Maintenance Manual

Model P520

© 2003 ZIH Corp. All rights reserved 980327-002A

FOREWORD
This manual contains service and repair information for P520 Card Printers manufactured
by Zebra Technology Corporation, Camarillo, California. The contents include maintenance,
diagnosis and repair information.

TECHNICAL SUPPORT
For technical support, users should first contact the distributor that originally sold the
product—phone +1 (800) 344 4003 to locate the nearest Eltron Products Distributor. Eltron
Products offers the following:

U.S.A Europe Asia Latin America

http://www.eltron.com
Internet
ftp://ftp.eltron.com
e-mail [email protected] [email protected] [email protected] [email protected]
Compu
102251,1164
Serve
Phone +805 578 1800 +44 (0) 870 241 1527 +65 73 33 123 +1 847 584 2714
+44 (0) 1189 895 762
FAX +1 805 579 1808 +65 73 38 206 +1 847 584 2725
+44 (0) 870 241 1527

RETURN MATERIALS AUTHORIZATION

Before returning any equipment to Eltron for either in- or out-of-warranty repairs, contact
the Eltron Repair Administration (in Europe, Eltron Technical Support) for a Return
Materials Authorization (RMA) number. Then repackage the equipment, if possible using
original packing materials, and mark the RMA number clearly on the outside. Ship the
equipment, freight prepaid, to one of the following addresses:

For USA and Latin America: For Europe, Asia, and Pacific:

Zebra Technologies Corporation Zebra Technologies Corporation

Eltron Card Printer Products Eltron Card Printer Products
1001 Flynn Road Zone Industrielle Rue d’Amsterdam
Camarillo, CA 93012-8706, USA 44370 Varades, France
Phone: +1 (805) 579-1800 Phone: +33 (0) 2 40 09 70 70
FAX: +1 (805) 579-1808 FAX: +33 (0) 2 40 83 47 45

COPYRIGHT NOTICE
This document contains information proprietary to Zebra Technology Corporation. This
document and the information contained within is copyright by Zebra Technology
Corporation and may not be duplicated in full or in part by any person without prior written
approval of Zebra.

While every effort has been made to keep the information contained within current and
accurate as of the date of publication, no guarantee is given or implied that the document is
error-free or that it is accurate with regard to any specification.

iii
This information is not intended as a license to practice or infringe on the patents of this
company or others. Zebra Technology Corporation reserves the right to modify, update or
revise this information at any time without notice.

TRADEMARKS
Eltron is a trademark of Zebra Technology Corporation. All other marks are trademarks or
registered trademarks of their respective holders.

FCC NOTICE:
This equipment has been tested and found to comply with the limits of a Class A digital
device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses and can radiate radio frequency
energy and, if not installed and used in accordance with the instructions, may cause harmful
interference to radio communications. However, there is no guarantee that interference will
not occur in a particular installation. Operation of this equipment in a residential area is likely
to cause harmful interference in which case the user will be required to correct the
interference at his own expense.

CSA NOTICE:
This equipment does not exceed Class A limits per radio noise emissions for digital
apparatus set out in the Radio Interference Regulation of the Canadian Department of
Communications. Operation in a residential area may cause unacceptable interference to
radio and TV reception requiring the owner or operator to take whatever steps are necessary
to correct the interference.

Ce matériel ne dépasse pas les limites de Classe A d’émission de bruits radioélectriques pour
les appareils numériques telles qu’établies par le ministère des Communications du Canada.
L’utilisation faite en milieu résidentiel peut entraîner le brouillage des réceptions radio et
télé, ce qui obligerait le propriétaire ou l’opérateur à prendre les dispositions nécessaires
pour en éliminer les causes.

iv
 Table of Contents

CHAPTER 1
GENERAL DESCRIPTION

PRINTER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Options · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-2
Major Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Card Feeder· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-2
Cleaning Rollers· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-3
Printer Station· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-3
Card Flip Station · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-4
Laminator Station · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1-4
Smart Card Docking (Option) · · · · · · · · · · · · · · · · · · · · · · · · · · 1-4
Magnetic Stripe Encoder (Option) · · · · · · · · · · · · · · · · · · · · · · · · 1-4
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
CAUTIONARY NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
PACKAGING CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . 1-7
PREPARING A STATIC-SAFE WORK AREA . . . . . . . . . . . . . . . . . 1-7
ENVIRONMENTAL AND SHOCK PROTECTION . . . . . . . . . . . . . . 1-7

CHAPTER 2
INSTALLATION AND OPERATION

INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Unpacking · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-2
Tape and Packing Removals· · · · · · · · · · · · · · · · · · · · · · · · · · · 2-3
Card Catcher Installation · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-3
Cleaning Roller Cartridge Preparation · · · · · · · · · · · · · · · · · · · · · · 2-4
Cleaning Roller Tape Removal · · · · · · · · · · · · · · · · · · · · · · · · · 2-4
Cleaning Roller Cartridge Installation · · · · · · · · · · · · · · · · · · · · · · 2-5
Location Concerns · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-6
Attaching Cables · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-6
Cable Diagrams · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Controls and Indicators · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-9
LCD Print Station Status Messages · · · · · · · · · · · · · · · · · · · · · · · 2-10
LCD Print Station Alert Messages· · · · · · · · · · · · · · · · · · · · · · · · 2-10
LCD Lamination Station Status Messages · · · · · · · · · · · · · · · · · · · 2-11
LCD Lamination Station Alert Messages · · · · · · · · · · · · · · · · · · · · 2-11
Menu Mode · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-12
Print Head Release and Latch Levers · · · · · · · · · · · · · · · · · · · · · · 2-14
Card Gate Adjustment · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-15
Ribbon Loading · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-16
Loading or Emptying the Card Input Hopper · · · · · · · · · · · · · · · · · · 2-18

v
 Starting the Cleaning Cycle· · · · · · · · · · · · · · · · · · · · · · · · · · · 2-18
Rejected Card Box · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-20

CHAPTER 3
THEORY OF OPERATION

COLOR AND IMAGING FUNDAMENTALS. . . . . . . . . . . . . . . . . 3-1

PRINTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
LAMINATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
CARD PATH ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
CIRCUITRY (Figures 3-2 and 3-3) . . . . . . . . . . . . . . . . . . . . . . 3-9

CHAPTER 4
TROUBLESHOOTING

DIAGNOSING BASIC PRINTER PROBLEMS . . . . . . . . . . . . . . . . 4-2

DIAGNOSING COMPUTER INTERFACE PROBLEMS . . . . . . . . . . . . 4-5

CHAPTER 5
REPLACEMENT PROCEDURES

REQUIRED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

PART REPLACEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Rear Case and Cover-Open Sensor Removals · · · · · · · · · · · · · · · · · · 5-2
Front Case Removal· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-4
Operator Panel Part Removals· · · · · · · · · · · · · · · · · · · · · · · · · · 5-5
Card Feeder Removal and Part Replacements · · · · · · · · · · · · · · · · · · 5-6
Card Flip Removal and Part Replacements· · · · · · · · · · · · · · · · · · · · 5-8
Printer Removal · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-14
Printer Power Supply Removal · · · · · · · · · · · · · · · · · · · · · · · · · 5-15
Smart Card Part Removals (Option) · · · · · · · · · · · · · · · · · · · · · · 5-16
Print Head Replacement · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-18
Fan Removal · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-22
Front Belt Removals · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-23
CPU and Encoder Board Replacements · · · · · · · · · · · · · · · · · · · · 5-24
Printer Rear Plate Removal· · · · · · · · · · · · · · · · · · · · · · · · · · · 5-25
Printer Daughter Board Removal· · · · · · · · · · · · · · · · · · · · · · · · 5-26
Ribbon Sensor Removal · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-27
Flag and Head Latch Sensor Board Replacement. · · · · · · · · · · · · · · · 5-28
Rear Belt and O-Ring Removal · · · · · · · · · · · · · · · · · · · · · · · · · 5-29
Printer Motor Replacements · · · · · · · · · · · · · · · · · · · · · · · · · · 5-30
Encoder Head Replacement · · · · · · · · · · · · · · · · · · · · · · · · · · 5-32
Ribbon Supply Spindle and Clutch Replacements · · · · · · · · · · · · · · · 5-36
Ribbon Take Up Spindle Replacements · · · · · · · · · · · · · · · · · · · · 5-38
Laminator Station Removal · · · · · · · · · · · · · · · · · · · · · · · · · · 5-40
Laminator Heater Removal · · · · · · · · · · · · · · · · · · · · · · · · · · 5-41
Laminator Front Belt Replacement · · · · · · · · · · · · · · · · · · · · · · · 5-42
Laminator Fan Removal · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-42

vi
 Laminator Spindle Removals · · · · · · · · · · · · · · · · · · · · · · · · · 5-44
Laminator Head Sensor Access · · · · · · · · · · · · · · · · · · · · · · · · 5-45
Cleaning Roller Spring Clip Removal · · · · · · · · · · · · · · · · · · · · · · 5-46
Laminator Power Supply Removal · · · · · · · · · · · · · · · · · · · · · · · 5-46
Laminator Station CPU Board Replacement · · · · · · · · · · · · · · · · · · 5-48
Laminator Bottom-Accessible Component Replacements · · · · · · · · · · · 5-48
Laminator Rear Plate Removal · · · · · · · · · · · · · · · · · · · · · · · · · 5-50
Laminator Middle Plate Sensor Replacements · · · · · · · · · · · · · · · · · 5-51
Laminator Motors and Rear Belts· · · · · · · · · · · · · · · · · · · · · · · · 5-52
Ribbon Supply Spindle and Clutch Replacements · · · · · · · · · · · · · · · 5-54
Laminator Ribbon Take Up Spindle Replacements · · · · · · · · · · · · · · · 5-56

