Zebra ZXP Series 7 Service Manual

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Page 1

ZXP Series 7™

P1036102-007

Card Printer

Service Manual

Page 2

Corporate Headquarters

+1 800 423 0442 inquiry4@zebra.com

Asia-Pacific Headquarters

+65 6858 0722 contact.apac@zebra.com

EMEA Headquarters

zebra.com/locations mseurope@zebra.com

Latin America Headquarters

+1 847 955 2283 la.contactme@zebra.com

http://www.zebra.com/locations

©2016 ZIH Corp. and/or its affiliates. All rights reserved. Zebra and the stylized Zebra head are trademarks of ZIH Corp., registered in many jurisdictions worldwide. All other trademarks are the property of their respective owners.

Page 3

Contents

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

Description ............................................................................................................................................. 1

Theory of Operation .......................................................................................................3

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

Card Movement During Printing .............................................................................................................4

Printing Technologies and Ribbons ........................................................................................................ 6

Dye Sublimation Printing .................................................................................................................8

Thermal Transfer Printing ................................................................................................................ 8

System-Level Electronics .......................................................................................................................9

Main PCBA (CPU) .........................................................................................................................10

High-Capacity Output Hopper .............................................................................................................. 13

Hopper Cassette ............................................................................................................................13

Stacker ..........................................................................................................................................13

Troubleshooting ........................................................................................................... 15

Introduction ..........................................................................................................................................15

OCP Error Messages ........................................................................................................................... 16

OCP Test Cards ................................................................................................................................... 25

Ethernet ...............................................................................................................................................26

Replacement Procedures for the Printer ...................................................................27

Introduction ..........................................................................................................................................27

Required Tools ..................................................................................................................................... 28

Removal Sequence ..............................................................................................................................29

Printer ............................................................................................................................................ 30

Feeder Module ..............................................................................................................................30

Flipper Module ............................................................................................................................... 31

Options Module .............................................................................................................................31

Procedures ...........................................................................................................................................32

Reject Bin ......................................................................................................................................32

Feeder Cartridge ...........................................................................................................................34

Ribbon Drawer ...............................................................................................................................40

Card Guides ..................................................................................................................................42

Shroud for Options ........................................................................................................................44

Back Cover .................................................................................................................................... 45

Rear Feeder Cover ........................................................................................................................ 46

Options Cover ................................................................................................................................47

P1036102-007 ZXP Series 7 Card Printer Service Manual i

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OCP PCBA .................................................................................................................................... 49

Right Cover ....................................................................................................................................51

Print Cover .....................................................................................................................................58

Door Button and Latch ...................................................................................................................60

Left Side Cover .............................................................................................................................. 63

Belt and Gear Panel ......................................................................................................................64

Bottom Cover .................................................................................................................................66

Feet ...............................................................................................................................................67

Reject Bin Bracket ......................................................................................................................... 68

Printer ............................................................................................................................................ 69

Main PCBA ....................................................................................................................................73

Ethernet PCBA ..............................................................................................................................76

Print Engine ................................................................................................................................... 77

Feeder/Flipper/Options Assembly ...............................................................................................137

Feeder/Flipper Assembly ............................................................................................................. 142

Ground Plate ...............................................................................................................................145

Power Switch ............................................................................................................................... 147

Feeder Module ............................................................................................................................149

Flipper Module ............................................................................................................................. 157

Options Module ...........................................................................................................................180

Torque Tools Calibration Instructions ........................................................................................... 187

Replacement Procedures for Factory Installed Options .......................................191

Introduction ........................................................................................................................................191

Required Tools ................................................................................................................................... 192

Procedures .........................................................................................................................................193

Barcode Scanner Assembly ........................................................................................................ 193

SmartCard Control PCBA ............................................................................................................199

MIFARE/Contact Encoder Module ...............................................................................................200

MIFARE Contact Encoder PCBA ................................................................................................. 203

Contact Station Module ...............................................................................................................205

Contact Station Module PCBA .....................................................................................................208

Pressure Roller Assembly ........................................................................................................... 209

Replacement Procedures for the Laminator ........................................................... 217

Introduction ........................................................................................................................................217

Required Tools ................................................................................................................................... 218

Removal Sequence ............................................................................................................................219

Procedures .........................................................................................................................................221

Back Cover .................................................................................................................................. 221

Side Cover ................................................................................................................................... 222

Lock Replacement for Left Cover ................................................................................................ 223

Lower Door .................................................................................................................................. 225

Door Assembly (Door and Hinges) ..............................................................................................227

Latch Assembly ...........................................................................................................................230

Laminator / Printer Separation .....................................................................................................232

Bottom Panel ............................................................................................................................... 236

Feet .............................................................................................................................................237

Mounting Plate .............................................................................................................................238

Molded Ribbon Spindle ...............................................................................................................240

Square Corner Spindle ................................................................................................................ 241

Laminator Heater Assembly ........................................................................................................ 242

Halogen Bulbs .............................................................................................................................243

24V Heater Fans .........................................................................................................................246

Motor and Plate Assembly ...........................................................................................................248

Laminator Controller PCBA .........................................................................................................251

Media Authentication PCBA .........................................................................................................253

ii ZXP Series 7 Card Printer Service Manual P1036102-007

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Top Laminator Control Motor ....................................................................................................... 254

Bottom Laminator Control Motor .................................................................................................255

Staging Motor ..............................................................................................................................256

Media Authentication Antenna PCBA ..........................................................................................257

Front Frame ................................................................................................................................. 259

Static Brush .................................................................................................................................261

Cassette Latch Assembly (Top & Bottom) ...................................................................................262

Thermopiles (Top & Bottom) ........................................................................................................ 270

Top Thermopile Cable ................................................................................................................. 274

Bottom Thermopile Cable ............................................................................................................ 275

Flexible Ribbed Rollers (Left & Right) .........................................................................................276

Card Staging Nip Rollers (Left & Right) ....................................................................................... 277

Platen Overrun Roller (Top & Bottom) ......................................................................................... 278

Exit Rollers ..................................................................................................................................279

Cutters (Upper & Lower) ..............................................................................................................280

Laminate Ribbon Rollers (Top & Bottom) .................................................................................... 284

Card Entry Sensor Cable Assembly ............................................................................................285

Card Laminator Sensor Cable Assembly .....................................................................................286

Card Exit Sensor Cable Assembly ...............................................................................................287

Door Sensor Cable Assembly .....................................................................................................288

Replacement Procedures for the High-Capacity Output Hopper ..........................289

Introduction ........................................................................................................................................289

Required Tools ................................................................................................................................... 290

Procedures .........................................................................................................................................291

Output Hopper Cassette .............................................................................................................. 291

High-Capacity Output Hopper .....................................................................................................292

Left Side Panel ............................................................................................................................304

Platen Roller ................................................................................................................................ 3 11

Pressure Roller ............................................................................................................................ 313

Sensors .......................................................................................................................................316

Drive Assembly ............................................................................................................................ 329

Elevator .......................................................................................................................................339

Elevator Bushing .........................................................................................................................346

Base Housing ..............................................................................................................................347

Base Cover and Latch Assembly .................................................................................................354

PCBA ...........................................................................................................................................355

Cleaning ......................................................................................................................361

Introduction ........................................................................................................................................361

Cleaning the Printer ...........................................................................................................................362

When to Clean ............................................................................................................................. 362

Initiate the Cleaning Process ....................................................................................................... 362

Clean the Card Path .................................................................................................................... 363

Clean the Feeder Path ................................................................................................................364

Polish the Printhead ....................................................................................................................365

Cleaning the Laminator ...................................................................................................................... 366

When to Clean ............................................................................................................................. 366

Initiate the cleaning process ........................................................................................................ 366

Clean the Laminator Card Path ................................................................................................... 367

Clean the Laminator Media Rollers ............................................................................................. 368

Clean the Laminator Oven (Heater Rollers) ................................................................................ 370

Cleaning the High-Capacity Output Hopper .......................................................................................373

Dual Cleaning Cartridge .....................................................................................................................374

Manual Feed Cleaning Cassette ........................................................................................................374

Cleaning Supplies .............................................................................................................................. 374

P1036102-007 ZXP Series 7 Card Printer Service Manual iii

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Field Upgrades............................................................................................................375

Introduction ........................................................................................................................................375

Placing Labels ....................................................................................................................................376

Field Upgrade Labels ......................................................................................................................... 377

iv ZXP Series 7 Card Printer Service Manual P1036102-007

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Description

This manual provides detailed information on the service of, and replacement procedures for the Zebra ZXP Series 7 Card Printer, the optional laminator, and the optional high-capacity output hopper.

Introduction

References to “the printer” in this document apply to either the single- or the doublesided printer. Similarly, references to “the laminator” apply to either the single- or the double-sided Laminator.

P1036102-007 ZXP Series 7 Card Printer Service Manual 1

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2 ZXP Series 7 Card Printer Service Manual P1036102-007

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Introduction

This section includes ﬁve major topics:

• Card Movement During Printing

Theory of Operation

• Printing Technologies and Ribbons

• System-Level Electronics

• Main PCBA (CPU)

• High-Capacity Output Hopper

Page 10

Theory of Operation

Card Movement During Printing

Step 1. The card is fed from the Feeder Cartridge into the Printer.

Step 2. As the card is moved into the Printer, it is cleaned via the Cleaning Cartridge;

this cleans dust and dirt particles from both sides of the card.

Step 3. If the Printer includes an optional Smart Card Encoder (either contact-style

or contactless), the card is moved to the Encoder; and the smart card is encoded. As the card is encoded, it is checked to verify that it was encoded properly. If encoding fails, the card is moved to the Reject Bin. This is done to avoid wasting time and ribbon panels on a defective card. If the encoding is successful, the card is moved into the pre-print position, just before the Printhead.

Step 4. If the Printer includes an optional Magnetic Stripe Encoder, the card is

moved to the Encoder; and the magnetic stripe is encoded. The card is then backed up and run through the Magnetic Stripe Encoder again; on this pass the card is read to verify that the magnetic stripe was properly encoded. If encoding fails, the card is moved to the Reject Bin. As with failed smart card encoding, this is done to avoid wasting time and ribbon panels on a defective card. If the encoding is successful, the card is moved into the preprint position, just before the Printhead.

