Zebra ZC100, ZC150, ZC300, ZC350 Service Manual

ZC100/300 Series

Service Manual

P1094921-001

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designs are subject to change without notice.

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are correct; however, errors do occur. Zebra Technologies reserves the right to correct any such errors and disclaims liability resulting therefrom.

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without limitation, consequential damages including loss of business pro󰘰ts, business interruption, or loss of business

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Contents

Introduction ....................................................................................................................................................................1

About This Manual......................................................................................................................................................1

About the Printer ........................................................................................................................................................1

Replacement Procedures ..............................................................................................................................................3

Introduction .................................................................................................................................................................3

Required Tools and Supplies ......................................................................................................................................3

Removal Sequence ....................................................................................................................................................4

Procedures .................................................................................................................................................................5

Left Side Cover ...........................................................................................................................................................5

Right Side Cover ........................................................................................................................................................7

Rear Cover .................................................................................................................................................................9

Bottom Cover ...........................................................................................................................................................11

Left Side Filler Panel ................................................................................................................................................13

Right Side Filler Panel ..............................................................................................................................................14

Main Logic Board .....................................................................................................................................................15

Preparation ...............................................................................................................................................................15

Printhead ..................................................................................................................................................................19

Installation ................................................................................................................................................................19

Printhead Cable ........................................................................................................................................................21

Printhead Fan ...........................................................................................................................................................25

Dual-Sided Module ...................................................................................................................................................26

Dual-Sided Module Enclosure ..................................................................................................................................31

Wi-Fi Module ............................................................................................................................................................33

Feeder Assembly ......................................................................................................................................................36

Contents

Feeder Front Bezel ...................................................................................................................................................38

Output Hopper Doors ...............................................................................................................................................40

Power Button ............................................................................................................................................................42

LED PCBA ................................................................................................................................................................43

Rear Deck ................................................................................................................................................................44

Rear Deck Encoder Module .....................................................................................................................................46

Ribbon Color Detect Sensor Assembly ....................................................................................................................49

Removal ...................................................................................................................................................................49

Card Detect Sensor Assembly .................................................................................................................................52

Front Deck Assembly ...............................................................................................................................................54

Top Cover Assembly .................................................................................................................................................55

Top Cover Dampener ...............................................................................................................................................56

Manual Advance Wheel ............................................................................................................................................57

Ribbon Drive Assembly ............................................................................................................................................59

Card Entry/Exit Module ............................................................................................................................................61

Tri-Sensor PCBA ......................................................................................................................................................63

Cam Position Sensor PCBA .....................................................................................................................................65

Lift Cam Motor ..........................................................................................................................................................67

Platen Drive Motor ....................................................................................................................................................68

Transport Rollers ......................................................................................................................................................69

Static Brush ..............................................................................................................................................................72

Feet ..........................................................................................................................................................................74

Troubleshooting ...........................................................................................................................................................75

Introduction ...............................................................................................................................................................75

Troubleshooting Table ..............................................................................................................................................75

Identifying Print Quality Issues .................................................................................................................................79

Color Accuracy .........................................................................................................................................................79

Dirt and Debris .........................................................................................................................................................79

Image Placement .....................................................................................................................................................79

Smear .......................................................................................................................................................................79

Black Extraction ........................................................................................................................................................79

Ribbon Wrinkle ............................................................................................................................................................79

Contents

Mis-registration ............................................................................................................................................................80

Ethernet Indicators—Detail..........................................................................................................................................80

Link/Activity Indicator (Green) .....................................................................................................................................80

Speed Indicator (Orange) ............................................................................................................................................80

Ribbon Repair..............................................................................................................................................................81

iii

Introduction

About This Manual

This manual provides service and troubleshooting instructions for the ZC100, ZC150, ZC300, and ZC350 printers, and their respective factory-installed options. Unless otherwise noted, instructions are identical for all printers.

About the Printer

The ZC100 Series and the ZC300 series printers provide full color dye sublimation or monochrome thermal transfer printing on standard CR70 (2.051” x 3.303”) and CR80 (2.125” x 3.375”) PVC or PVC composite 10- to 40-mil cards.

The integrated card feeder and ipper minimizes printer size while maximizing performance. Zebra ribbon cartridges

have an integrated card cleaning roller for easy ribbon changing or replacement. A variety of options (some of which

can be factory-installed or eld-installed as upgrades) are available.

Replacement Procedures

Introduction

The following sections describe removing both major assemblies and—where applicable—sub-assemblies and/or components that are considered replaceable.