CHAPTER 6
MAINTENANCE AND ADJUSTMENTS

CLEANING MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Card Transport, Platen, and Cleaning Rollers · · · · · · · · · · · · · · · · · · 6-2
Cleaning the Print Head · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-4
OBTAINING AND INSTALLING FIRMWARE UPDATES . . . . . . . . . . . 6-5
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Printer Stepper Belt Tension · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-6
Print Head Tilt Adjustments · · · · · · · · · · · · · · · · · · · · · · · · · · 6-10
Print Head Peel Bar Position Adjustment · · · · · · · · · · · · · · · · · · · · 6-13
Image Centering · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-14
Laminator Stepper Belt Tension · · · · · · · · · · · · · · · · · · · · · · · · 6-16
Laminator Head Sensor and Peel Bar Adjustments · · · · · · · · · · · · · · · 6-19

APPENDIX A
TEST SOFTWARE

INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Launching the Card Printer Test Software · · · · · · · · · · · · · · · · · · · · A-2
Changing the COM Port· · · · · · · · · · · · · · · · · · · · · · · · · · · · · A-4
Operating in Terminal Mode · · · · · · · · · · · · · · · · · · · · · · · · · · A-5
Typical Sub List · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · A-6
Sensor Test Selection · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · A-7

vii
 Table of Figures

Figure 1-1. Major Elements 1-2

Figure 2-1. Packaging Materials 2-2

Figure 2-2. Tape and Packing. 2-3

Figure 2-3. Card Output Hopper. 2-3

Figure 2-4. Cleaning Roller Installation. 2-4

Figure 2-5. Cleaning Roller Cartridge Preparation. 2-4

Figure 2-6. Cleaning Roller Cartridge Installation. 2-5

Figure 2-7. Cables. 2-6

Figure 2-8. Centronics Cable Wiring. 2-7

Figure 2-9. USB Interface. 2-8

Figure 2-10. Controls and Indicators 2-9

Figure 2-11. Laminater Menu Mode Selection Diagram. 2-12

Figure 2-12. Printer Menu Mode Selection Diagram. 2-13

Figure 2-13. Print and Lamination Head Latch and Release Levers. 2-14

Figure 2-14. Card Gate Adjustment 2-15

Figure 2-15. Ribbon Installation. 2-17

Figure 2-16. Card Input Hopper Loading. 2-18

Figure 2-17. Cleaning Card Installation. 2-19

Figure 2-18. Rejected Card Box. 2-20

Figure 3-1. Card Path Elements. 3-8

Figure 3-2. Printer Assembly Block Diagram. 3-10

Figure 4-1. Problems Duplicated by a Test Print. 4-2

viii
Figure 4-2. Interface Diagnostic Flow. 4-5

Figure 5-1. Rear Case Fasteners. 5-3

Figure 5-2. Front Case Removal. 5-4

Figure 5-3. Operator Panel Part Access. 5-5

Figure 5-4. Card Feeder Replacements. 5-7

Figure 5-5. Card Flip Card Sensor. 5-8

Figure 5-6. Card Flip Circuit Board. 5-9

Figure 5-7. Card Flip Assembly Removal. 5-10

Figure 5-8. Card Flip Stepper Motors. 5-11

Figure 5-9. Card Flip Pinch Roller. 5-12

Figure 5-10. Card Flip Transport Roller. 5-13

Figure 5-11. Printer Removal. 5-14

Figure 5-12. Printer Power Supply. 5-15

Figure 5-13. Smart Card Interface Board. 5-16

Figure 5-14. Smart Card Lift Solenoid. 5-17

Figure 5-15. Smart Card Contact Station. 5-17

Figure 5-16. Print Head Upper Fasteners 5-18

Figure 5-17. Print Head Ground Lug 5-19

Figure 5-18. Print Head Assembly Removal 5-19

Figure 5-19. Print Head Connectors5-20

Figure 5-20. Properly Positioned Print Head 5-21

Figure 5-21. Fan Replacement 5-22

Figure 5-22. Front Belts. 5-23

ix
Figure 5-23. CPU and Encoder Boards. 5-24

Figure 5-24. Rear Plate Removals. 5-25

Figure 5-25. Printer Daughter Board. 5-26

Figure 5-26. Ribbon Sensor Removal. 5-27

Figure 5-27. Flag and Head Latch Sensor Board. 5-28

Figure 5-28. Rear Belts and O-Ring.5-29

Figure 5-29. Head Up-Down Motor Removal. 5-30

Figure 5-30. Stepper Motor Removal. 5-31

Figure 5-31. Ribbon Take-Up Motor Removal. 5-31

Figure 5-32. Encoder Station Shroud. 5-32

Figure 5-33. Encoder Head (Above-the-Card-Path). 5-32

Figure 5-34. Encoder Station Pressure Roller Rod. 5-33

Figure 5-35. Encoder Head Pinch Roller Removal.5-34

Figure 5-36. Pressure Roller Rod Removal. 5-34

Figure 5-37. Encoder Head Fasteners. 5-35

Figure 5-38. Encoder Head Protective Tape. 5-35

Figure 5-39. Supply Spindle Assembly 5-37

Figure 5-40. Ribbon Take Up Spindle 5-39

Figure 5-41. Laminator Station Removal. 5-40

Figure 5-42. Laminator Heater Removal. 5-41

Figure 5-43. Laminator Front Belts. 5-42

Figure 5-44. Laminator Fan Removals. 5-43

x
 CHAPTER 1
GENERAL DESCRIPTION

1.1 PRINTER DESCRIPTION

Eltron® Model P520 plastic card printers offer low cost solutions to those that need to
print, encode magnetic stripes, or program Smart Cards. An integral Lamination Station
applies transparent patches that protect card images and extend card life. Eltron offers
imaging ribbon varieties that include dye sublimation color, and thermal transfer
monochrome in various colors. Dye sublimation ribbons include panels that support the
thermal transfer of black resin. Lamination Ribbon is available for Smart and Magnetic
Stripe Cards so that these elements remain uncovered. Surfaces without these features
receive full-coverage patches.

Standard P520 printers have a Card Feeder, Card-Flip Assembly, Printer Station, and
Lamination Station supporting double-sided plastic card printing. Users can set the Card
Feeder for the wide range of plastic card thicknesses offered.

980327-002 1-1
CHAPTER 1

Software support exists for the selection, imaging, and positioning of two internal fonts
and eight bar code formats. This means that the units recognize associated software
commands. Users can avoid using either an application or the printer driver to image these
objects. For those who wish to create card graphics from their software applications, the
units ship with both Windows 95/98 and NT drivers. Both drivers support True Type fonts.

1.1.1 Options

Plastic card varieties include Smart Cards and cards with Magnetic Stripes. Because not
everyone may want to use associated capabilities, integration of related hardware is
offered as options. Encoders can place data on either high- or low-coercivity stripes.

1.2 Major Elements

Figure 1-1 shows the Printer assemblies visible with the cover raised.

Figure 1-1. Major Elements

1.2.1 Card Feeder

With the Card Feeder set for a proper card thickness, Cards placed in the Card Input
Hopper enter the printer one at a time in response to Card Feed Commands. A manual
Card Gate adjustment lets users establish a suitable card thickness setting. Eltron Card
Printer Products offers cards in popular 0.02- and 0.03-inch thicknesses. However, users
can adjust the feeder for other thicknesses as well. The Card Feed Hopper, has an
attached Card Weight that positions itself on top of a stack of cards in the Hopper. This

1-2 980327-002
 CHAPTER 1

added weight increases the grip of the card feed rollers and assures reliable card feeds
throughout hopper-full to hopper-empty conditions.

1.2.2 Cleaning Rollers

Cards transitioning between the Card-Feed Hopper and Printer Assemblies travel through
a pair of rollers. Above one of these rollers resides a removable cartridge that contains a
Cleaning Roller. A tacky surface on this roller collects any lint or other loose particles that
may adhere to the underlying rollers due to contact with passing cards. To maintain its
ability to collect particles, users must periodically replace the outer core of this Roller.
Users should watch for evidence of particle buildup on the Cleaning Roller or print
anomalies having related characteristics.

Another Cleaning Roller located between the Card Flip and Lamination Station performs
a similar function. This roller is not typically replaced. Instead, a periodic cleaning keeps
the tacky surface of this roller sufficiently free of particles to maintain its function.

1.2.3 Printer Station

Card imaging occurs as the cards transition through the Printer Station. For color imaging,
the cards transition past the Print Head three times. Yellow, magenta, and cyan (YMC)
dyes transfer from ribbon panels onto the cards in amounts controlled by heat produced
by Print Head elements. Each of the 32K color possibilities results from a particular mix of
the YMC dyes. The density of Print Head elements produces images with 300
dot-per-inch (dpi) resolution. Commonly used color ribbons also have panels that can lay
down black monochrome images during related additional pass(es) across the Print Head.

Whereas the CMY panels of color ribbons lay down dye sublimation dyes, the black
panel(s) of these same ribbons deposits a thermal transfer resin (Kr) that only images at
one heat setting. While this essentially eliminates resin as a medium for gray scale, a
capability already made available by the YMC panels, resin serves as a particularly good
choice for text and bar codes. In summary, images produced using color ribbons typically
have four or five panels (CMYKr or CMYKrKr) and require a corresponding number of
passes across the Print Head.