Step 5. The card is printed.

Dye-Sublimation Printing

When the Print Cover is opened and closed, the ribbon is synchronized, thereby bringing the leading edge of the Yellow ribbon panel (e.g., a YMCKO ribbon) under the Printhead.

The leading edge of the card is moved under the Printhead (over the Platen Roller), and the Printhead is lowered. Lowering the Printhead reduces the space between the Printhead, the ribbon, and the card, which produces sharper images.

As the card and ribbon move along, each element of the Printhead receives a pulse of variable width; a wider pulse results in a hotter element which melts a larger amount of yellow dye onto that particular spot on the card.

After this Yellow (Y) pass is completed, the Printhead is raised, the card is moved back, and printing continues with the Magenta (M) ribbon panel, then the Cyan (C) panel, then the Black (K) panel, and ﬁnally the Overlay (O) panel.

Thermal-Transfer Printing

If using a monochrome ribbon, the card makes a single pass under the Printhead. The Printhead elements are energized to either on or o. The on level actually transfers the spot of resin under the Printhead 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 un-printed areas.

4 ZXP Series 7 Card Printer Service Manual P1036102-007

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Theory of Operation

Card Movement During Printing

Step 6. For double-sided printing, the card is now moved back to the Card Flipper

where the card is turned over (rotated 180 degrees). The card is moved into the Print Engine; and the card is printed (same as Step 5).

Step 7. If the Printer has a Laminator:

a. The card is moved through the Printer into the Laminator.

b. As the card passes through the Laminator, laminating ﬁlm is applied to

the card, the top side or both sides depending on the Laminator.

c. The card (with the laminating ﬁlm) then passes between a pair of heated

rollers, which seal the laminating ﬁlm to the card.

d. The card is moved from the Laminator to the Card Exit, where it falls into

the Output Hopper attached to the left side of the Laminator.

Step 8. If the Printer does not have a Laminator; the card moves through the Printer,

where it falls into the Output Hopper attached to the left side of the Printer.

P1036102-007 ZXP Series 7 Card Printer Service Manual 5

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Theory of Operation

Printing Technologies and Ribbons

There are two types of printing technology used in the printer: Dye Sublimation and Thermal Transfer. The technology to use is determined by the type of dye or ink on the ribbon.

Monochrome Ribbons have a single color ink on the length of the ribbon. The printer is programmed to use Thermal Transfer printing for monochrome ribbons.

Multi-Panel Ribbons have a repeating sequence of panels of dierent dye. RFID Multi-Panel Ribbons have an RFID tag on the supply spool; the RFID code identiﬁes the ribbon type 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 Printhead, once per panel.

For double-sided printing, a typical situation would be to print a full-color graphic (such as a person’s picture) along with black text and/or bar-coding on the front, and black text and/or bar-coding on the rear. In this case, a YMCKOK Multi-Panel Ribbon would be used.

A YMCKO ribbon has successive panels as follows:

Color Technology Function / Usage

Yellow (“Y”) Dye Sublimation

Magenta (“M”) Dye Sublimation

Cyan (“C”) Dye Sublimation

Black Resin (“K”) Thermal Transfer

Overlay (O) - -

Thermal Transfer

Printing Process

(YMCKO)

Pattern

Repeats)

Overlay

(O)

Black

(K)

Resin

Cyan

(C)

Dye

Full-Color Printing and Dye Sublimation Black Printing

K Resin Black Printing (for the front of the card)

Dye Sublimation Printing Process

Magenta

(M)

Dye

Yellow

(Y)

Dye

Ribbon movement from supply spool

Other ribbons are available for the printer; see the Supplies List on the Driver and Documentation CD that came with the printer, or visit the Zebra Card Printer Solutions website at zebra.com/supplies.

6 ZXP Series 7 Card Printer Service Manual P1036102-007

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Theory of Operation

Printing Technologies and Ribbons

The ribbon synchronizes to it’s “starting” position whenever the Print Cover is opened and then closed. For a YMCKO ribbon, the starting position is with the leading edge of a Yellow Panel at the printhead location.

The ﬁgure below shows how the YMCKO ribbon and card move relative to each other during printing.

Printhead in fixed position1. Ribbon move yellowpanel into

position at printhead.

2. Card is fed to printing position under the printhead.

3. Card and ribbon move together as yellow panel is printed.

4. Card and ribbon stop at the end of the yellow panel.

5. Ribbon remains stationary as card is moved back to printing position.

6. Card and ribbon move together as magenta panel is printed.

In addition, the driver software allows the user to specify which ribbon panels are printed on either side of the card.

P1036102-007 ZXP Series 7 Card Printer Service Manual 7

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Theory of Operation

Printing Technologies and Ribbons

Dye Sublimation Printing

In Dye Sublimation Printing, each printhead heating element is applied voltage at one of a number of pulse widths.

A wider pulse results in the element getting hotter, which converts more of the dye (at that pixel location) to a gas and diuses 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.

Ribbon Carrier

Layer

Ribbon Ink

Layer

Card

Printhead

Gaseous dye is absorbed by the card

Thermal Transfer Printing

In Thermal Transfer Printing, voltage is either applied or not applied to each printhead 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 is transferred to the card) or not; there are no intermediate levels.

Thermal Transfer printing with a black (K) resin panel is used for printing bar codes, since contrast between the light and dark areas is the highest and the edges are the sharpest.

Ribbon Carrier

Layer

Ribbon Ink

Layer

Card

Printhead

Ink is transferred to the surface of the card

8 ZXP Series 7 Card Printer Service Manual P1036102-007

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System-Level Electronics

)

MAG_ISO(P1029189

Mag Head

MTR_OPMG

(P1039207)

LED

Detector

(PCBA_MAG_

SEN_OPMG

P1038451-01)

Mag Module PCBA

(PCBA_MAG_MOD_IF

(P1031857)

Mag PCBA

CA_MAG_MOD_IF

Options Module

(P1027378-02)

PCBA_FELICA_CAR

UHF Mod

Felica Mod

OPTIONS MODULE

DB9 for

External

(P1027378-01)

PCBA_UHF_CAR

SmartCard

for User Auth)

Authentication

(Contact SmartCard

Reader

Barcode

(BARCD)

USB

Host

Ports

Station

Contact

MAG

MOD_DET,

P1038478-01)

CA_MTR_OPMG-MOD_GND (P1033288)

P1038415-01)

(PCBA_OPMAG,

(P1029200)

(if required)

MTR_OPCM

(P1033220)

(PCBA_CPLR_SC)

SmartCard Coupler

CA_MTR_OPCM_GND

PCBA

(SC_MOD,

P1006651-01)

806882-001) or

Ext Contact Stn i/f

SmartCard Module

(PCBA_EXTCNT_IF,

CA_SC_MOD

(P1029151) or

CA_EXT

(P1043050)

(P1042978)

CA_EXT_DB9

CA_OPMAG (P1026484)

CA_USRAUTH

CA_BARCD

CA_UCONN

Theory of Operation

System-Level Electronics

SEN_OPCD

(300238G-002)

Gap

Sensor

CA_MTR_OPCM-MOD_GND (P1033283)

OPMAG_PD_N

Gap

Sensor

SEN_OPCM

SmartCard

Module PCBA

P1028126-01)

(PCBA_SC_MOD,

_EXT

(P1042729)

(P1044093)

MTR_OPCD

CA_MTR_OPCD_GND

(P1042321)

MTR_FLCD

CA_MTR_FLCD_GND

SEN_FLCD

MTR_FLRO

(P1026465-002)

CA_MTR_FLRO_GND

Gap

SEN_FDOP

(P1030185)

SEN_FLRO

(300364-006)

(300364-007)

Gap

Sensor

SMARTCARD

(P1026478)

CA_FLOPMAG

are combined into

These connections

(P1026476)

(P1029126)

Connectors

P1028104-01)

(PCBA_OPSC,

Options Module

SmartCard PCBA

CA_OPSC_RF

CA_OPSC

(P1027859)

CA_FLOPSC

are combined into

These connections

CA_FLIP_PWR (P1026479)

CA_FLIP_CTL (P1026480)

MTR_OPMG_CTL

MTR_OPCM_CTL

OPSC_PD_N

(PCBA_FLIP,

P1021234-01)

Flipper Board PCBA

FLIPPER

FEEDER

CA_MTR_FEED_GND

(P1041216)

MTR_FEED

CA_MTRS_ENG_GND

MTR_MAIN (P1009157-001)

MTR_CAM (P1009302)

MTR_RIBS (P1020449)

CA_MTR_RIBS_GND

CA_MTR_MCB (P1014939)

MTR_RIBT (P1020406)

CA_MTR_RIBT_GND

(Individual motor cables)

WiFi Antenna (ANT, P1005199)

(300844-001)

CA_CPLR_MA

(PCBA_MAB,

P1008230-02)

(PCBA_CPLR_MA,

Media Auth Coupler

(P1029730)

CA_MTRS_ENG_GND

P1008702)

(PWR_SUP,

200W Power Supply

(P1014040)

CA_SUP_GND

CA_ACPWR (P1013793)

EMI Filter

P1035695)

(PWR_SW,

AC Switch &

404870-003P)

Media Auth PCBA

DC output CN2 is term block)

DC output CN2 is conn)

(P1029884)

(P1022300)

CA_MTR_RIBT_GND

CA_BRUSH_EXIT

CA_ENGINE_GND

CA_OPTIONS_GND

P1010902)

(GND_MCB,

Ground Plate

(P1013891)

CA_SW_GND

CA_LAM_DC (P1030139)

(P1041281)

CA_LAM_GND

(Osprey P/N: P1004275)

CA_LAM_AC (P1029986)

Board

Ethernet

(P1025470)

CA_MAB

(Osprey P/N: 300827-001:

CA_DCPWR (P1030122:

(Osprey P/N: P1004276)

CA_LAM_CTL (P1030001)

Laminator

FSI Conn

P1006890-02

P1006890-03)

(PCBA_ENET,

Port

USB

Periph

CA_PH

are combined into

These connections

Tri-Color

SEN_RIBA

(Osprey P/N: P1004277)

(LAM)

(PCBA_MCB,

P1047494-01)

Main Controller Board PCBA

P1043417-01)

(PCBA_DIAG_IF,

(P1037316)

Emitter

Print Head

(404790-003P)

(P1044307)

FAN_PH (blower)

CA_ENGINE_GND (P1032223)

(P1032163)

IP/EP Diagnostic Board

CA_OCP_RECEPT

JTAG

(P1032161)

CA_IP_DEBUG

CA_EP_DEBUG

CA_OCP_PLUG

(PH,

P1040725)

(OCP,

OCP Assy

P1027292)

PH_GND

P1030086)

(GND_ENG,

Ground Plate

Thermistor

(P1051848) CA_THERM

Gap

(P1037399)

CA_SEN_RIBB

CA_BRUSH_CLSOUTS (P1029745-001)

Gap

Sensor

Detector

Tri-Color

SEN_EXIT

SEN_RIBB

SEN_TENC

(300364-003)

(405030-003B)

CA_BRUSH_FEED_RGHT (P1029727)

CA_MTR_RIBS_GND (P1029883-001)

CA_BRUSH_FEED_LEFT (P1029728)

CA_MTR_FEED_GND (P1029744-001)

CA_OPTIONS_GND

(300364-010)

(P1032220)

MTR_SP

CA_SEN_MCB (P1014941)

Gap

Sensor

SEN_SENC

(300364-002)

P1029901)

Ground Plate

(GND_FLOP,

FAN_PWR

Gap

Sensor

SEN_CAM

SEN_CSYN

SEN_DOOP

(300364-009)

(300364-008)

CA_FLIP_SHFT_GND (P1029747-001)

CA_MTR_FLCD_GND (P1032300)

CA_MTR_OPCD_GND (P1032300)

FAN_SP2

FAN_SP1

Sensor

(300238G-004)

CA_MTR_FLRO_GND (P1032281)

CA_BRUSH_ATM (P1029833)

CA_BRUSH_FLIP (P1032340)

CA_MTR_OPMG-MOD_GND (P1033288)

CA_MTR_OPCM-MOD_GND (P1033283)

P1036102-007 ZXP Series 7 Card Printer Service Manual 9

Page 16

Theory of Operation

System-Level Electronics

Main PCBA (CPU)

PCBA Layout

* J50, J51, and J52 are on the bottom side of the Main PCBA

10 ZXP Series 7 Card Printer Service Manual P1036102-007

Page 17

Theory of Operation

System-Level Electronics

PCBA Connections

Connector PCBA ID Functional Description

J1 ETHERNET INTERFACE Ethernet Daughterboard

J2 USB_PERIPH_PC USB peripheral interface from host PC

J3 SEN_RIBA Ribbon tri-color sensor (detector)

J4 SEN_RIBB Ribbon tri-color sensor (emitter)

J5 PH_PWR Power to printhead

J6 JTAG RESERVED

J7 DCPWR DC power input to board

J8 MTR_RIBT Ribbon take-up motor

J9 SEN_TENC Ribbon take-up encoder wheel sensor

J10 LAM_CTL Control signals to Laminator or Hopper

J11 SEN_EXIT Exit sensor

J12 -- RESERVED

J13 -- RESERVED

J14 -- RESERVED

J15 -- RESERVED

J16 MTR_MCB Stepper motors driven by MCB

J17 -- RESERVED

J18 USB_HOST_SP RESERVED

J19 USRAUTH User Authentication

J20 BARCD Barcode Reader

J21 OCP Operator Control Panel

J22 MAB Media Authentication Board

J23 SEN_CAM RESERVED

J24 SEN_MCB Various sensors

J25 N/A N/A

J26 UHF/FELICA RESERVED

J27 FDFLIP_CTL Control signals to Flipper Board

J28 FDFLIP_PWR Power to Flipper Board

J29 PH_DATA Printhead Data

J30 USB_HOST_PANEL USB Dual Host cable

J31 -- RESERVED

J32 IP_DEBUG RESERVED

J33 EP_DEBUG RESERVED

J34 SEN_RIBA_NEW Ribbon tri-color sensor (emitter)

J35 SEN_RIBB_NEW Ribbon tri-color sensor (detector)

J36 THERM RESERVED

J50* OPSC SmartCard option board

J51* OPMAG Mag option board

J52* DIAG I/F Diagnostic test

* J50, J51, and 52 are on the bottom side of the Main PCBA

P1036102-007 ZXP Series 7 Card Printer Service Manual 11

Page 18

Theory of Operation

MTR_

System-Level Electronics

PCBA Block Diagram

Most of the circuitry in the printer is on the Main PCBA. Since the Main PCBA is not a serviceable unit, there is no component level circuit analysis.

SEN_RIBB

SEN_RIBA

Emitter

Detector

Tri-Color

Thermistor

CA_THERM

P1043417-01)

(PCBA_DIAG_IF,

IP/EP Diagnostic Board

Board

Ethernet

Daughter

(PCBA_ENET)

Main PCBA

CA_UCONN

SEN_SENC

Gap

J24

J35

J34

J36

J52

J30

SEN_CSYN

SEN_CAM

Gap

Sensor

USB_PERIPH_PC

SEN_DOOP

Gap

Sensor

CA_SEN_MCB

Sensor Interface

A2D for analog inputs)

(tri-color sensor circuit,

74HC14's for digital sensor inputs,

Debug Interfaces

USB Interfaces

USB Logic

USB_HOST_PANEL

Remote Board Interfaces

SEN_TENC

Gap

Sensor

MCB Sensor Interfaces

Print Head Interface

CPU Subsystem

(FPGA, DDR, Flash,

clock buffering, I2C mux, etc.)

External Module Interfaces

(PH)

Print Head

SEN_EXIT

FAN_PH

Gap

Sensor

CA_PH

(PH_DATA)

(PH_PWR)

J11

J29

MTR_RIBT

BEMF Circuit

A3966

A4983

J16

MCB Motor Driver Interfaces

A3979

connects to J16 here.

a C/A (CA_MTR_MCB) that

These motors each plug into

MTR_RIBS

MTR_CAM

MAIN

(PWR_SUP)

200W Power Supply

CA_DCPWR

J28

CA_FDFLIP_PWR

Flipper

Module

Power

DC-DC

Conversion

J21

J10

J51

J27

CA_OPMAG

CA_FDFLIP_CTL

PCBA

Mag PCBA

(PCBA_FLIP)

(PCBA_OPMAG)

CA_OPSC

SmartCard PCBA

J50

(PCBA_OPSC)

Media Auth

J22

CA_OCP

CA_LAM_CTL

CA_MAB

CA_CPLR_MAB

(PCBA_MAB)

Coupler PCBA

Media Auth PCBA

(PCBA_CPLR_MAB)

(PCBA_OCP)

Laminator (LAM)

OCP Support PCBA

J26

J19

J20

CA_BARCD

Reader

Barcode

(BARCD)

CA_UHF-FELICA

UHF/Felica

CA_USRAUTH

SmartCard

for User Auth)

Authentication

(PCBA_USRAUTH)

(Contact SmartCard

12 ZXP Series 7 Card Printer Service Manual P1036102-007

Page 19

High-Capacity Output Hopper

Hopper Cassette

Stacker

Theory of Operation

High-Capacity Output Hopper

Hopper Cassette

• Easily removable from, and replaceable back onto, stacker base (full, partial, or empty of cards).

• Equipped with a locking mechanism for capturing and holding stacked cards.

• Open front slot to allow for manual removal of cards (from 1 to 250 cards) without removing stacker from base.

• With the hopper cassette removed, cards can be removed from top, not from bottom as locking mechanism is not reversible.

Stacker

The high-capacity output hopper receives and automatically stacks cards in the order they were printed—top face up—with the ﬁrst card printed at the top of the stack, and the last card printed at the bottom of the stack.

The high capacity output hopper runs independently of the printer and responds only to the card present sensor at the entrance to the hopper. With the cassette in place, the hopper will stack cards continuously based on print job (including overﬁlling over the top of the cassette). With the cassette removed, the elevator will not actuate, but the printer will continue to print and printed cards will accumulate on the stacker base—up to 9 cards (30 mil) will accumulate before being pushed o the stacker base.

P1036102-007 ZXP Series 7 Card Printer Service Manual 13

Page 20

14 Hopper Cassette

Page 21

Introduction

The table on the next page oers causes and solutions to symptoms related to improper operation. Check the table on the following pages when experiencing any loss of operation or print quality.

Troubleshooting

For additional information on troubleshooting and advanced operations, you can access an extensive Knowledge Base at km.zebra.com.

P1036102-007 ZXP Series 7 Card Printer Service Manual 15

Page 22

Troubleshooting

OCP Error Messages

Important • If the Possible Solution does not solve your problem, contact Zebra Technical Support.

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

6 DIAGNOSTIC ERROR

3001 PRINTER OFFLINE

4003 CARD JAM Card is jammed in the Printer. Clear the card path.

4014 CARD FEED ERROR

FIRMWARE UPGRADE ERROR

CRITICAL ERROR SHUTTING DOWN

Firmware upgrade incompatibility.

Error encountered in Diagnostic Mode.

Firmware upgrade failed.

Major malfunction encountered. Contact Zebra Technical Support.

Status toggled (ofine/online)

via the OCP Advanced Settings Menu.

Card is jammed in Feeder Cartridge.

Verify the version, and retry installing

the rmware.

Power cycle the printer, and retry.

Verify the version, and retry installing

the rmware.

Change status to ONLINE via the OCP Advanced Settings Menu.

1. Clear card jam in Feeder Cartridge, and re-seat Feeder Cartridge.

2. Ensure that cards are not stuck together and that they are the correct thickness (10 to 50 mil).

1. Load cards in the Feeder

Printer is out of cards.

Card was not fed into the

4015 CARD NOT INSERTED

5001 OUT OF RIBBON Print ribbon has run out. Load a new roll of print ribbon.

5002 INVALID RIBBON

5003 RIBBON JAM Print ribbon is jammed.

5004 RIBBON MOTION ERROR

5006 RIBBON BEMF ERROR

5007

RIBBON COLOR DETECT ERROR

Manual Feed Slot within 30-second period.

Print ribbon does not match the printer.

Print ribbon is stretched. Recalibrate ribbon torque.

Print ribbon is broken.

Problem with the Back EMF (BEMF) of the ribbon motors.

Print ribbon is not installed correctly.

Cartridge.

2. Re-seat the Feeder Cartridge.

Retry and feed a card into the Manual Feed Slot, or cancel the operation.

Verify the part number of the print ribbon is correct on OCP.

1. Check the print ribbon.

2. Reinstall the print ribbon.

3. Repair the break in the print ribbon and reinstall.

Tape the broken ends of the ribbon together, roll the ribbon around the take-up spool, place the ribbon back in the printer, and power cycle the printer.

Contact Zebra Technical Support.

Reinstall the print ribbon. If reinstalling the ribbon does not solve the problem, contact Zebra Technical Support.

16 ZXP Series 7 Card Printer Service Manual P1036102-007

Page 23

Troubleshooting

OCP Error Messages

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

1. Verify the part number of the print ribbon is correct on OCP.

2. Power cycle the printer, and retry.

Power cycle the printer, and retry.

1. Clear card jam in Feeder Cartridge, and re-seat Feeder Cartridge.

2. Ensure that cards are not stuck together and that they are the correct thickness (10 to 50 mil).

1. Load cards in the Feeder Cartridge.

2. Re-seat the Feeder Cartridge.

Check printhead cable connection, reconnect if loose or disconnected.

Remove the card from the exit area.

Move the printer to a cooler environment, or cool the area of operation.

Move the printer to a warmer environment, or warm the area of operation.

This warning will be cleared when the printer cover is closed.

Power cycle the printer, and retry.

5008 INVALID RIBBON

6001 6008

6009 FLASH ERASE ERROR

6010

6011

6012

6013 INVALID FW S-RECORD

6015 6025

7001 CARD FEED ERROR

7002 CARD CLEAN ERROR

7003

7004 CARD EJECT ERROR

7005 PRINTHEAD TOO HOT

7006 PRINTHEAD TOO COLD

7008 PRINT COVER OPEN

7010

7013

7014

7015 MAG MOTION ERROR

GENERAL MEMORY ERROR

FLASH ERASE VERIFY ERROR

FLASH PROGRAM ERROR

FLASH PROGRAM VERIFY ERROR

GENERAL MEMORY ERROR

PRINTHEAD CABLE ERROR

PRINTHEAD MOTION ERROR

MOTOR VOLTAGE ERROR

SCRIPT PROCESSING ERROR

Print ribbon does not match the printer.

There is a problem when accessing general memory.

There is a problem when

accessing ash memory.

There is a problem when

accessing ash memory.

There is a problem when

accessing ash memory.

There is a problem when

accessing ash memory.

There is a problem when

accessing ash memory.

There is a problem when accessing general memory.

Card is jammed in Feeder Cartridge.

The printer is out of cards.

Printhead cable loose or disconnected.

Card from previous job is stuck in the exit area.

Environmental issue -- the ambient temperature is too hot.

Environmental issue -- the ambient temperature is too cold.

This warning will be displayed if the cover protecting the Printer Module is opened.

Printhead did not move to proper position during initialization.

Incorrect voltage detected at one or several motors in the unit.

Internal logic error. Power cycle the printer, and retry.

This is a magnetic encoding retrace error.

P1036102-007 ZXP Series 7 Card Printer Service Manual 17

Page 24

Troubleshooting

OCP Error Messages

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

1. Ensure that you are using the correct card type.

7018 SMARTCARD ERROR

7019

7020 SCRIPT SEND ERROR Internal logic error. Power cycle the printer, and retry.

7023

7024 OPTIONS CARD JAM

7026 FLIPPER CARD JAM Card is jammed in the Flipper. Clear the card path.

7028 OPTIONS COVER OPEN

7029

7032 SINGLE CARD FEED JAM

7033 FLIPPER BOARD ERROR The Flipper has failed. Contact Zebra Technical Support.

7034

7035 OPTIONS CARD JAM

7036 7039

9001 MAG READ ERROR

SCRIPT CONTENT ERROR

SMART CARD CAM INIT ERROR

FLIPPER ROTATION ERROR

REJECT BIN FULL REMOVE CARDS

PRINT CARD JAM

• Encoding error.

• Faulty card.

Internal logic error. Power cycle the printer, and retry.

Mechanical positioning issue. Power cycle the printer, and retry.

Card is jammed in the Options Module, Feeder Cartridge.

This warning will be displayed if the cover protecting the Options Module is opened.

The Flipper has failed. Contact Zebra Technical Support.

Card is jammed in the Options Module, Single Card Feed Slot.

The Reject Bin is full.

Card is jammed in the Options Module, Magnetic Encoder.

Card is jammed in Printer Module.

• Encoding error.

• Defective magnetic stripe.

2. Check that the cards are loaded in the correct orientation.

3. Ensure that the data conforms to

ISO Specications.

4. Retry writing and reading.

Clear the card path.

This warning will be cleared when the options cover is closed.

Clear the card path.

Remove the cards from the bin, and reset the reject bin card count to 0 via the OCP (Main Menu > Advanced Settings > Clear Reject Bin).

Clear the card path.

1. Ensure that you are using the correct card type.

2. Check that the cards are loaded with the magnetic stripe in the correct orientation.

3. Ensure that the cards are setup correctly in the printer driver (coercivity setting).

4. Ensure that the data conforms to

ISO Specications.

5. Retry reading.

18 ZXP Series 7 Card Printer Service Manual P1036102-007

Page 25

Troubleshooting

OCP Error Messages

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

1. Ensure that you are using the correct card type.

2. Check that the cards are loaded with the magnetic stripe in the

9002 MAG WRITE ERROR

9004 NO MAG STRIPE Magnetic stripe not detected.

10001 CONTACT READ ERROR

10002

11001

11002

15001 MISSING MAB

15002

17001 LAMINATOR MISSING

17002

CONTACT WRITE ERROR

CONTACTLESS READ ERROR

CONTACTLESS WRITE ERROR

MAB FIRMWARE MISSING

LAMINATOR FAILED INITIALIZATION

• Encoding error.

• Defective magnetic stripe.

• Wrong card type is in use.

• Card orientation in the Feeder Cartridge is wrong.

• Smart Card Options Module is incorrectly installed.

• Wrong card type is in use.

• Card orientation in the Feeder Cartridge is wrong.

• Wrong card type is in use.

• Smart Card Options Module is incorrectly installed.

• Wrong card type is in use.

• Smart Card Options Module is incorrectly installed.

An error occurred when reading the RFID Tag by the MAB (Media Authentication Board).

MAB (Media Authentication Board) Firmware is missing.

Laminator was detected by the printer, but was unable to communicate to it.

correct orientation.

3. Ensure that the cards are setup correctly in the printer driver (coercivity setting).

4. Ensure that the data conforms to

ISO Specications.

5. Retry writing.

1. Ensure that you are using the correct card type.

2. Check that the cards are loaded with the magnetic stripe in the correct orientation.

1. Ensure that you are using the correct card type.

2. Check that the cards are loaded with the chip in the correct orientation.

3. Re-seat the Smart Card Options Module.

1. Ensure that you are using the correct card type.

2. Check that the cards are loaded with the chip in the correct orientation.

3. Re-seat the Smart Card Options Module.

1. Ensure that you are using the correct card type.

2. Re-seat the Smart Card Options Module.

1. Ensure that you are using the correct card type.

2. Re-seat the Smart Card Options Module.

1. Check print ribbon orientation.

2. Verify part number of the print ribbon.

3. Power cycle the printer, and retry.

Install the rmware.

Contact Zebra Technical Support.

P1036102-007 ZXP Series 7 Card Printer Service Manual 19

Page 26

Troubleshooting

OCP Error Messages

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

17003

17004

17005

17006

17007

17008

17009

17010

17011

17012

LAMINATOR UNKNOWN ERROR

MISSING LAMINATOR MAB

TOP LAMINATE FEED FAIL

BOTTOM LAMINATE FEED FAIL

TOP LAMINATE REGISTRATION ERROR

LAMINATOR CARD FEED FAIL

LAMINATOR EARLY CARD JAM

LAMINATOR MIDDLE CARD JAM

LAMINATOR LATE CARD JAM

LAMINATOR POLL TIMEOUT

An unknown error has occurred – this is an indication of a FW problem and should not occur.

An error occurred when trying to communicate to the Laminator MAB (Media Authentication Board).

• Top laminate cartridge is not installed properly.

• Cartridge is not removed when that side of the card is not being laminated.

• A mis-cut piece of laminate (rare) is obscuring the media sensor.

• Bottom laminate cartridge is not installed properly.

• Cartridge is not removed when that side of the card is not being laminated.

• Improperly prepared registered laminate.

• Media misfeed.

• Patch length improperly set.

• Unexpected end of laminate roll detected.

Printer has not fed the card far enough into laminator mechanism for infeed rollers to grab it.

Card did not make it to the staging rollers.

Card and laminate have jammed inside heater assembly, often due to mispositioned laminate patch sticking to heated rollers.

Card did not unblock the exit

sensor in the specied time.

The laminator expects the printer to periodically send commands to it within a

specied time period. If it

fails to do so, it assumes that something is wrong with the communication link or that the printer is down. This error may occur if the printer-to-laminator communications is having intermittent problems.

1. Press RETRY on the OCP.

2. Contact Zebra Technical Support.

1. Power cycle the printer, and retry.

2. Contact Zebra Technical Support.

1. Remove, reposition, and re-install the top laminate cartridge.

2. Remove the top laminate cartridge.

3. Remove the mis-cut piece of laminate.

1. Remove, reposition, and re-install the bottom laminate cartridge.

2. Remove the bottom laminate cartridge.

Remove and re-cut laminate in the center of the index notch, re-install, and retry.