Prior to any removal procedure, remove any ribbon and all cards in the printer

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

Electrostatic Discharge • This replacement procedure must be performed at a static-free work station or other suitable environment; an anti-static wrist strap must be worn and properly terminated, or other appropriate protection must be used.

Caution • Before beginning any of the steps that follow, read completely through this procedure. If you do

not have the speci󰘰ed 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 additional parts removed in addition to removals for the process being described.

Required Tools and Supplies

The following list species the tools required to perform the replacement procedures described in this section. Naturally, not all tools are required for a particular procedure; specic tools are called out in each step as

appropriate.

y Nylon Pry Tool (two or more for certain procedures)

y TORX T10 Driver

y Flathead Screwdriver

y 5 mm E-Ring Clip Tool

y Rubbing Alcohol

y Lint-free Cloth or Wipes

y Gloves (for handling the LCD as necessary)

Replacement Procedures

Removal Sequence

The following gures show the recommended removal sequence. For each item, follow the diagram upward to see

what must be removed for access. For example: to remove the LED PCBA, remove the left- and right-side covers, then remove the feeder front bezel.

LeftSide

Cover

LeftSideFiller

Panel

RibbonDrive

Assembly

Tri‐Sensor

PCBA

CamPosition SensorPCBA

PlatenDrive

Motor

RightSide

Cover

RightSide

FillerPanel

Wi‐FiModule

Manual

Advance

Wheel

Feeder

Module

TopCover

Assembly

CardEntry/ ExitModule

FeederFront

Bezel

Printhead

LCDPCBA

TopCover

Dampener

LEDPCBA

PrintheadFan

Printhead

Cable

RearPanel

BottomPanel

MainLogic

Board

LiftCam

Motor

Flipper

Module

Flipper

Enclosure

RearDeck

RearDeck

Encoder Module

Ribbon

DetectSensor

Assembly

CardDetect

Sensor

Assembly

RearPlaten

Roller

NipRoller Assembly

FrontDeck

FrontPlaten

Rollers

Procedures

Left Side Cover

Removal

Note • Before placing the printer on its side cover, place a towel or cloth on the work surface to avoid scratching the side cover.

Step 1. Open the top cover.

Replacement Procedures

Step 2. Turn the printer onto its right side.

Step 3. Using a nylon pry tool, release the three locking tabs securing the left side cover to the printer.

Step 4. Set the printer upright.

Step 5. Lift the left side cover from the printer.

Replacement Procedures

Installation

Step 1. Open the top cover.

Step 2. Hang the left side cover onto the printer frame using the mounting tabs.

Step 3. Push the bottom of the cover onto the printer frame until the tabs lock into place.

Step 4. Close the top cover.

Right Side Cover

Removal

Step 1. Open the top cover.

Replacement Procedures

Step 2. Turn the printer onto its left side.

Step 3. Using a nylon pry tool, release the three locking tabs securing the right side cover to the printer.

Step 4. Lift the right side cover from the printer.

Replacement Procedures

Installation

Step 1. Open the top cover.

Step 2. Hang the right side cover onto the printer frame using the mounting tabs.

Step 3. Push the bottom of the cover onto the printer frame until the tabs lock into place.

Step 4. Close the top cover.

Replacement Procedures

Rear Cover

Removal

Step 1. Place the printer on its side.

Step 2. Using a nylon pry tool, gently pry the rear cover at the slot at the bottom.

Step 3. Once unlocked, slide the rear panel downward.

Step 4. Remove the rear panel.

Replacement Procedures

Installation

Step 1. Place the rear cover tabs into the respective mounting holes on the printer frame.

Step 2. Slide the rear cover upward until the rear cover locks into place.

Replacement Procedures

Bottom Cover

Note • This procedure is for reference only, there is no replacement kit for the bottom cover.

Removal

Step 1. Remove the left side cover (page 5).

Step 2. Remove the right side cover (page 7).

Step 3. Remove the rear cover (page 9).

Step 4. Using a nylon pry tool, release the locking tabs securing the bottom cover to the printer frame.

RIGHT

LEFT

Step 5. Slide bottom cover to the rear to release it from the printer frame.

Step 6. Remove the bottom cover.

Replacement Procedures

Installation

Step 1. Place the bottom cover tabs into the respective mounting holes on the printer frame.

Step 2. While securing the bottom cover, open the output hopper doors to avoid interference.

Step 3. Push the bottom cover onto the printer frame until the tabs lock into place.

Replacement Procedures

Left Side Filler Panel

Removal

Step 1. Open the top cover.

Step 2. Push down on the top of the ller panel to release the locking tabs from the printer frame.