Note that imaging requirements serve as a basis for ribbon selections. For example, a
YMCKr ribbon best serves those needing: color images plus perhaps black on both sides of
the card, single side imaging, or YMC images on one side and only black images on the
other. A CMYKrKr ribbon can produce color plus black on one side and only black on the
other side while only using a single set of ribbon panels per card.

Ribbons also exist in single-coated varieties. Single-coated ribbons deposit a resin. Users
have a choice of many resin colors.

While the forgoing describes the major imaging ribbon types, readers should check the list
of supplies for other varieties that can serve special imaging needs.

980327-002 1-3
CHAPTER 1

1.2.4 Card Flip Station

Cards exiting the Printer Station enter the Card Flip Station. Card flips occur to prepare for
printing on the opposite card side. Additionally, the Card Flip station can drop cards that
fail read-after-write encoding checks into the Rejected Card Box, which lies below. This
facility keeps flawed cards from intermixing with properly encoded cards in the Card
Catcher.

1.2.5 Laminator Station

The Laminator applies clear protective patches or coatings over card images. These
devices transfer from related Lamination Ribbons through the application of heat and
pressure. The variety of ribbons offered includes patches with pre-printed security devices,
patches that have cutouts for Smart Card Contacts, and patches that leave magnetic
stripes uncovered. As with imaging ribbons, users should check the list of supplies for
varieties that serve their special needs.

After lamination, cards transition through an area that supports card cooling. The amount
of time spent in this area determines the degree of cooling. Cards exiting this area drop
into the Card Catcher after receiving all required operations.

1.2.6 Smart Card Docking (Option)

At a Smart Card Station, located inside the Printer Assembly, Smart Card contacts
connect to a DB-9 connector at the rear of the Printer. This implementation supports the
use of an external Smart Card Programming device. Docking occurs with a card
positioned under the contacts; after which, a solenoid mechanism raises the card to make
the connections.

1.2.7 Magnetic Stripe Encoder (Option)

Printers equipped with Magnetic Stripe Encoders fully support the encoding of cards with
either high- or low-coercivity magnetic stripes. This includes several encoding formats.
Read-After-Write checking occurs with each encoding to assure a reliable result. After
receipt of related data, encoding of all three tracks occurs in a single pass through the
encoder. Encoding occurs as the cards transition between the Print Station and the Card
Flip Station, where the read/write heads and an associated card sensor reside.

1-4 980327-002
 CHAPTER 1

The Encoder Head usually resides below the card path in support of a down-facing card
stripe. However, an above-the-card-path option also exists. Although the printer has a
Card Flip, and could, therefore, support Card Input Hopper loadings of either up- or
down-facing stripes, printer efficiency concerns can take precedence:

• Encoding always occurs first, so that any related failure produces a card reject without
a card print and a related waist of time and ribbon. A required card flip on the way to
the Encoder Head would slow up the process.
• The panel sequence for color ribbon is fixed at YMCKrKr and is established during the
ribbon manufacturing process. Ribbon feeds in one direction only. This means that
YMC, or color imaging, must occur first. Imaging always occurs on an up-facing card
surface. A card load with the side to receive color imaging already facing up avoids a
card flip between encoding and the first print sequences.
• Because of the preceding conditions, those who wish to image color only on the side
opposite the stripe are best served by the standard configuration—Encoder Head
placed below the card path, cards placed in the Card Input Hopper with down-facing
stripes.
• In contrast, those who wish to image color only on the side with the stripe are best
served with an Encoder Head that resides above the card path. This configuration
suits a Card Input Hopper loaded with up-facing card stripes.

While the forgoing lays the groundwork for imaging using the popular YMCKr and
YMCKrKr ribbons, other ribbon types or imaging needs also exist that may not have
similar concerns.

1.3 ABOUT THIS MANUAL

Eltron Products has directed the Information contained in this manual at returning P520
printer functions to normal operation in the shortest time possible. With this in mind,
service personal should focus on items listed in their recommended spares list. Avoid
lower level replacements whenever possible. Service personnel should keep a log of the
repairs made in support of the concept of continuous product improvement. Chapters
include: General Description, Installation and Operation, Theory of Operation,
Troubleshooting, Part Replacement Procedures, and Maintenance and Adjustments.

Follow the instructions as closely as possible. When unsure of any procedure, please
contact either an Eltron Service Representative (contact Eltron Product Management for
nearest representative) or Eltron Technical Support at 1-800-344-4003 or 805-578-1800.

Eltron Products stocks all commonly used replacement parts for P520 Printers. For depot
repairs, contact Eltron Sales to place orders and to establish a program for bulk purchases
and credited returns of warranted parts.

980327-002 1-5
CHAPTER 1

1.4 CAUTIONARY NOTES

Exercise reasonable care when servicing P520 printers, as follows:

Other than prescribed operator maintenance, only qualified

personnel should remove the case or otherwise attempt to
repair this equipment. Eltron Products offers product training to
those wishing to service this equipment.

Servicing personnel must avoid touching exposed circuitry.

Inputs to the Power Supply operate at power line voltages. Any
removal of protective insulation can expose dangerous voltages.
Always remove the power cord while effecting repairs.

During operation, the Print and Lamination Heads operate at

elevated temperatures. Exercise caution when touching parts on
or near these areas.

Servicing Personnel should avoid any rough handling of the

Printers or their component parts. The icon to the left also
serves as an indicator alerting conditions of general concern to
users.

An electrostatic discharge (ESD) of energy can damage or

destroy the circuit components inside the Printer. People
acquire such charges while they move around. ESD problems
typically increase with drops in humidity.

Users should not twist the Printer Ribbon Take Up Spindle

manually. Doing so unnecessarily stresses an associated belt.
Any slack left after the ribbon installation gets removed during
the following initialization.

Particle contamination, such as dust, can reduce image quality

and produce excess wear to some printer components. Locate
Printers and print media in areas essentially contamination free.

To avoid fiber deposits, any Cleaning Swabs used must have

foam tips. Also, cleaning solution impurities can leave deposits.
Therefore, only use 99-percent pure or better alcohol.

1-6 980327-002
 CHAPTER 1

1.5 PACKAGING CONSIDERATIONS

The factory-supplied shipping carton contains the Printer placed inside a protective ESD
(Electrostatic Discharge) bag. Form-fitting end cushions made from a foam material keep
the unit suspended within the carton. These are the only materials approved for P520
shipments. Any shipping damage may not be covered by either the product warranty or
the carrier if the printer is shipped with packaging materials that do not meet associated
shipping standards. If necessary, order replacement factory-approved shipping materials
from a P520 distributor.

1.6 PREPARING A STATIC-SAFE WORK AREA

To avoid component damage while performing troubleshooting and repair procedures,

service personnel should work in a static-safe area. Items under test should rest on a
properly grounded, conductive, and cushioned mat. Service personnel should wear a
conductive wrist strap. (Most electronic supply stores carry ESD protective devices. For a
local supplier, contact 3M Corporation at 1-800-328-1368 or 512-984-1800.)

1.7 ENVIRONMENTAL AND SHOCK PROTECTION

Avoid extremes of temperature and humidity or mishandling. These conditions can

damage most electronic equipment.

When moving the printer from a cool, dry location to a warmer, more humid location,
allow the printer to temperature stabilize for at least 30 minutes before opening the
protective ESD bag. Otherwise, moisture can condense on the surface of many
components. Moisture can degrade performance or even damage some components.

Avoid rough handling. Careful handling can avoid possible mechanical damage that
might otherwise result from dropping or impacting the printer on a hard surface.

980327-002 1-7
CHAPTER 1

1-8 980327-002
 CHAPTER 2
INSTALLATION AND OPERATION

This chapter includes information on the following:

• Unpacking
• Installation
• Controls and Indicators
• Card and Ribbon Loading

Similar descriptions also appear in the associated User’s Guide and other manuals
shipped with the printer. The intent here is to make this manual as complete as possible
with a minimum of references to other manuals. Operations related to software
applications and the Windows Driver do not appear in this manual. Information on the
Test Software appears in Appendix A.

980327-002 2-1
CHAPTER 2

2.1 INSTALLATION

2.1.1 Unpacking

Figure 2-1 shows the carrier-approved packaging materials used for shipping and how
these items fit within inside and outside cartons.

Note that customers should keep these materials on hand for future shipping needs. The
product warranty may not cover a printer damaged during a shipment if the printer is
packaged using unapproved shipping materials. If necessary, users can order
replacements before shipping the Printer.

Figure 2-1. Packaging Materials

2-2 980327-002
 CHAPTER 2

2.1.2 Tape and Packing Removals

Figure 2-2 shows the tape and packing materials that require removal prior to printer
operation.

Figure 2-2. Tape and Packing.

2.1.3 Card Catcher Installation

Figure 2-3 shows the installation of the Card Catcher.

Figure 2-3. Card Output Hopper.

980327-002 2-3
CHAPTER 2

2.1.4 Cleaning Roller Cartridge Preparation

Figure 2-4 shows how to install the Cleaning Roller into the Cleaning Roller Cartridge.

Figure 2-4. Cleaning Roller Installation.

2.1.5 Cleaning Roller Tape Removal

Figure 2-5 shows removal of the tape protecting the tacky surface.

Figure 2-5. Cleaning Roller Cartridge Preparation.

2-4 980327-002
 CHAPTER 2

2.1.6 Cleaning Roller Cartridge Installation

Figure 2-6 shows where the Cleaning Roller Cartridge fits into the Printer. Note that the
arrow on top of the Cleaning Roller Cartridge points toward the notch that holds the back
side of the cartridge in place.

Figure 2-6. Cleaning Roller Cartridge Installation.

980327-002 2-5
CHAPTER 2

2.1.7 Location Concerns

Users should avoid dusty locations. Until ready for use, keep ribbon and card media in
their cartons. Select a location that offers easy access to all sides plus an unrestricted air
flow. Avoid locations that experience extremes in temperature and/or humidity.

2.1.8 Attaching Cables

Figure 2-7 shows the Rear Panel of a Printer. This panel has the following:

• Power ON-OFF Switch

• Power Connector
• Computer Interface Connectors
• Smart Card Connector (Option)

The internal power supply automatically adjusts to most of the ac outlet voltages
encountered world wide. Always connect the Power Cable last.

Figure 2-7. Cables.

2-6 980327-002
 CHAPTER 2

2.1.9 Cable Diagrams

Figures 2-8 and 2-9 show Centronics and USB (Universal Serial Bus) information.

Male DB-25 to Male Centronics

DB-25 Centronics
Host Pin No. (Cable) Pin No. Printer
STROBE 1 1 STROBE/*
AUTO- 14 19 GND
2 2 P0
FEED
15 20 GND
DATA 0
3 3 P1
ERROR/
16 21 GND
DATA 1
4 4 P2
INIT
17 22 GND
DATA 2
5 5 P3
SELECTIN/
18 23 GND
DATA 3
6 6 P4
GND
19 24 GND
DATA 4
7 7 P5
GND
20 25 GND
DATA 5
8 8 P6
GND
21 26 GND
DATA 6
9 9 P7
GND
22 27 GND
DATA 7
10 10 ACK/
GND
23 28 GND
ACK/
11 11 BUSY
GND
24 29 GND
BUSY
12 12 PERROR
GND
25 30 N/A
PAPER ERR.
13 13 SELECT
GND
31 INIT/
14 AUTOFD/*
32 FAULT/
15 N/A
33 GND
16 N/A
34 N/A
17 GND
35 N/A
18 N/A
36 SELECTIN/*

SHIELD

1 13 1 18

14 25 19 36

Cable Ends

Figure 2-8. Centronics Cable Wiring.

980327-002 2-7
CHAPTER 2

USB Concerns
(USB Specification Rev. 2.0)

1. USB-Equipped Host Computers have Hub

connection(s) and software that supports the
connections for up to 127 devices (either USB
Functions or USB Hubs), all hot swapable.

2. Hubs implement one connection path upstream

to, or toward, the Host and typically several Ports
for downstream Functions and/or other Hub
connections. Functions refer to Printers, Mice,
Keyboards, etc.

3. USB Cables each have both A- and B-type

connectors. The A connectors attach to upstream
devices, while the B connectors attach to
downstream devices. Hub loopback connections
(requiring an A-to-A cable) are not allowed.
A End Views B
2 1
4. System Software keeps track of the paths and 4 3 2 1

path parameters both to and from Functions (as

Pipes). System Software does not support more 3 4

than five Hubs, not counting the host, along any

path.

5. A Pipe can operate at USB High Speed

(480Mb/s), USB Full Speed (12Mb/s), or USB
Low Speed (1.5 Mb/s). Functions report needed
parameters as part of setup phases during
operations (e.g., following hot swaps).

6. USB Ports and Cables have a shield and four

conductors—two for data and two that can
supply 5 volts to Bus-Powered Devices.

7. It is important to have cables that can support

the bandwidth requirements of a particular path.
Low Speed Cables should not be used in paths
that can also operate at High/Full Speeds.
V Bus 1 1 V Bus
8. Cable designers must meet specified D+ 2 2 D+
requirements for data integrity between devices D- 3 3 D-
Ground 4 4 Ground
by using materials suitable for the lengths
offered. Extension Cables can add factors that Shield Shield
breach critical design elements and should not Cable Wiring
be used.

Figure 2-9. USB Interface.

2-8 980327-002
 CHAPTER 2

2.2 OPERATION

2.2.1 Controls and Indicators

Figure 2-10 shows the push-buttons, LEDs (Light Emitting Diodes), and LCD (Liquid
Crystal Display) that appear on the front of the Printer. The Power Switch resides on the
rear. Users press the Clear Button to initiate a Retry upon completion of an alert response.
Users press the Menu button to enter Menu Mode, after which, the Next and Select
(formally Menu and Clear) buttons serve to navigate and select menu items.

Figure 2-10. Controls and Indicators

980327-002 2-9
CHAPTER 2

2.2.2 LCD Print Station Status Messages

LCD Status Messages Status Condition Reported

(No Operator Response Needed)
INITIALIZING Start-Up Testing in Progress
READY Printer Idle, Awaiting Receipt of Print Files
WAIT TEMPERATURE Print Head too Hot; Cool Down in Progress
SELF TEST Printing of Test Card in Progress
DOWNLOADING DATA Printer Receiving Data
PRINTING YELLOW Yellow Imaging in Progress
PRINTING MAGENTA Magenta Imaging in Progress
PRINTING CYAN Cyan Imaging in Progress
PRINTING BLACK Black Imaging in Progress
PRINTING VARNISH Overlay Varnish Application in Progress
PRINT HOLOGRAM Hologram Application in Progress
CLEANING Operator-Initiated Cleaning in Progress

2.2.3 LCD Print Station Alert Messages

LCD Alert Messages Operator Action Required*

(Operator Response Needed)
CLEAN PRINTER Clean Printer and Replace Cleaning Roller at Next Best Opportunity
CLEAN MAG HEAD Clean Printer Using Cleaning Card at Next Best Opportunity
REMOVE RIBBON During Cleaning, Remove Ribbon
OUT OF RIBBON Replace Ribbon
MECHANICAL ERROR Card Transport Problem; Find and Remove Card
OUT OF CARD Refill Card Input Hopper*
ROTATION ERROR Card Flip Problem; Find and Remove Card
COVER OPEN Close Cover
HEAD OPEN Latch Down Print Head
COMMAND ERROR Host Data not Recognized; Re-send
PARAMETERS ERROR Unsuitable Setup; Check Parameters Selected in Driver
ENCODING ERROR Reject Box Full, Stripe Coercivity, Stripe Orientation, or ISO Problem*
READING ERROR Read-after-Write Failure; Verify Suitable Cards or Proper Card Loading*
REJECT BOX FULL Empty Card Reject Box*
MAGNETIC ERROR Magnetic Stripe not Found; Check Cards or Hopper Loading*
FLASH ERROR Error Executing Firmware Download
NO ACCESS Operational Change Attempted is Not Allowed
*Note: Some Alerts require that Operators press Clear upon completion of the prescribed Operator Action. This
requests a Retry of the action(s) that led to the Alert.

2-10 980327-002
 CHAPTER 2

2.2.4 LCD Lamination Station Status Messages

LCD Status Messages Status Condition Reported

(No Operator Response Needed)
INITIALIZING Start-Up Testing in Progress
READY Laminator Idle
LAMINATING Laminate Application in Progress
WARMING UP Lamination Temperature Not Reached
STANDBY MODE Standby Power in Effect (Reduced after 30 minute Idle)

2.2.5 LCD Lamination Station Alert Messages

LCD Alert Messages Operator Action Required

(Operator Response Needed)
COVER OPEN Close Cover
ROTATION ERROR Card Flip Problem; Find and Remove Card
OUT OF RIBBON Replace Lamination Ribbon
MECHANICAL ERR Card Transport Problem; Find and Remove Card
TEMPERATURE ERR Cycle Power Off and On
RIBBON FAILURE Remove Card with Glued-On Lamination Ribbon

980327-002 2-11
CHAPTER 2

2.2.6 Menu Mode

Figures 2-11 and 2-12 show the push button actions necessary to navigate to and within
Menu Mode. Users first select between Printer and Laminator Main Menus. Once inside a
Main Menu, Sub Menu selection can occur. Sub Menu selections allow users to monitor
status, initiate cleaning, and print Test Cards.

Printer
READY Status
Laminator
Status
READY

After 10 seconds of selection

inactivity, READY returns
automatically.
MENU MODE’S
MENU PRINTER
[NEXT] [SELECT]
PRINTER
MAIN MENU
(See Next Figure)
Printer
MENU LAMINATOR
Status
Laminator
[NEXT] [SELECT]
Status

Lamination
Temperature
Menu Clear
Next Select LAMINATOR INFO Temp:
[NEXT] [SELECT] [NEXT]

Speed Through
Laminator

Speed:
[NEXT]

Lamination Ribbon
(Driver Selection)
MENU MODE’S
f:
LAMINATOR MAIN MENU
[NEXT]

Firmware Version
Installed

Offset from Ribbon Firmware:

Initialization marker [NEXT]

Offset 1st:
[NEXT]

Card/Ribbon Advance GO TO MAIN MENU

Offset Patch-to-Patch [NEXT] [SELECT]

Offset syn:
[NEXT]

Card Advance out

of Laminator Applies Lamination
Patch to Blank Card
Peel Offset: SELF TEST MENU LAM CYCLE
[NEXT] [NEXT] [SELECT] [NEXT] [SELECT]

GO TO MAIN MENU LAMINATOR DEFAULTS GO TO MAIN MENU

[NEXT] [NEXT] [SELECT] [NEXT] [SELECT]

Figure 2-11. Laminater Menu Mode Selection Diagram.