Open the Laminator and printer doors to check for jammed/stuck cards.

Remove the card and/or laminate that is stuck in the laminator staging/ cutting area.

Remove the oven, and inspect for stuck cards.

1. Check for card jam in the exit area.

2. Assure that the sliding exit door is not partially blocking the exit path.

Power cycle the printer, and retry.

20 ZXP Series 7 Card Printer Service Manual P1036102-007

Page 27

Troubleshooting

OCP Error Messages

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

Top heater did not turn on after being instructed to do so. When the heater is enabled, the controller

17013

17014

17015

17016

17017

17118

17019

17020

17021

17022

17023 LAMINATOR FAN FAIL

LAMINATOR TOP HEATER FAIL

LAMINATOR BOTTOM HEATER FAIL

LAMINATOR TOP TEMPERATURE HIGH

LAMINATOR BOTTOM TEMPERATURE HIGH

LAMINATOR TOP CUTTER STALL

LAMINATOR BOTTOM CUTTER STALL

LAMINATOR TOP CUTTER FAIL

LAMINATOR BOTTOM CUTTER FAIL

LAMINATOR TOP TEMP SENSOR FAIL

LAMINATOR BOTTOM TEMP SENSOR FAIL

will wait a certain specied

amount of time for it to attain the set target temperature. If the heater fails to reach the

target in the specied time, the

TopHeaterFail fault will be set.

Bottom heater did not turn on after being instructed to do so. When the heater is enabled, the controller

will wait a certain specied

amount of time for it to attain the set target temperature. If the heater fails to reach the

target in the specied time, the

BotHeaterFail fault will be set.

If the top roller temperature

ever exceeds a xed

temperature threshold, the over temp error occurs.

If the bottom roller temperature

ever exceeds a xed

temperature threshold, the over temp error occurs.

Top cutter blade is obstructed, or top cutter mechanism is damaged.

Bottom cutter blade is obstructed, or bottom cutter mechanism is damaged.

Top cutter has failed.

Bottom cutter has failed.

The top temperature (thermopile) sensor has failed.

The bottom temperature (thermopile) sensor has failed.

This should only happen if one or both cooling fans fail or the cooling vents near the heated roller assembly are blocked or the fan(s) have failed.

Replace the top halogen bulb.

Replace the bottom halogen bulb.

1. Power cycle the printer, and retry.

2. If this error persists, contact Tech Support.

1. Power cycle the printer, and retry.

2. If this error persists, contact Tech Support.

If this error persists, contact Tech Support.

Check for blocked vents.

P1036102-007 ZXP Series 7 Card Printer Service Manual 21

Page 28

Troubleshooting

OCP Error Messages

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

The parameters stored in EEPROM have been reset to their default values. This will not normally happen, but

17024

17026

17027 TOP LAMINATE OUT The top laminate has run out. Load new roll of laminate.

17028 BOTTOM LAMINATE OUT

17029 INVALID TOP LAMINATE

17030

17031

17032 REMOVE TOP LAMINATE

17033

17034

17038

17040

17041

LAMINATOR EEPROM DEFAULT

TOP AND BOTTOM LAMINATES OUT

INVALID BOTTOM LAMINATE

BOTTOM LAMINATE REGISTRATION ERROR

REMOVE BOTTOM LAMINATE

REMOVE TOP AND BOTTOM LAMINATES

LAMINATOR COVER OPEN

LAMINATOR INITIALIZING

LAMINATOR FIRMWARE MISSING

could be seen with certain FW upgrades when new parameters have been added by Engineering. It could also indicate a problem with the Laminator’s EEPROM.

The top and bottom laminates have run out.

The bottom laminate has run out.

Laminate does not match the printer.

Laminate does not match the type allowed in the laminator or top and/or bottom has been swapped.

• Improperly prepared registered laminate.

• Media misfeed.

• Patch length improperly set.

• Unexpected end of laminate roll detected.

Top laminate is installed when the driver lamination mode “Bottom” is selected.

Bottom laminate is installed when the driver lamination mode “Top” is selected.

Top and bottom laminates are installed when the driver lamination mode “Pass through” is selected.

This warning will be displayed if the cover protecting the laminator is opened.

This warning will be displayed after the laminator door is closed and laminate spools are re-read/detected.

Laminator Controller Board (LCB) Firmware is missing.

1. Press RETRY on the OCP when this error occurs.

2. Power cycle the printer, and retry.

Load new rolls of laminate.

Load new roll of laminate.

1. Verify the part number of the laminate is correct on OCP.

2. Power cycle the printer, and retry.

1. Verify that the top and bottom laminate cassettes are installed in the correct locations.

2. Verify the part number of the laminate is correct on OCP.

3. Power cycle the printer, and retry.

Remove and recut laminate in the center of the index notch, re-install, and retry.

Remove the top laminate cassette.

Remove the bottom laminate cassette.

Remove both laminate cassettes.

This warning will be cleared when the laminator cover is closed.

No action needed

Install the rmware.

22 ZXP Series 7 Card Printer Service Manual P1036102-007

Page 29

Troubleshooting

OCP Error Messages

CODE MESSAGE POSSIBLE CAUSE POSSIBLE SOLUTION

17042

18001

19001 WIFI COMM ERROR Hardware failure. Replace the Wireless PCBA.

19002

19003 WIFI LINK LOST Network failure.

19004

19005

19006

20001 BARCODE ERROR INIT

20002 BARCODE ERROR READ

20003

LAMINATOR MAB FIRMWARE MISSING

ETHERNET COMM ERROR

WIFI ACCESS POINT MISSING

WIFI INCOMPATIBLE NETWORK

WIFI ASSOCIATION FAILED

WIFI CONNECTION FAILED

BARCODE ERROR NO DATA

Laminator MAB (Media Authentication Board) Firmware is missing.

Ethernet connection failed. Check network connectivity.

Network failure.

The Barcode Scanner Assembly may be incorrectly installed or defective.

Communications problem with the Barcode Scanner Assembly.

Cannot read the barcode.

Install the rmware.

Attempt to reconnect to the Access Point (AP).

Check the Barcode Scanner Assembly.

1. Check for defective barcode on the card being read.

2. Check the orientation of the cards in the Feeder cartridge.

3. The barcode is printed in the wrong location.

P1036102-007 ZXP Series 7 Card Printer Service Manual 23

Page 30

Troubleshooting

OCP Error Messages

21001 STACKER MISSING

21002

21003 STACKER INIT ERROR

21004 STACKER CARD JAM

21005

21006 STACKER COMM ERROR

21010 STACKER FW MISSING

STACKER UNAUTHORIZED

STACKER ELEVATOR JAM

Stacker is missing but is

congured to have it. Stacker

may have been removed or communication has been lost between stacker and main logic board. Printer will still print, however no cards will stack.

Stacker has been found but has not been enabled. Printer will not print until stacker is enabled.

Something mechanically has prevented the stacker from fully initializing. Printer will not print.

Card has jammed at the stacker entry sensor. Printer will not print.

Elevator jam in which the elevator has not detected the home position. Could be the possibility of a faulty cam sensor for elevator, a card jam, or too many card in the hopper. Printer will not print.

Cannot communicate between printer and hopper. Printer will

not print until error is xed.

Firmware corrupt or missing. Printer will not print until

stacker rmware is installed

and power is cycled.

Replace the stacker. The printer

conguration will recognize the

stacker and operate normally.

Remove the stacker. The printer

must be congured at the factory

to recognize the stacker. Once the stacker is removed, the printer will operate normally.

Check the card path. Remove the high-capacity output hopper from the stacker and clear any obstruction.

Clear the card jam.

1. Replace cam sensor.

2. Check the stacker card path for jammed or stuck cards.

3. Remove nished cards from the hopper.

Cycle printer power. Check connections between printer and stacker.

Update printer and stacker rmware.

24 ZXP Series 7 Card Printer Service Manual P1036102-007

Page 31

OCP Test Cards

Image Title Description Use

Troubleshooting

OCP Test Cards

GRADIENT BOXES

DENSITY SETUP

MONOCHROME ONLY Barcode and text

3 sets of light-to-dark grayscale ramps

Mid-gray and maximum

density elds on a at gray

surface

For factory use only.

Used to measure mid and max densities. Also used to check the left/right offsets or the centering of the image on the card.

Used to verify monochrome print capability.

Also used to check the left/right osets or the centering of the image on the card.

P1036102-007 ZXP Series 7 Card Printer Service Manual 25

Page 32

Troubleshooting

Ethernet

• Indicators -- Detail

• Link Speed Indicator (Orange)

O No link (disconnected)

1 Blink The LED blinks once (one blink, pause, one blink,

etc.) when a 10Base link has been established.

2 Blinks The LED blinks twice (two blinks, pause, two blinks,

etc.) when a 100Base link has been established.

• Link Activity Indicator (Green)

O No link (disconnected)

On Network link has been established

Blinking Network activity has been detected

• Issues

If both LEDs are o, the printer has not detected the presence of a network cable. To solve the problem:

• Verify that the network cable is appropriate and has an RJ-45 connector.

• Remove the network cable from the printer. Plug the network cable back in until you hear a positive click. Check the other end of the cable in the same manner. If the printer still does not detect a cable, then continue.

• Connect the printer to a known good network. If the printer is still unable to detect the network cable, contact Technical Support for assistance.

26 ZXP Series 7 Card Printer Service Manual P1036102-007

Page 33

Introduction

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

Replacement Procedures

for the Printer

In general, only removal directions are presented. Unless otherwise noted, replacement would be performed by reversing the removal steps. Replacement instructions for some common or simple procedures are not presented.

For a complete listing of Spare Part Kits and Upgrade Kits available for the Zebra ZXP Series 7 Card Printer, see the ZXP Series 7 Spare Parts Catalog at www.zebra.com/

parts.