Step 3. Remove the ller panel.

Installation

Step 1. Insert the bottom tab into its respective mounting hole on the printer frame.

Step 2. Push the ller panel into place until the tabs lock into place.

Step 3. Close the top cover.

Replacement Procedures

Right Side Filler Panel

Removal

Step 1. Open the top cover.

Step 2. Push down on the top of the ller panel to release the locking tabs from the printer frame.

Step 3. Remove the ller panel.

Installation

Step 1. Insert the bottom tab into its respective mounting hole on the printer frame.

Step 2. Push the ller panel into place until the tabs lock into place.

Step 3. Close the top cover.

Replacement Procedures

Main Logic Board

Important • A con󰘰guration 󰘰le, NVM_bkup_< printer serial number >.xml, is saved when the driver and printer are 󰘰rst installed. If the Main PCBA is not functional, you can use that 󰘰le to restore the printer

settings.

Preparation

Before you replace the main logic board, save the printer conguration settings:

Step 4. Open the Printing preferences control panel and click on the Advanced utility.

Step 5. Click on the Printer Settings tab and select Firmware and Settings.

Step 6. In the Save/Restore Settings section, click on SAVE under Printer Settings.

Step 7. Enter a name for your saved data and click SAVE.

Replacement Procedures

Feeder

Connection

(J28)

LCD (J26)

(not present on ZC100)

Ribbon

Authentication

Sensor (J24)

Card Detect

Sensor (J23)

Transport

Motor (J19)

Color Detect

Sensor (J22)

Printhead Cam

Sensor (J13)

Wireless Module

Connection (J18)

Motor (J16)

Ribbon Take-Up

Motor (J7)

Printhead (J6)Cam Lift

Encoder

Module

Connection (J8)

Printhead

Fan (J5)

Dual-Sided Module Connection (J4)

(not present on ZC100)

Ethernet (J3)

USB (J2)

Power (J1)

Removal

Step 1. Remove the left side cover (page 5).

Step 2. Remove the right side cover (page 7).

Step 3. Remove the rear cover (page 9).

Step 4. Disconnect the ribbons and cables from the main logic board. If equipped, disconnect the Wi-Fi

antenna from the Wi-Fi module.

Step 5. Remove the bottom cover (page 11).

Replacement Procedures

Step 6. Using a Torx T10 driver, remove the two screws securing the main logic board to the printer frame.

Step 7. Remove the main logic board lifting from the front and sliding forward.

Installation

Step 1. Place the rear of the main logic board into the printer frame with the connection receptacles placed

into their respective holes on the printer frame..

Step 2. Using a Torx T10 driver, secure the main logic board to the printer frame using the two screws.

Step 3. Replace the bottom cover.

Step 4. Reconnect the ribbons and cables to the main logic board.

Step 5. Replace the rear cover.

Step 6. Replace the side covers.

Step 7. Open the Printing preferences control panel and click on the Advanced utility.

Step 8. Click on the Printer Settings tab and select Firmware and Settings.

Replacement Procedures

Restore Settings

Step 1. Open the Printing preferences control panel and click on the Advanced utility.

Step 2. Click on the Printer Settings tab and select Firmware and Settings.

Step 3. In the Save/Restore Settings section, click on Restore under Printer Settings.

Step 4. Select the le you save previously and click OPEN.

Replacement Procedures

Printhead

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

Removal

Step 1. Open the top cover.

Step 2. Push the printhead assembly upward until it becomes free from its locking hooks.

Step 3. Disconnect the printhead cable.

Installation

Note • Prior to installing the new printhead, note the serial number and resistance value.

Step 1. Connect the printhead cable to the printhead.

Step 2. Place the mounting knob into its receptacle and press upward to secure the printhead into its locking

hooks.

Step 3. Close the top cover.

Replacement Procedures

Restore Settings

Step 4. Open the Printing preferences control panel and click on the Advanced utility.

Step 5. Click on the Sensors and Calibration tab and select Calibration.

Step 6. In the Printhead section, enter the Serial Number and Resistance of the new printhead and click

Replacement Procedures

Printhead Cable

Note • Subsequent releases have added a sleeve for the printhead cable and printhead fan cable not shown in the following pictures.

Removal

Step 1. Continue with Printhead Removal (see “Printhead” on page 19).

Step 2. Remove the right side cover (page 7).

Step 3. Disconnect the printhead cable (J6) from the main logic board.

Step 4. Release the printhead mounting frame from the top cover frame by carefully spreading the two

locking hooks outward.

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Zebra ZC100, ZC150, ZC300, ZC350 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual