element (pixel) heats up until the temperature reaches the transfer threshold. At
this point, pigment from the print ribbon will adhere to the card. The longer the
element remains on, the more material gets applied.
• At temperatures below the transfer threshold, no pigment is transferred to
the card.
• If the temperature of an element is too high, the area surrounding the
element may also get hot enough to transfer pigment. This will lead to
reduced resolution, blotching, and ribbon breaks.
• The intensity of the printed pixel is controlled by the length of time the
pixel’s thermal element is turned on. The longer the pixel is on, the darker
(more intense) the color will be.
CP80 and CP80 Plus Service Manual 2-13
Printhead Settings
A printed card is made up of 1013 discrete vertical (short edge of the card)
columns printed across the length of the card. As each column is printed, the
printhead circuitry activates the necessary pixels to transfer pigment from the
ribbon to the card.
Controlling when and how these pixels heat up is determined by several
parameters: power, base power, and strobe.
Power
In the past, printhead pixels were controlled by varying the voltage to the pixel
element. On the newer generation of printheads, the power to the pixel is
controlled by pulsing the voltage, commonly referred to as Pulse Width
Modulation (PWM). This concept is also known as Duty-Cycle.
The heat of a thermal element on the printhead is controlled by how long it is
turned on versus how long it is turned off. In a sense, the printhead control was
analog but is now digital.
To increase the temperature, or heat, on a single element, it is turned on more
than it is turned off. The higher the duty-cycle, the hotter the element becomes.
Because the printhead now receives full voltage from the power supply,
swapping the power supply for another power supply will have an impact on
printing intensity. The printer can easily be adjusted to compensate when a new
power supply is required.
Base Power
The Base Power sets the upper limit to the power PWM. In simple terms, this sets
the bandwidth (gamut) of the printing. Increasing the base power darkens the
available colors in the printer, but does not impact the lighter colors. Note that
there is an upper threshold after which increasing the base power has little or no
effect on the final printing. At this point, the image is saturated and cannot be
increased in gamut any further. However, note that this is not the same as
darkening the image in the printer driver control panel, which will darken the
whole image, including the lighter areas.
2-14 Theory of Operation
Strobe
If an entire column of thermal elements (pixels) needs to be activated, the overall
power to the printhead will drop due to the current draw. The strobe setting
compensates for this drop in voltage by increasing the time the pixels are active.
For example, if all 672 pixels were turned on, it would take longer for each pixel
to reach the threshold temperature than it would if only 300 pixels were turned
on. This would result in a lighter image if more pixels are needed, and a darker
image if only a few pixels are needed.
The Strobe setting is a time factor that compensates for this reduction in power
by increasing the "on-time" for each pixel based on how many pixels are required
for the printed column. The strobe setting value is a baseline number for a
look-up table that the printer calculates for each printed column.
The gray test card is used to detect strobe misadjustment. This test card is
available only to the Advanced User in Diagnostics.
CP80 and CP80 Plus Service Manual 2-15
Magnetic Cards
The information presented in the following section is not required for servicing
the CP80 and CP80 Plus printers but is presented to augment the customer
engineer’s training and knowledge base.
Magnetic Data Principles
This discussion is intended to be a primer for those who are not completely
familiar with the principles of writing data to and reading data from a magnetic
stripe. It covers some advanced theory, but is not intended to be a
comprehensive discussion into the physics of electromagnetism. Those wishing to
delve deeper into the physics of electromagnetism should be able to find
additional information on the Internet or from their local library (Search Topics
include: Electromagnetism, Gauss, Magnetic Stripe).
Magnetism
All magnets, including the Earth, have a north pole and a south pole. These poles
always appear in north/south pairs, and there will never be one without the
other. A magnetic field is comprised of Magnetic Lines of Force, or Magnetic Flux,
which travel from north to south between the poles. Even though magnetic flux
is invisible, the effects of these lines can be seen as they interact with particles of
iron. If a piece of paper is placed over a common bar magnet, and iron filings are
sprinkled across the paper, the iron particles will line up in a fashion similar to
the drawing below
magnetism. From the drawing below, we can see that the magnetic field is
strongest near the poles.
1
. The greater the density of these lines, the stronger the
1 This is the same principle used with magnetic stripe developing fluid. The fluid contains magnetic particles in an
evaporative fluid. When the fluid evaporates, the particles align on the strongest magnetic areas.
2-16 Theory of Operation
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