2-12 980327-002
 CHAPTER 2

Printer
READY Status
Laminator
Status
READY
After 10 seconds of selection
inactivity, READY returns Model Number of
automatically. Printer

MENU PRINTER PRINTER

[NEXT] [SELECT] [NEXT]

Firmware Version
Installed

MENU LAMINATOR FIRMWARE

[NEXT] [SELECT] [NEXT]

Number of Cards
Printed

PRINTER INFO CARD PRN:

[NEXT] [SELECT] [NEXT]
MENU MODE’S
Number of Cards in
LAMINATOR Reject Box

MAIN MENU REJECTED BOX:

(See Previous Figure) [NEXT]

GO TO MAIN MENU
MENU MODE’S
[NEXT] [SELECT]
PRINTER MAIN MENU

Printer
Status CLEANING MENU CLEAN PRINT HEAD
Laminator
Status [NEXT] [SELECT] [NEXT] [SELECT]
• Remove Ribbon
• Remove Cards
• Insert Cleaning
Menu Clear Card in Hopper
Next Select CLEAN MAG. HEAD
[NEXT] [SELECT]

Ribbon GO TO MAIN MENU Remove Cleaning

(Driver Selection) Card from Card
[NEXT] [SELECT]
Catcher
RIBBON
[NEXT]

Origin Offset in
Pixels Prints a
Test Card
OFFSET SELF TEST MENU TEST PATTERN
[NEXT] [NEXT] [SELECT] [NEXT] [SELECT]
Coercivity Setting
HICO, LOCO,
or NONE (No Encoder) Prints Card Listing
Printer Parameters
MAG OPTION PRINTER DEFAULTS PRINT PARAMETERS
[NEXT] [NEXT] [SELECT] [NEXT] [SELECT]
xx = YMC Color Inten-
sities and K Contrast Prints Card Listing
Encoder Parameters
Yxx Mxx Cxx Kxx MAG PARAMETERS
[NEXT] [NEXT] [SELECT]

GO TO MAIN MENU GO TO MAIN MENU

[NEXT] [SELECT] [NEXT] [SELECT]

Figure 2-12. Printer Menu Mode Selection Diagram.

980327-002 2-13
CHAPTER 2

2.2.7 Print Head Release and Latch Levers

Figure 2-13 shows the Release and Latch levers for the Print and Laminator Heads. Users
open the Cover and raise the Heads during manual Cleaning Procedures, removal of card
jams, and ribbon loads.

Figure 2-13. Print and Lamination Head Latch and Release Levers.

2-14 980327-002
 CHAPTER 2

2.2.8 Card Gate Adjustment

Figure 2-14 shows the Card Gate Adjustment Lever with arrows that show the directions
of travel.

Step 1. Set the Card Gate Thickness Lever to match the thickness of the cards being
used. Note that lever positions closer to the back of the printer open the Card Feed
Gate for thicker cards. For cards of unknown thicknesses, close the gate, issue a
print command, and gradually open the gate until a feed occurs. Then set the
opening to the closest card thickness as marked on the Card Gate Decal.

Step 2. If during operation cards either fail to feed or multiple card feeds occur, check
the setting of the Card Gate Adjustment Lever. Increase the opening if cards fail to
feed, and decrease the opening if too many cards feed at the same time. Also,
avoid using warped cards or cards with burrs. These card flaws can require Card
Gate openings greater than the one indicated for the card size loaded.

Figure 2-14. Card Gate Adjustment

980327-002 2-15
CHAPTER 2

2.2.9 Ribbon Loading

Figure 2-13 shows the loading of ribbons. Note that by keeping the power turned ON
during ribbon loads, a suspended operation resumes automatically with the head
latch-down that completes the load. Lamination ribbons have a limited range for
temperature tolerance. Be sure to check the ribbon packaging for acceptable storage and
operating temperatures.

Step 1. Raise the Print or Laminator Head, corresponding to the ribbon being
installed or replaced. Then, remove and discard any old ribbon, ribbon cores
included.

Step 2. Remove the new ribbon from its packaging and the material holding the
Supply and Take-up Rolls together.

Step 3. Unroll enough ribbon from the Supply Roll to bridge the space between the
Supply and Take-up Spindles.

For Printer or Laminator Ribbon, slide the new ribbon cores onto the spindles such
that ribbon travels off of the top of the Supply (right) Spindle and onto the top of
the Take-up (left) Spindle.

CAUTION: On Printer Stations a keying design assures the proper mating of cores
with spindles. However, to avoid any possible damage to delicate Print Head
elements, make sure the dye-coated side of any ribbons used faces away from the
Print Head.

For Lamination Ribbon, the material applied to the cards must face away from the
Lamination Head roller. A notched out section on the Take-up Core must
surround a set screw in the Take-up Spindle to prevent core slippage during ribbon
advances.

WARNING: Lamination Head rollers operate at very high temperatures. Avoid any
physical contact with these or other nearby items. Print Heads operate at
somewhat lower, but still elevated, temperatures, with ESD damage also a
concern. Therefore, avoid physical contact here as well.

Step 4. Latch down the associated Print or Lamination Head.

2-16 980327-002
 CHAPTER 2

Do Not Twist Hot ESD Sensitive

Figure 2-15. Ribbon Installation.

980327-002 2-17
CHAPTER 2

2.2.10 Loading or Emptying the Card Input Hopper

Figure 2-15 shows the Card Input Hopper actions necessary to remove or replenish cards.

Step 1. Rotate the Card Input Hopper to the open position.

Step 2. Place or remove cards in Card Input Hopper. The side to receive the first
printing normally faces up.

Cards with Magnetic strips normally get installed with down-facing stripes, but
some Encoder installations support up-facing stripes because of a desire to have
the first printing on side with stripe. Place the card edge that is nearer to the stripe
away from the front of the Card Input Hopper. If Magnetic Stripes do not pass
over the read-write heads, Encoder Errors occur.

Note: Due to the versatile nature of these printers, driver setups may exist that
dictate different considerations.

Step 3. Return Hopper to closed position.

Figure 2-16. Card Input Hopper Loading.

2.2.11 Starting the Cleaning Cycle

The CLEAN PRINTER message appears at card count intervals determined by a printer
command (see Programmer's Manual). Users can either wait for the message to appear or
initiate a Cleaning Cycle at another time. Also, when necessary, users can continue
printing after the message appears. Each Cleaning Cycle resets the card counter that
triggers the CLEAN PRINTER message. Refer to Figure 2-17, and proceed as follows:

Step 1. While leaving power on, remove both the plastic card and ribbon media. Note
that a Cleaning cycle cannot occur with ribbon installed, and that the Card Input
Hopper must not contain anything other than a Cleaning Card.

2-18 980327-002
 CHAPTER 2

Step 2. Either place an alcohol-moistened Cleaning Card in the Card Feed Hopper or
feed one through the opening in the hopper used for single card feeds. Be sure to
use a fresh, still moist, card (one just removed from its pouch) and to push the card
under the Card Weight. If necessary, increase the Card Gate opening.

Step 3. Users can choose to initiate a cleaning in response to the CLEAN PRINTER
message or at some other time using Menu Mode:

For Cleaning in response to the CLEAN PRINTER message, press Clear with a
Cleaning Card inserted into the Card Feed Hopper.

For cleaning at a time other than when the CLEAN PRINTER message appears,
enter Menu Mode (see Section 2.2.6) and then navigate first to CLEANING MENU
in the Main Menu and then to either CLEAN PRINT HEAD or CLEAN MAG.
HEAD in the related Sub Menu.

Step 4. Upon completion, remove the Cleaning Card from the Card Catcher.
Replace the Cleaning Roller (see Sections 2.1.4 through 2.1.6). Return the printer
to normal operation by installing ribbon (Section 2.2.9) and plastic card media
(Section 2.2.10) and returning the Card Gate opening to a proper setting (Section
2.2.8).

Figure 2-17. Cleaning Card Installation.

980327-002 2-19
CHAPTER 2

2.2.12 Rejected Card Box

Cards that do not pass a read-after-write encoder check end up in the Rejected Card Box.
The printer keeps track of the number of cards placed in the box. At 20 cards, the message
REJECT BOX FULL appears, and an operator must empty the box. Refer to Figure 2-18,
and proceed as follows:

Step 1. quickly press and release the upper area of the access door to the Rejected
Card Box.

Step 2. Remove the rejected cards inside the box, and close the door.

Figure 2-18. Rejected Card Box.

2-20 980327-002
 CHAPTER 3
THEORY OF OPERATION

This chapter includes five major topics:

• Color and Imaging Fundamentals

• Printing
• Laminating
• Card Path Elements
• Circuit Descriptions
3.1 COLOR AND IMAGING FUNDAMENTALS

The following offers readers a perspective on how imaging occurs in various systems, with
a particular emphasis on card printers, their interaction with other system elements, and a
comparison of techniques.

Color refers to the hues people see. This refers to the visual spectrum. People can see the
whole spectrum when they look at a rainbow or at the dispersal of white light through a
prism. The extremes of this spectrum are red (the longest wavelength perceivable) and
violet (the shortest wavelength perceivable). The remaining orange, yellow, green, etc.,
shades lie between the red and violet extremes. Ultra Violet and Infrared spectrums exist
above and below the visual.

A light source, such as the sun, generates the full range of color frequencies, which
combine to produce white. Black results when light fails to reflect off of an object due to an
absence of the object color in the source illumination or when a printed color prevents
reflected light. Object colors converge toward black as source illumination decreases.