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 • All replacement procedures must be performed at a staticfree work station, an anti-static wrist strap must be worn and properly terminated, or other appropriate protection must be used.

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 additional parts removed in addition to removals for the process being described.

P1036102-007 ZXP Series 7 Card Printer Service Manual 27

Page 34

Replacement Procedures for the Printer

Required Tools

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

• Flat-blade Screwdrivers: from 1/16 inch (1.5 mm) to 1/4 inch (6.5 mm)

• Phillips Screwdrivers: #0, #1, and #2

• TORX T8, T9, and T10 (standard, 12-inch shaft, and/or ball-end; magnetic tip recommended)

• Fine-Point, Oset Fine-Point, and Needle-Nose Pliers

• Small Diagonal Cutters or other cutter for cutting cable ties

• 5.5 mm nut driver (this can also be used for securing push nuts)

• 3–10 mm E-Ring Clip Tool

• Small and Medium Spring Hooks

• Adjustable Wrench

• Multimeter

• Loctite® 242

The following list speciﬁes the Zebra Special-Purpose Tools required to calibrate speciﬁc parts/assemblies reinstalled in selected procedures. Note that the Zebra Part Number is in parentheses following the description.

• Torque Tools for RTU Motor Calibration ZXP7 (P1037750-400)

This kit is comprised of a High Torque Tool and a Low Torque Tool. The recommended calibration cycle for these tools is 50 uses or every 6 months. Please return your torque tools to the nearest Zebra Repair Center for calibration; or see

page 187 for torque tool calibration instructions.

• Print Head Cam Sync Fixture ZXP7 (P1037750-401).

• Flipper Deck Level (P1037750-402).

• Contact Station Upgrade Tool (P1037750-403).

• AC Power Filter Release Tool (P1037750-404).

• Mag Tensioning Spring Tool (included with all magnetic encoder upgrade kits).

• Gates Sonic Tension Meter 507C. Note that this item is not being sold by Zebra.

• Kit Service CD / ZXP7 (P1037750-090).

• ZMotif Service Partner Tool (SW0000194)

28 ZXP Series 7 Card Printer Service Manual P1036102-007

Page 35

Removal Sequence

The following ﬁgures 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 control panel door open sensor, remove the back cover, the options cover, and the right cover.

Replacement Procedures for the Printer

Removal Sequence

“Ribbon

Drawer” on

page 40

“Left Side Cover” on

page 63

“Belt and

Gear Panel”

on page 64

“Reject Bin” on page 32

“Back Cover”

on page 45

“Ethernet

PCBA” on

page 76

“Rear Feeder

Cover” on

page 46

“Print Cover”

on page 58

“Door Button

and Latch” on

page 60

“Bottom

Cover” on

page 66

“Main PCBA”

on page 73

“Ground

Plate” on

page 145

“Right Cover”

on page 51

“Lock Replacement

for Right Cover” on

“Control Panel Door

Open Sensor” on

“Options

Cover” on

page 47

page 53

page 57

“Card Guides”

on page 42

“OCP PCBA”

on page 49

“Printer” on page 69

P1036102-007 ZXP Series 7 Card Printer Service Manual 29

Page 36

Replacement Procedures for the Printer

Removal Sequence

Printer

“Printer” on page 30

Feeder Module

“Print Engine”

on page 77

Assembly” on page

“Feeder

Module” on

page 149

“Torque Tools Calibration

Instructions” on page

Options Assembly”

“Feeder/Flipper

142

187

“Feeder/Flipper/

on page 137

“Flipper

Module” on

page 157

“Options

Module” on

page 180

“Feeder

Module” on

page 149

“Feeder

Motor” on

page 155

“Drive Assembly

Feeder” on page

149

30 ZXP Series 7 Card Printer Service Manual P1036102-007

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Flipper Module

Replacement Procedures for the Printer

Removal Sequence

“ESD Brush” on page 159

“Flipper

PCBA” on

page 161

“Flipper

Module” on

page 157

“Flipper

Position

Sensor” on

page 163

“Flipper

Assembly” on

page 157

“Flipper

Rotation

Gear” on

page 164

“85/35T Gear”

on page 166

“Flipper

Rotation Motor” on page 167

“Flexible Roller” on page 169

“Flipper Drive

Motor” on page 168

Options Module

“Drive Platen

Roller” on page 183

“Flipper Deck Platen Roller”

on page 176

“Options

Module” on

page 180

“Card Sensor”

on page 180

“Card Present

On Flipper Sensor” on

page 178

“Options

Motor” on page 182

P1036102-007 ZXP Series 7 Card Printer Service Manual 31

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Replacement Procedures for the Printer

Procedures: Reject Bin

Procedures

Reject Bin

Step 1. Locate the Reject Bin (circled below).

Step 2. Slide the Reject Bin out of the Printer until it stops.

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Replacement Procedures for the Printer

Procedures: Reject Bin

Step 3. Using two ﬁngers, simultaneously, depress the two locking tabs (arrows

below) that prevent the Reject Bin from being removed.

Step 4. Slide the Reject Bin out of the Printer, and set it aside.

P1036102-007 ZXP Series 7 Card Printer Service Manual 33

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Replacement Procedures for the Printer

Procedures: Feeder Cartridge

Feeder Cartridge

This is the replacement kit for the Standard Feeder Cartridge (i.e., the entire assembly).

Feeder Cartridge Cover

Step 1. With a Flat-blade screwdriver, carefully press the pivot arm in (arrow below)

to free the tab and thereby releasing the Feeder Cartridge Cover.

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Replacement Procedures for the Printer

Procedures: Feeder Cartridge

Step 2. Set the Feeder Cartridge Cover aside.

Retainer for Feeder Cartridge

Step 1. Lift the Retainer slightly; then slide it forward, up, and out of the Feeder

Cartridge—see arrows below.

P1036102-007 ZXP Series 7 Card Printer Service Manual 35

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Replacement Procedures for the Printer

Procedures: Feeder Cartridge

Step 2. Remove the Spring (under the Retainer).

Step 3. Set the Retainer and Spring aside.

Lock Replacement for Security Feeder Cartridge

Step 1. With a TORX T10 driver, remove the ﬁve screws on the bottom of the Feeder

Cartridge; arrows below.

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Replacement Procedures for the Printer

Procedures: Feeder Cartridge

Step 2. With a TORX T10 driver, remove the two screws holding the Side Cover in

place; arrows below.

Step 3. Separate the Feeder Cartridge into its three components: Top Cover, Bottom

Cover, and Side Cover.

Step 4. With an adjustable wrench, remove the small nut from the Lock Assembly in

the Side Cover.

P1036102-007 ZXP Series 7 Card Printer Service Manual 37

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Replacement Procedures for the Printer

Procedures: Feeder Cartridge

Step 5. Remove the Lock Pawl; arrow below. Note the orientation of the Lock Pawl.

Step 6. With an adjustable wrench, remove the large nut (arrow below).

Step 7. Remove the Lock Assembly, and set it aside.

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Replacement Procedures for the Printer

Procedures: Feeder Cartridge

Reassembly

Step 1. For proper lock orientation, install the replacement lock with key inserted

slightly, teeth up.

Step 2. Continue installing the replacement Lock Assembly by reversing the

removal steps.

Step 3. Reassemble the Feeder Cartridge as follows:

a. Fit the Side Cover into the slots in the Bottom Cover; ensure that the rod

ﬁts into the alignment hole in the Side Cover.

b. With a TORX T10 driver, install the two screws holding the Side Cover in

place.

c. Fit the Top Cover onto the Bottom Cover; the pieces will “snap” together.

d. With a TORX T10 driver, install the ﬁve screws on the bottom of the

Feeder Cartridge.

P1036102-007 ZXP Series 7 Card Printer Service Manual 39

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Replacement Procedures for the Printer

Procedures: Ribbon Drawer

Ribbon Drawer

Step 1. Open the Print Cover.

Step 2. If a ribbon is installed, remove the ribbon.

Step 3. Slide the Ribbon Drawer out of the Printer until it stops.

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Replacement Procedures for the Printer

Procedures: Ribbon Drawer

Step 4. Depress the two locking tabs (one on each side) to free the Ribbon Drawer.

Step 5. Slide the Ribbon Drawer out of the Printer, and set it aside.

P1036102-007 ZXP Series 7 Card Printer Service Manual 41

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Replacement Procedures for the Printer

Procedures: Card Guides

Card Guides

Step 1. Remove the Ribbon Drawer (page 40).

Step 2. Locate the Card Guides.

Note • To facilitate reassembly, mark the Card Guides appropriately upon removal;

e.g., left, top; and right, top.

Step 3. With a Flat-blade screwdriver, free the Left Card Guide; it snaps into place.

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Replacement Procedures for the Printer

Procedures: Card Guides

Step 4. With a Flat-blade screwdriver, free the Right Card Guide; it snaps into place.

Step 5. Set the Card Guides aside.

P1036102-007 ZXP Series 7 Card Printer Service Manual 43

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Replacement Procedures for the Printer

Procedures: Shroud for Options

Shroud for Options

Step 1. Open the Options Cover.

Step 2. Depress the two tabs (one on each side) to unlock the Shroud.

Step 3. Lift the Shroud up and out of the Printer, and set it aside.

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Back Cover

Step 1. With a TORX T10 driver, remove the three screws holding the Back Cover in

Replacement Procedures for the Printer

Procedures: Back Cover

place. Use an 8-inch tapered bit TORX T10 driver for the screw on the left.

Step 2. Remove the Back Cover, and set it aside.

P1036102-007 ZXP Series 7 Card Printer Service Manual 45

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Replacement Procedures for the Printer

Procedures: Rear Feeder Cover

Rear Feeder Cover

Step 1. With a TORX T10 driver, remove the left screw holding the Rear Feeder

Cover in place.

Step 2. With a TORX T10 driver, remove the right screw and washer holding the Rear

Feeder Cover in place.

Step 3. Remove the Rear Feeder Cover, and set it aside.

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Options Cover

Step 1. If not already done, remove the Cleaning Cartridge and Cleaning Cassette.