980327-002 3-1
CHAPTER 3

Saturated colors are colors in their purest state. This means they contain no white (as in
pastels) or black (contrast reduction) components. A so-called trained observer can
discern about 450 fully saturated shades. When these colors are diluted by black, the
number of discernable shades diminishes. However, white dilutions increase the number
of colors discernible.

In Card Printers, images result from two types of ribbon coatings—dye and resin. Dye
coatings allow color gradations from a light application to a dense application using Dye
Sublimation imaging. P-Series printers can apply dye in 32 steps (from zero to 31). This
allows the mixing of dye colors to produce a non ribbon panel color and determines how
much of the white card color shows through. Resin, however, is applied at full saturation,
meaning no card or other underlying colors show through. A saturated color absorbs all
non-reflected spectrum elements. In contrast, a non-saturated dye color acts as a filter that
absorbs a percentage of the elements returned to a viewer and all of the non-reflected
spectrum elements.

In any printer imaging system, memory capacity becomes a concern. One typically reads
about systems offering say 24-bit color. This refers to an RGB system that uses eight bits to
describe each of the primary colors red, green, and blue. Such a system can quantify each
primary color in a range of steps of from zero to 256. Twenty-four bit color yields a
16,777,216 shade pallette for each pixel in the desired image. Fifteen-bit color yields
32,768 shades and requires 15-bits for each pixel in the desired image. Thirty-two bit color
adds an eight-bit transparency component to 24-bit color, which along with other
non-color data, becomes an Alpha Channel component.

Data compression is also a factor. Note that the memory required for images expands
substantially with the number of shades. Compression attempts to reduce the memory
requirements. Some compression schemes only attempt to identify repeating colors.
Others, such as JPEG, can treat various amounts of change as the same repeating colors.
Carried to an extreme, JPEG compression would produce a posterized result, meaning
color changes would step unnaturally. This would become noticeable in blends and in
photographic images.

Color matching also depends on the colors available within Color Palettes. Systems
typically offer palette selections that range from 256 to several million colors. Some
applications also offer choices that support file size reductions. Others are file format
determined. An application that creates 24-bit RGB color images needs to have a way to
send data to a printer capable of say 15-bit color. An application typically creates a palette
based on the colors used in its image file. For printing, a Printer Driver must map source file
colors to nearby colors in the palette used by the printer. A similar process can occur
during exports to some file formats.

In color printing processes, particular shades of color derive by mixing quantities of the
basic colors cyan, magenta, yellow, and sometimes black (usually referred to as CMY or
CMYK—where K designates black). When users choose some other color definition from
their application—e.g., hue saturation intensity (HSI) or red green blue (RGB)—a
conversion to CMY/CMYK must take place to support a printer. Color mixing occurs at the
level of each pixel. Pixels serve as the basic elements of images. Pixels can comprise either
one dot (the smallest printable element) or a small matrix of dots, depending on the
methodology used to form the images.

3-2 980327-002
 CHAPTER 3

Offset printing and Dye Sublimation can produce a substantial range of colors within just
one dot. Color Monitors produce their range of colors using a red, green, and blue (RGB)
three-dot matrix. Scanners and digital cameras employ charge-coupled devices (CCDs)
that capture and deliver RGB components.

Thermal Transfer and most Ink Jet printers produce their range of colors using larger dot
matrixes—typically up to four-by-four or equivalent dots—where each dot color can be a
fundamental (CMY) or the combination of fundamentals (which adds RGB and black).
Therefore, these particular devices limit their dot colors to cyan, magenta, yellow, red,
green, blue, black, and the media color (usually white). Since these colors remain
unmixed, color perception beyond the eight relies on a person's natural tendency to mix
dot color components where associated dots appear too small for individual perception.

With eight dot colors possible, a four-by-four dot pixel matrix can produce in excess of four
billion combinations ((4 x 4)8). However, as long as the color components remain the
same, the dots in a matrix can be shuffled into any pattern without changing the color
perceived. For example, a matrix containing all-white dots except for one red dot
produces the same shade of pink no matter where in the matrix the red dot lies. Therefore,
a matrix containing n dots can produce each color in n different ways. This makes a
four-by-four matrix capable of producing more than 268 million different shades
((4 x 4)8/16 + white). For monochrome printing, which is the only matrix-based printing
that users might want to apply to a P-Series printer, this same matrix can produce 16
different gray (or other thermal transfer ribbon shades) levels plus white ((4 x 4)2/16 +
white).

Mixing of dot colors in Offset Printing and Dye Sublimation occurs by controlling the
amount of each dye or ink that gets applied to each dot. Mixing in color monitors occurs
from control of RGB intensities. For CRTs (cathode ray tubes) three beams act on the
respective phosphors. For Active Matrix Displays, liquid crystals emit the RGB levels.

Of all the methods, Dye Sublimation produces the best quality printouts, because as is the
case for all P-Series Printers, each dot can have the full range of 15-bit color (32 shades per
dye color) at a full 300 dpi resolution. In fact, even with resolutions equal, Dye
Sublimation still holds an advantage over offset printing. Dye Sublimation creates a dot
color by applying varying densities of the CMY dyes. Offset printing creates a dot color by
varying the diameter of the CMYK ink dots, which can make individual dots more
observable and subject to moire pattern generation. Since without magnification no one
can see individual dots at 300 dpi and since each dot results from percentages of YMC
ribbon colors, Dye Sublimation offers card printer users essentially the continuous-tone
quality of photographs.

Moire (typically herringbone) patterns can become a factor when users generate either
print files or hard copy separations for offset printing. Users creating related print files
typically ask the people that do their offset printing which separation angles best reduce
these patterns before risking a distorted result. Many applications offer Print Dialog
options for these settings.

All the non Dye Sublimation print methods work because we naturally mix dot colors that
appear too small for individual perception. To see individual dot intensities or colors, view
the monitor or printed page using an Eye Loup or other such magnifier.

980327-002 3-3
CHAPTER 3

Not all images require high dot densities. The need for high dot density decreases as the
viewing distance increases. For example, a large roadside sign may require separations
screened at only four lines-per-inch. Such a sign would appear like a mosaic of CMYK dots
if viewed from too close a distance. Note that press men use lines per inch instead of dots
per inch, because they image color separations through screens to generate dot-based
images from continuous-tone images. However, both refer to picture resolution.

Pixelization, or the ability to see individual pixels, typically becomes a factor when a digital
image undergoes magnification. At 300 dpi, a dot measures 0.00333... inches
(0.081666... mm). Individual pixels in such an image remain unobserved to the naked
eye. Observable pixels do not show up until a magnification reduces the resolution well
below 200 dpi. Notably, monitors display images at 72 dpi.

An original at 72 dpi is at a threshold. Any magnification of pixels of a 72 dpi original for a

screen image occurs by repeating pixels taken from the original. Higher resolution
originals can sustain greater magnifications before the need for repeats begins. In other
words, an original bitmap can only be magnified so much before the need for duplicated
pixels occurs and pixelation begins to become an issue.

In raster systems, where line scans take data from a video memory, graphic objects
comprised of lines typically undergo antialiasing. Without this, lines created at other than
zero, 45, 90 degrees and their complements would have a jagged appearance. Line
Generators can only put data in available dot positions in a video memory. In effect, each
line-dot generated lands on the closest dot position available. A jagged appearance occurs
as one axis element has intervals that stay the same while the other axis element marches
along step-by-step. Antialiasing compensates for a lack of ideal dot positions by averaging
the line-dot intensities with those of near-by dots. An illusion of straight lines results.

Office Printers offer resolutions typically from 300 to 600 dpi. A degree of resolution
reduction (down sampling) can be tolerated in order to reduce the amount of data
required. When a file size needs to be kept in check by not exceeding a viewer's needs, the
printed image should typically tolerate a resolution reduction to about 180 dpi. Typically,
the down-sampling process occurs by averaging pixel groups, with group size a function of
the desired change from one pixel density to another.

Because a monitor and a printer produce color through different methods, users can
expect somewhat different results. A monitor uses an additive process, meaning a
particular color derives from intensity control. For example, a color moves toward the
green by intensifying excitation of green CRT phosphors. Printed images, on the other
hand, use a subtractive process. These images display their color through reflected light.
To generate a particular printed color, the process must subtract (that is, filter out and not
reflect) parts of the source illumination, which then lets other parts dominate. For
example, a reduction in cyan (greater cyan filtering) would allow yellow and magenta
components to become more dominate.

The light reflected off of the surface of a white card passes through any colored dyes
deposited on the surface of the card, both going and coming. The dyes used to form
printed images serve as filters of light that would otherwise reflect off of what is typically a
white print media. In printed images, complete filtration (or what serves as the maximum
subtraction capability) results in black. Conversly, the absence of filtration results in the

3-4 980327-002
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color of the print media. In monitors, maximum intensities (maximum additions) result in
white, and minimum intensities produce black. Because light reflected from print media
depends on ambient lighting, users may get darker images from a printer than they see on
their monitor, where a brightness setting exists.

Print illumination (generally from room or outdoor lighting) affects color for all printed
images. When a light source emits less in certain parts of the visual spectrum, a print
illuminated by such a source by necessity reflects less of the associated colors. This occurs
even though the corresponding light reflecting capability remains inherent in the print.
Imagine, for example, the effect of placing a color filter in front of a light source. Only the
visual spectrum parts passed by this filter can reach the print. Viewers can sometimes see
subtle effects of this by observing the same print under sunlight, incandescent lights, and
fluorescent lights.

Sunlight radiates fairly evenly over the entire visual spectrum, rising only slightly higher at
the center. Incandescent lights radiate far more on the red side than on the blue side of the
visual spectrum. Fluorescent lights radiate differently depending on their phosphor
blends. Such classifications as “Cool Light” and “Warm Light” refer to blue-rich and
red-rich enhancements, respectively.

In scientific terms, the question “How white is my source?” is resolved by a side-by-side

comparison between a source in question and a heated black body radiator. The term
“black body” refers to a material that produces no color other than that which results from
heating. Imagine such a material first appearing reddish and then gradually becoming
white hot followed by bluish white as its temperature is pushed higher. These are the
whites to which comparisons are made. In the Graphic Arts industry, the following
standards for white exist:

Region Black Body Temperature

US. 5000°K
Europe 6500°K

The NTSC standard for white is 6500°K. However, only a properly adjusted television or
monitor can produce a standard white.

When close concern for color is important in displaying prints, users should find similar
ambient conditions for a color check. If a color is closely related to identifying a printed
feature, users may find themselves dealing with this level of concern, with skin tones
typically offering the greatest challenge. However, most applications tend to require a less
critical evaluation. Usually, what looks good in one setting tends also to look good in
another, despite any subtle differences in ambient lighting.

Color is very much a function of the device either sensing or producing the color. A
computer monitor that uses a CRT, for example, can produce very bright images, typically
brighter than those produced by a television set. A television set typically can produce a
broader range of colors than can a CRT monitor. Television manufactures emphasize
color range over brightness; monitor manufacturers emphasize brightness over color
range. While the forgoing compromises generally hold true, each device manufacturer, in
fact, takes a different perspective when deciding which formulations to use in the red,

980327-002 3-5
CHAPTER 3

green, and blue CRT phosphors. Moreover, devices with a brightness control allow a wide
range of image intensities. Active Matrix Displays generate images from a back-lighted
grid that activates red, green, and blue LCD pixel elements. For paper, and other print
media, gloss affects brightness, and Black Body Temperature affects hue.

More issues arise with the addition of a color scanner to a system. These devices also differ
between manufacturers. WYSIWYG (what you see is what you get) from scanned picture
to monitor to printer gets complicated because of different device color ranges (Gamuts)
and by the different color systems used. A printed color outside the range of a scanner
cannot make it to a monitor; only a nearby color can. Users that attempt to use a computer
application to edit the image received from a scanner may add colors beyond the range of
their printer. Notably, some applications issue gamut warnings. Both monitors and
scanners use the RGB system, while color printers use the CMY/CMYK system. Additive
systems produce a better range of colors using RGB, while subtractive systems do better
with CMY/CMYK.

An important concern then becomes "how does a device handle color data beyond its
range?" If a device just substituted the best color available, objects filled with blends,
starting from inside the gamut and ending at some point beyond the gamut, would lose
their desired appearance. For example, an object blending from say an orange to a red
beyond its red range would abruptly stop blending at the point the device could no longer
produce a deeper red. The remaining blend would then continue with the same color.
Some devices avoid this effect by compressing (via re mapping) the gamut. While
compression can maintain the desired effect, similar to JPEG data, too much compression
produces posterized images.

Even in nature, different conditions produce different colors. Painters of Seascapes point
out how the ocean reflects the color of the sky. The bright, sunny day colors differ from the
cloudy day colors. Women have more color sensitivity than men. Different colors provoke
different emotional responses, which do not necessarily remain the same from one
country to the next. All-in-all, there is much to consider, but most decisions rely on
subjectivity before they become final.

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3.2 PRINTING

Color imaging requires three passes of Card media underneath the Print Head. Card
media shuttles back and forth across the print head during this process. The ribbon feeds
between the image head and the card media and during printing advances from its supply
to its take-up reels in step with an advancing Card.

Heat, when generated at an image head element, transfers ribbon dye in a measured
quantity onto the print media. In color printing, the ribbon advances from one color panel
to the next between each imaging pass. A card either exits a Printer following the last pass
or transitions to the Card Flip in preparation for printing on the opposite side.
Monochrome printing for black resin images requires an additional pass, as would the
application of a clear overlay varnish. However, card printers with laminating capabilities
would not normally use ribbons with varnish panels.

Printers employ an image head with a single row of 672 print head elements, 300 to the
inch (11.8 per millimeter). Notably, the capability for card coverage exceeds the needs of a
standard card size by 0.115 inches (2.9mm), or about 34 dots. This excess supports both
programmable centering and near full bleed imaging. Each element can generate five
different heat levels (zero to 32 dye densities) for color and a single heat level for resin
monochrome.

3.3 LAMINATING

During lamination, a Patch transfers from the Lamination Ribbon onto the up-facing
surface of the card. The transfer occurs while the card passes under the Lamination Head.
The Laminator Head Roller resides above the card and is maintained at a temperature
sufficient to activate the bonding agent of the Patch. A combination of heat and downward
pressure on the ribbon and card applies the Patch.

Following application of the Patch, the card transitions through a Heat Sink area. The
timing of this transition determines the amount of cooling. Cards continuing beyond the
Heat Sink area drop into the Card Catcher.

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3.4 CARD PATH ELEMENTS

Figure 3-1 shows the significant printer and laminator elements. Sensors detect the
various events that occur during card printing. Events include: reception of cards, ribbon
initialization, Head Up and Head Down Head positions, and whether a Head and/or the
Cover is open or closed. Flag Sensors signal incremental ribbon advances. This signals the
need for downward adjustments in ribbon take up travel as the accumulation of ribbon
increases the effective Take Up diameter. The Printer Ribbon Panel Sensor signals when a
yellow panel is next in line for imaging. Card Flip sensors signal flip, and card positions. A
sensor on the Laminator signals ribbon index marks.

Ribbon Cleaning
Take Up Print Head Roller
Latched Flag
Magnetic Sensor
Encoder
(Option) Ribbon
Print Head Sensor Card
Sensor
Card Feed
Hopper

Card Feed
Transport and Roller
Card Platen Rollers
Path (Both Stations)
Smart Card Head
Station Up/Down
Daughter (Option)
Board Sensors

Cam Follower (Raises Encoder Station Pinch Card Feed and Printer Stations

Ribbon Laminator Ribbon Cleaning Card Card-Flip

Shroud Position Assembl
Sensor Station Supply Rollers

Card
Catcher

Flip
Rotatio
n
Card
Cooling Head Up/Down
Cam (Both Stations)

Card
Reject LED
Transmitter

Card Flip and Laminator Stations

Figure 3-1. Card Path Elements.

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 CHAPTER 3

3.5 CIRCUITRY (Figures 3-2 and 3-3)

If possible, spend some time with these figures. The intent is to offer another perspective to
descriptions given in other parts of the manual. P520 Printers have the following circuits:

• Print Head Circuitry

• Motor Control Circuitry
• Status Circuitry
• Host I/O
• Operator Panel Circuitry
• Card Flip Circuitry
• Optional Encoder and/or Smart Card Circuitry

Most of the circuitry resides on CPU Boards. The Printer CPU Board controls the Card
Feeder, Printer Station, reception of data from the host computer, and to some degree the
Card Flip, Operator Panel, and optional Smart Card and Magnetic Encoder Stations.
Additional circuitry resides on circuit boards for the Card Flip and the Daughter Boards.
Optional printer installations include an Encoder Board, and for Smart Cards, the Smart
Card Docking Station and Smart Card Interface Boards.

The Laminator CPU Board has similar circuitry for controlling motors and collecting
status. Absent a Print Head, the Laminator CPU instead controls heat for the Lamination
Head Roller. Daughter Board circuitry for the Laminator includes a Watch Dog Circuit
that turns off the heater if heat-requesting signals from the CPU should stop.

The figures depict soldered-in circuit blocks without shading. The lighter shading indicates
ICs in sockets. The darker shading indicates external assemblies connected to the CPU
Board by cabling.

The Micro Controllers determine operations through data and address busses and control
signals. Flash memory on the CPU Boards contain the associated microcode. The Test
Software can download firmware updates. Firmware in EEPROMs determine operation
of the Card Flip, Operator Panel, and USB Interface. Note also that the CPU Board
Address Buses primarily serve transfers involving the Flash and RAM chips. Most other
data transfers occur with a chip enable or other Micro Controller signal.

Two types of status are collected—sensor and parameter. Two types of sensors
exist—reflective and beam interrupt. Digital-to-Analog converters determine input power
to the sensor LEDs, which in turn determines sensor sensitivity and output levels.
Associated setups occur using the Test Software (see Appendix A).

Motors exist in two types—dc and stepper. Some associated driver ICs have socket
mounts in support of IC-level replacements. Stepper Motor driver ICs have heat sinks. Dc
motors receive 24-volt dc power. This same supply powers a dc-to-dc converter that
delivers 5-volt power to the remaining circuitry.