Replacement Procedures for the Printer

Procedures: Options Cover

Step 2. With a TORX T10 driver, remove the two screws holding the Options Cover

in place.

P1036102-007 ZXP Series 7 Card Printer Service Manual 47

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Replacement Procedures for the Printer

Procedures: Options Cover

Step 3. Disconnect the OCP cable connection.

Step 4. Remove the Options Cover, and set it aside.

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OCP PCBA

Step 1. With a TORX T10 driver, remove the ﬁve screws holding the Faceplate to the

Step 2. Set the Faceplate aside.

Replacement Procedures for the Printer

Procedures: OCP PCBA

Options Cover;.

Step 3. With a TORX T10 driver, remove the two screws holding the OCP PCBA to

the Options Cover.

P1036102-007 ZXP Series 7 Card Printer Service Manual 49

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Replacement Procedures for the Printer

Procedures: OCP PCBA

Step 4. Remove the OCP PCBA.

Step 5. Disconnect the Plug at J2 (circled above).

Step 6. Set the OCP PCBA aside.

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Right Cover

Step 1. From the front of the Printer: With a TORX T10 driver, remove the two screws

Replacement Procedures for the Printer

Procedures: Right Cover

holding the Right Cover in place.

Step 2. From the back of the Printer: With a TORX T10 driver, remove the two screws

holding the Right Cover in place.

P1036102-007 ZXP Series 7 Card Printer Service Manual 51

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Replacement Procedures for the Printer

Procedures: Right Cover

Step 3. Disconnect the Control Panel Door Open Sensor at connector J12 on the

FLIPPER MODULE PCBA.

Step 4. Carefully cut the cable tie to free the sensor cable.

Step 5. Remove the Right Cover.

Step 6. Set the Right Cover aside.

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Replacement Procedures for the Printer

Procedures: Right Cover

Lock Replacement for Right Cover

Step 1. With a TORX T10 driver, remove the ﬁve screws holding the Inner Cover to

the Right Cover; arrows below.

Step 2. Separate the Inner Cover from the Right Cover, and set the Inner Cover

aside.

Step 3. Remove the Reject Bin Lock Lever and Spring; dashed arrows below. Note

the position of the spring legs.

P1036102-007 ZXP Series 7 Card Printer Service Manual 53

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Replacement Procedures for the Printer

Procedures: Right Cover

Step 4. With an adjustable wrench, remove the small nut from the Lock Assembly;

arrow below.

Step 5. Remove the Right Lock Pawl; arrow #1 below. Note the orientation of the

Lock Pawl.

Step 6. With an adjustable wrench, remove the large nut; arrow #2 above.

Step 7. Remove the Lock Assembly, and set it aside.

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Replacement Procedures for the Printer

Procedures: Right Cover

Reassembly

Step 1. Install the replacement lock with key inserted slightly, teeth up.

Step 2. With an adjustable wrench, install and tighten the large nut holding the Lock

Assembly in place.

Step 3. Install the Right Lock Pawl, and install and loosely tighten the small nut

holding the Right Lock Pawl in place.

Step 4. Install the Spring.

P1036102-007 ZXP Series 7 Card Printer Service Manual 55

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Replacement Procedures for the Printer

Procedures: Right Cover

Step 5. Set the Reject Bin Lock Lever in place.

Step 6. Set a 10-mil card between the Reject Bin Lock Lever and the Cover Guide,

arrows below; then tighten the small nut (loosely tightened in Step 3).

10-MIL Gap

Step 7. Remove the 10-mil card.

Step 8. Reassemble the Inner Cover and the Right Cover

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Replacement Procedures for the Printer

Procedures: Right Cover

Control Panel Door Open Sensor

Step 1. With a TORX T10 driver, remove the ﬁve screws holding the Inner Cover to

the Right Cover.

Step 2. Remove the Inner Cover.

Step 3. With a TORX T8 driver, remove the two screws holding the Sensor in place;

and set the Sensor (and cable) aside.

P1036102-007 ZXP Series 7 Card Printer Service Manual 57

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Replacement Procedures for the Printer

Procedures: Print Cover

Print Cover

Step 1. If not already done, open the Print Cover.

Step 2. With a small Flat-blade screwdriver, carefully remove the left-side E-ring

holding the shaft in place.

Step 3. Slide the shaft out of the print cover brackets.

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Replacement Procedures for the Printer

Procedures: Print Cover

Step 4. Free the two springs (right side and left side of the Print Cover). Note that

you may need to use needle-nose pliers.

Step 5. Slide the cover to the rear thereby freeing the left and right guide pins from

their respective guides.

Step 6. Set the Print Cover (and two springs) aside.

Replacement

Note • the springs go in the slots on the Print Cover when reassembling.

P1036102-007 ZXP Series 7 Card Printer Service Manual 59

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Replacement Procedures for the Printer

Procedures: Door Button and Latch

Door Button and Latch

Step 1. With a TORX T10 driver, remove the six screws holding the Door Enclosure

and Door Frame together.

Step 2. Separate the Door Enclosure from the Door Frame.

Step 3. Remove the Door Button (arrow above).

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Replacement Procedures for the Printer

Procedures: Door Button and Latch

Step 4. With a TORX T10 driver, remove the two screws holding the Upper Bearings

in place.

Step 5. Remove the Upper Bearings.

P1036102-007 ZXP Series 7 Card Printer Service Manual 61

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Replacement Procedures for the Printer

Procedures: Door Button and Latch

Step 6. With a small Flat-blade screwdriver, release and remove the two latch

springs (solid arrows below). There is a LEFT and RIGHT latch spring; note the orientation of each spring.

Step 7. Remove the Latch (dashed arrow above), and set it aside.

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Left Side Cover

Step 1. From the front of the Printer: With a TORX T10 driver, remove the two screws

holding the Left Cover in place.

Replacement Procedures for the Printer

Procedures: Left Side Cover

Step 2. From the back of the Printer: With a TORX T10 driver, remove the two screws

holding the Left Cover in place.

Step 3. Remove the Left Cover, and set it aside.

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Replacement Procedures for the Printer

Procedures: Belt and Gear Panel

Belt and Gear Panel

Step 1. With a TORX T10 driver, remove the four front screws holding the Belt and

Gear Panel in place.

Step 2. Remove the Belt and Gear Panel, and set it aside.

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Replacement Procedures for the Printer

Procedures: Belt and Gear Panel

Plunger and Spring Assemblies

Step 1. Press each Plunger in, and rotate it counterclockwise. This will free the

assembly.

Step 2. Set the Plungers and associated Springs aside.

P1036102-007 ZXP Series 7 Card Printer Service Manual 65

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Replacement Procedures for the Printer

Procedures: Bottom Cover

Bottom Cover

Step 1. With a TORX T10 driver, remove the eight screws holding the Bottom Cover

in place.

Step 2. Carefully move the Bottom Cover away from the Printer. Note the green

ground wire attached.

Step 3. With a 5.5-mm nut driver, remove the nut holding the ground wires to the

ground lug; then remove the ground wire.

Step 4. Remove the Bottom Cover.

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Feet

Replacement Procedures for the Printer

Procedures: Feet

Step 1. With a Flat-blade screwdriver, carefully loosen each Foot. Note that the feet

are attached with adhesive.

Step 2. Set the Feet aside.

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Replacement Procedures for the Printer

Procedures: Reject Bin Bracket

Reject Bin Bracket

Step 1. Locate the Reject Bin Bracket (arrow below).

Step 2. With a TORX T10 driver, remove the four screws holding the Reject Bin

Bracket in place.

Step 3. Remove the Reject Bin Bracket, and set it aside.

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Printer

The Printer is comprised of three assemblies: the Print Engine, the Feeder/Flipper Module, and the Options Module. This section details the steps required to separate the Print Engine from the Feeder/Flipper/Options Assembly.

Replacement Procedures for the Printer

Procedures: Printer

PRINT ENGINE OPTIONS

FLIPPER /

FEEDER

Step 1. With a 5.5-mm nut driver, remove the two nuts (circled below) holding the

print engine ground wires in place.

Step 2. Remove the ground wires connecting the Print Engine with the Options

Module.

P1036102-007 ZXP Series 7 Card Printer Service Manual 69

Page 76

Replacement Procedures for the Printer

Procedures: Printer

Step 3. For printers with a Mag Encoder and/or Smart Card Encoder: Disconnect

connectors J112 and/or J4 (arrows below). Note that these connectors have locking tabs; use a small Flat-blade screwdriver to unlock the tabs.

J112J4

Step 4. Disconnect connectors J5 and J7 from the FLIPPER MODULE PCBA (arrows

below).

Step 5. With a 5.5-mm nut driver, remove ground wires from the L-shaped ground

plate (circled above).

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Replacement Procedures for the Printer

Procedures: Printer

Step 6. Turn the printer on its side so that you can access the Main PCBA.

Step 7. Disconnect connector J21 from the Main PCBA (arrow above).

Step 8. From the top of the Printer: With a long TORX T10 driver, remove the two

screws holding the modules together. Use an 8-inch tapered bit or ball-end TORX T10 driver for the lower screw.

P1036102-007 ZXP Series 7 Card Printer Service Manual 71

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Replacement Procedures for the Printer

Procedures: Printer

Step 9. From the front of the Printer: With a TORX T10 driver, remove the two screws

holding the modules together.

Step 10. Lift the Feeder/Flipper/Options Assembly, and slide it to the right.

Step 11. Disconnect the two ground wires and cut the cable tie.

Step 12. Separate the Print Engine from the Feeder/Flipper/Options Assembly.

PRINT ENGINE OPTIONS

FLIPPER /

FEEDER

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Main PCBA

Important • A conﬁguration ﬁle, NVM_bkup_< printer serial number >.xml, is saved when the driver and printer are ﬁrst installed. If the Main PCBA is not functional, you can use that ﬁle to restore the printer settings.

Preparation

Before you replace the Main PCBA, save the printer conﬁguration settings.

• NVMEM (Non-Volatile Memory): This control is used to back up NVMEM to XML for importing back into the printer. This does a full restore of all printer settings and calibration data; e.g., ribbon torque, program values, MAC address, etc.

Replacement Procedures for the Printer

Procedures: Main PCBA

Use this control when replacing the Main PCBA (MCB):

Step 1. Use the ZXP Toolbox (accessible from Printer Preferences) to save the

printer settings.

Step 2. Select Save/Restore from the menu list.

Step 3. Click Save.

Step 4. In the ﬁle save dialog, enter a name for your settings ﬁle and click Save.

P1036102-007 ZXP Series 7 Card Printer Service Manual 73

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Replacement Procedures for the Printer

Procedures: Main PCBA

Removal

Step 1. Disconnect all the connectors to the Main PCBA. Cut cable ties as required.

Step 2. With a Phillips #2 screwdriver, remove the three screws holding the Main

PCBA in place.

Step 3. With a Phillips #1 screwdriver, remove the ﬁve screws holding the Shield and

Main PCBA in place; and set the Main PCBA and Shield aside.

Step 4. Carefully pull the PCBA o the mounting posts.

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Replacement Procedures for the Printer

Procedures: Main PCBA

Firmware Update

Step 1. Download the latest ﬁrmware from the Zebra web site (www.zebra.com)

under Support & Downloads.

Step 2. Use the ZXP Toolbox (accessible from Printer Preferences) to update the

printer ﬁrmware.

Step 3. Select Firmware and Lookup Tables from the menu list.

Step 4. Click Browse.

Step 5. In the ﬁle open dialog, locate the ﬁrmware (BIN ﬁle type) that was

downloaded in Step 1.

Step 6. The update process will begin automatically—do not close the Toolbox

window or turn o the printer until the update is complete.

P1036102-007 ZXP Series 7 Card Printer Service Manual 75

Page 82

Replacement Procedures for the Printer

Procedures: Ethernet PCBA

Ethernet PCBA

Step 1. With a Phillips #0 screwdriver, remove the four screws holding the Ethernet

PCBA to the Main PCBA.

Step 2. Remove the Ethernet PCBA, and set it aside.

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Print Engine

Cooling Fan

Step 1. With a TORX T10 driver, remove the four screws holding the Cooling Fan in

Replacement Procedures for the Printer

Procedures: Print Engine

place.

Step 2. Remove the Cooling Fan, and set it aside.

P1036102-007 ZXP Series 7 Card Printer Service Manual 77

Page 84

Replacement Procedures for the Printer

Procedures: Print Engine

Power Supply

Step 1. Disconnect the input power and ground connections at the Power Switch;

circled below.

Step 2. Disconnect J7 (DCPWR) from the Main PCBA; arrow below.

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Replacement Procedures for the Printer

Procedures: Print Engine

Step 3. With a TORX T10 driver, remove the four screws holding the Power Supply in

place.

Step 4. Remove the Power Supply, and set it aside.

P1036102-007 ZXP Series 7 Card Printer Service Manual 79

Page 86

Replacement Procedures for the Printer

Procedures: Print Engine

Print Engine Ground Plate

Step 1. With a TORX T10 driver, remove the three screws holding the Print Engine

Ground Plate in place—see arrows below.

Step 2. With a 5.5-mm nut driver, remove all nuts and associated ground wires.

Step 3. Remove the Print Engine Ground Plate, and set it aside.

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Replacement Procedures for the Printer

Procedures: Print Engine

Printhead Assembly

Step 1. Pull the Printhead Assembly and Printhead Housing out of the Print Engine.

Step 2. Push the Printhead Assembly into the Printhead Housing, then pull it up and

out of the Printhead Housing.

Caution • Pulling the Printhead Assembly too far out of the Printhead Housing may break the wire connected to the ground lug (circled below).

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Replacement Procedures for the Printer

Procedures: Print Engine

Step 3. With a small Flat-blade screwdriver, carefully disconnect the Printhead

Power and Data Cable, and then remove the Ground (circled below).

Step 4. Set the Printhead Assembly aside.Set the Printhead Assembly aside.

Replacement

Replacement is performed by reversing the removal steps.

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Replacement Procedures for the Printer

Procedures: Print Engine

Test and Adjustment

Printhead Serial Number and Resistance Change

Note • Access to Print Head options (Serial Number and Resistance) is controlled via Advanced Security > Security Roles.

After replacing the Printhead, you will need to change the printhead serial number and resistance value stored in the printer. The new value is located on the label applied to the Printhead; e.g., R=3662.

Step 1. Select Start > Devices and Printers, right-click on the Zebra ZXP Series 7

Card Printer listing, and select Printer Properties > Device Information. Click on the ZXP Toolbox button.

Step 2. From the ZXP Toolbox, select Conﬁguration > Printer Settings.

Step 3. In the Printhead > Serial Number and Resistance ﬁelds (circled above),

enter the serial number and resistance of the replacement Printhead. The new resistance value is located on the label applied to the Printhead; e.g., R=3380.

Step 4. Click on the Save Settings button.

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Page 90

Replacement Procedures for the Printer

Procedures: Print Engine

Power Adjustment

Step 1. Print a card.

Step 2. If card is too dark or too light in comparison with the previously used

printhead, access the ZXP Toolbox.

Select Start > Devices and Printers, right-click on the Zebra ZXP Series 7 Card Printer listing, and select Printer Properties > Device Information. Click on the ZXP Toolbox button.

Step 3. From the ZXP Toolbox, go to Printer Settings, select Advanced Settings, then

select the Mechanical and Power Adjustment tab.

Step 4. In the Power Adjustment section (circled below), adjust the settings as

follows:

• If the card is too dark, decrease the appropriate power settings (1% increments recommended).

• If the card is too light, increase the appropriate power settings (1% increments recommended).

Typically, the following adjustments should be set to the same value; individual adjustments can be made as required:

• Yellow, Magenta, and Cyan

• K-resin front and K-resin back

• K-dye and Overlay (the overlay option should be disabled with a laminator)

• UV front and UV back

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Replacement Procedures for the Printer

Procedures: Print Engine

Printhead Housing Assembly

Printhead Housing

Step 1. Remove the Printhead Assembly from the Printhead Housing Assembly

(page 81).

Step 2. Pull the Printhead Power and Data Cable out of the Printhead Housing.

Step 3. Unplug the ribbon sensor cable-to-cable connection.

Step 4. Set the Printhead Housing Assembly aside.

Printhead Latch Assembly

Step 1. When the slot is in the vertical position, the Printhead Latch is locked.

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Page 92

Replacement Procedures for the Printer

Procedures: Print Engine

Step 2. With a Flat-blade screwdriver, rotate the slot 90o counter-clockwise to

unlock the Printhead Latch.

Step 3. Slide the Latch out of the housing, and remove the Spring.

Printhead Lift Spring Assembly

Step 1. Remove the eight screws holding the Printhead Front Cover in place. Note

the in-lb torque dierence for Steps a and b.

a. With a TORX T10 driver, remove the “outside” four screws.

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Replacement Procedures for the Printer

Procedures: Print Engine

b. With a TORX T10 driver, remove the “inside” four screws.

Step 2. Locate the Printhead Lift Spring Assembly.

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Page 94

Replacement Procedures for the Printer

Procedures: Print Engine

Step 3. Remove the spring, lift, pulley, and dowel.

Ribbon Sensor

Step 1. With a TORX T10 driver, remove the two screws holding the Ribbon Sensor

Assembly (sensor housing and sensor) in the Printhead Housing Assembly.

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Replacement Procedures for the Printer

Procedures: Print Engine

Step 2. Unplug the ribbon sensor cable-to-cable connection, and set the Ribbon

Sensor Assembly aside.

Covers for Printhead

Printhead Front Cover

Step 1. Remove the eight screws holding the Printhead Front Cover in place. Note

the in-lb torque dierence for Steps a and b.

a. With a TORX T10 driver, remove the “outside” four screws.

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Replacement Procedures for the Printer

Procedures: Print Engine

b. With a TORX T10 driver, remove the “inside” four screws.

Step 2. Remove the Printhead Front Cover.

Step 3. Unplug the door open sensor cable-to-cable connection.

Step 4. With a TORX T8 driver, remove the screw holding the Door Open Sensor in

place.

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Replacement Procedures for the Printer

Step 5. Remove the Door Open Sensor, and set it aside.

Procedures: Print Engine

Printhead Back Cover

Step 1. Remove the screw holding the cable harness anchor in place.

Step 2. Cut the cable ties as required to free the cable harness.

Step 3. Disconnect J5 (printhead power) and J29 (printhead data) from the Main

PCBA.

Step 4. Disconnect the Cooling Fan.

Step 5. With a TORX T10 driver, remove the four screws holding the Printhead Back

Cover in place.

Step 6. Remove the Printhead Back Cover.

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Replacement Procedures for the Printer

Procedures: Print Engine

Step 7. Set the Front and Back Covers aside.

Ribbon Spindles

Step 1. Open the Print Cover.

Step 2. Remove the Ribbon Drawer.

Step 3. With a TORX T10 driver, remove the screws holding the Spindles in place.

When replacing the screws, use Loctite 242. In the ﬁgure below, parts have been removed for clarity.

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Replacement Procedures for the Printer

Step 4. Remove the Spindles, and set them aside.

Replacement

Procedures: Print Engine

The spindles need to be rotated to engage the ﬂat on the shaft.

Ribbon Supply Spindle Assembly

Media Authentication PCBA (MAB)

Step 1. Locate the Media Authentication PCBA.

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Replacement Procedures for the Printer

Procedures: Print Engine

Step 2. Disconnect J4 and J5 (arrows below).

Step 3. With a TORX T10 driver, remove the two screws holding the Media

Authentication PCBA in place; circled above.

Step 4. Remove the Media Authentication PCBA, and set it aside.

Spindle Clutch Assembly

Step 1. Remove the retaining ring/clip (circled below).

Step 2. With a TORX T10 driver, remove the four screws holding the Bearing Plate in

place—see arrows above.

Step 3. Remove the Bearing Plate, and set it aside.

94 ZXP Series 7 Card Printer Service Manual P1036102-007