980327-002 3-9
CHAPTER 3

Clock
Card (32.7 MHz)
Lift MICROCONTROLLER
Solenoid LCD Operator
DB-9 Messages
Smart
Smart
Card Data Bus Control Address
Card I/O
Contact (16-bits) Signals Bus Alert Response
PWB
Station Complete—Retry
(Option)

FLASH
Serial Port
Driver

Read/Write
Heads Encoder
Board RAM
(Option)
DB-25

Parallel
I/O Print Print
Head Head
Drive Assembly

Daughter
Board

PHASE1
Stepper PHASE2 Stepper
Motor PHASE3 Motor
Status Drive PHASE4
• Card
• Ribbon
• Flag
Flag • Head Ribbon
Up/Dn dc Motor
Head • Head
Latch Drive
Open/ Head
Latched Up/Dn
Head Up/Dn
Sense
Vdd Card
Print Head Voltage Parameter Feed
Status

Print Head

Card Flip PCBA PHASE1

Flip Position Stepper PHASE2 Flip
Sense Status
Driver PHASE3 Stepper
Card Position • Card
PHASE4
Sensor Board Position
• Flip
Rotation Controller
PHASE1
Card
Stepper PHASE2
PHASE3 Transport
PROM Driver
PHASE4 Stepper

Figure 3-2. Printer Assembly Block Diagram.

3-10 980327-002
 CHAPTER 4
TROUBLESHOOTING

Typically, troubleshooting begins with an attempt to relate a problem to an associated

component or system function. In this phase, servicing personnel may attempt to
duplicate the problem and then use various means to test for a malfunction or improper
system setup.

This chapter hopes to aid in this process by presenting a table that offers some areas
related to an observed problem. Those with replacement components on hand can often
speed up the repair process by swapping related components. This process either narrows
the possibilities or eliminates the problem. Trial-and-error works particularly well with
easily accessible components, such as those accessible by opening the cover or removing
the rear case.

Only a symptom-related list of possibilities appears. When the suggestions presented fail
to lead to a repair, a CPU Board replacement, if not prescribed, should nevertheless be
tried. A check for broken or disconnected cables and any loss of either ac or dc power
should also take place along with checks for obvious mechanical damage. The Test
Software described in Appendix A includes selections to exercise most printer functions
with a selection that leads steps-by-step to a printer setup. Beyond this, Eltron Card Printer
Products offers Technical Support and factory repair as options.

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CHAPTER 4

4.1 DIAGNOSING BASIC PRINTER PROBLEMS

Figure 4-1 shows a diagnostic flow diagram designed to reproduce problems related to
card images and card transports. Tables follow that offer some potential causes along with
section references.

Diagnosing Basic
Printer Step 1
Turn Power On

Power No Check Power,

LED Turns Fuse, Cord, etc.
On?
Yes

Print Test
Pattern Card
(See 2.2.4 Menu Mode)

Check for Print Check Card

Anomalies Yes Test Card No
Emerges? Transport
(Both Sides) Path

LOOK FOR: LOOK FOR:

No Image
Faint Image
Artifacts No Card Feed
Horizontal Line(s) Multiple Card Jam
Vertical Lines Partial Card Feed
Sticking Ribbon Stall at Cleaning Roller
Washout Stall Past Platen Roller
Ribbon Sheared Stall at Encoder
Image Off Center Guides
CMYK Not Aligned Stall in Laminator
Abrupt Color Change
Bad Ribbon Sync.
Poor Lamination

Figure 4-1. Problems Duplicated by a Test Print.

4-2 980327-002
 CHAPTER 4

Printer Problems Associated with Print Anomalies

References
Symptom Possible Causes Adjustment Replace-
or Cleaning ment
Non Eltron Ribbon Installed Upside Down 2.2.9
CPU Board 5.2.12
No Image
Head Up/Dn Motor 5.2.18
Head Position Sensors 5.2.16
Low Print Head Voltage 5.2.12
Faint Image
Dirty Print Head 6.2.2
2.1.4~2.1.6
Artifacts Particles on Feed or Transport Rollers
2.2.6, 6.2.1
Horizontal Lines Dirty or Damaged Print Head Element 2.2.6, 6.2.2 5.2.9
Multiple
Evenly-Spaced CPU Board Print Head Registers 5.2.12
Horizontal Lines
Vertical Lines Stepper Belt too Tight 6.3.1
Sticking Ribbon Peel Bar Adjustment 6.3.4
Washout Peel Bar Adjustment 6.3.4
Sheared Ribbon Image Not Centered 6.3.6
Image Off Center X- and Y-Offset Values 6.3.6
CMYK Not 2.2.11, 6.2.1,
Erratic Card Feed due to Belt Tension or dirty rollers
Aligned 6.3.1
Initialization/Ribbon Sensor/Proper Ribbon 2.2.6 5.2.15
Abrupt Color Flag Sensor 5.2.16
Change Clutch Pads 5.2.20
Ribbon Take-Up Motor/O-Ring 5.2.17

Laminator Problems Associated with Patch Applications

References
Symptom Possible Causes Adjustment Replace-
or Cleaning ment
Lamination Heater Open 5.2.23
Patch not Applied CPU not Controlling Heater 5.2.30
Laminator Daughter Board 5.2.31
Patch Bubbles Improper Heat 6.3.5 5.2.23
Warped Cards Improper Ribbon Advance 5.2.27
Ribbon Index Mark Sensor
Patch Offset 6.3.5 5.2.27
Improper Ribbon Advance
Ribbon Take Up Motor
Ribbon Stall 5.2.34
Ribbon Take Up Motor Belt
Patch Skewed Peel Bar Adjustment 6.3.4
5.2.25
Cards too Hot Fan not operating
5.2.31

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CHAPTER 4

Printer Problems Associated with Card Transport Failures

References
Symptom Possible Causes Adjustment Replace-
or Cleaning ment
Card Gate Adjustment
2.2.8
Dirty Card Feed Roller
2.1.4~2.1.6
No Card Feed
6.2.1
Card-Feed Motor 5.2.4
Card-Feed Belt 5.2.4
Multiple Card Jam Card Gate Adjustment 2.2.8
Card Transport Belt 5.2.4, 5.2.11,
Partial Card Feed 5.2.17
Card Position Sensor 5.2.5
Stall near Cleaning Card Position Sensor 5.2.5
Roller Rear Card Transport Belt 5.2.17
Stall Past Platen Front Card Transport Belt 5.2.11

Laminator Problems Associated with Card Transport Failures

References
Symptom Possible Causes Adjustment Replace-
or Cleaning ment
Card Sensor 5.2.31
Card Stall Before Interface Between CPU Boards 5.2.30
Platen Stepper Motor 5.2.34
Broken Rear Belt 5.2.34
Card Stall After
Broken Front Belt 5.2.24
Platen

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4.2 DIAGNOSING COMPUTER INTERFACE PROBLEMS

Figure 4-2 shows a flow diagram that checks the interface to the computer. For additional
information, see:

• Cabling—
• Theory—
• Replacements—

Diagnosing Interface
Connect Printer to PC,
Prepare Printer with
Ribbon and Cards, and
Turn Power On

Issue Commands
Using Either:
• Windows Driver
• Test Software

Printer Yes Interface

Responds? Is OK

No

Repair/Replace:
• I/O Cable
• Printer CPU Bd.
Cable
• Printer CPU Bd.

Figure 4-2. Interface Diagnostic Flow.

980327-002 4-5
CHAPTER 4

4-6 980327-002
 CHAPTER 5

CHAPTER 5
REPLACEMENT PROCEDURES

This chapter consists of part replacement procedures for those items either found or
suspected of malfunctioning. These procedures cover the items checked during the
troubleshooting presented in the previous chapter. However, this manual does not cover
all components and only represents an attempt toward identifying a potential set of
components. As a result, servicing personal may discover additional items that warrant
procedures.

Eltron Card Printer Products encourages servicing personal to report these and any other
problems in support of continuous product improvement, publication of Tech Notes, and
revision of this manual. For servicing beyond the scope of this and the other P520 Printer
publications, Eltron Card Printer Products offers factory repair and Technical Support
assistance as options.

As with all well-designed products, most parts should remain operational well beyond a
typical product life. Therefore, product abuse may cause most failures. In this regard, the
operating environment most likely acts as the prime factor influencing card-image quality,
with airborne particles the chief cause of problems.

Descriptions show how the various components fasten to the printer and the best
sequence for their removal. This makes the procedures reversible, meaning installation of
a new component typically occurs by reversing of the removal procedure.

980327-002 5-1
CHAPTER 5

5.1 REQUIRED TOOLS

The following tools and fixtures are the basic items required for repair and adjustment:

Item No. Tool Description

1 Number 1 Phillips Bit
2 1.5 Millimeter Allen Bit
3 2.5 Millimeter Allen Bit
4 5.9 Millimeter Allen Bit
5 3-Millimeter E-Ring Tool
6 5.5-Millimeter Open End Wrench
7 5-Millimeter E-Ring Tool
8 Needle Nose Pliers
9 T10 Torx Bit
10 Torque Wrench, Dial, 0- to 100-inch pounds
11 Torque Wrench, Screwdriver, Adjustable, 1.5- to 30-inch pounds
12 Volt Meter
13 Wire Cutters (Small)
Eltron Part
Fixture Description
No.
C011 Printer Stepper Belt Tensioning Fixture
C037 Laminator Head Peel Bar Adjustment Fixture
C177 Laminator Head Sensor Adjustment Fixture
C730 Laminator Stepper Belt Tensioning Fixture

5.2 PART REPLACEMENTS

The following sections describe the requirements for removing both major assemblies
and, where applicable, components on those assemblies that appear in the list of spares.
Only removal descriptions appear. Unless noted otherwise, replacements can take place
by reversing the steps required for removals. Also, replacements for some items in the
spares list may not appear. Replacements for these items should be obvious without
procedures.

5.2.1 Rear Case and Cover-Open Sensor Removals

Figure 5-1 shows the fasteners holding the Rear Case member and the connectors for the
Cover-Open Sensor on the CPU Boards. Proceed as follows:

Step 1. Remove the seven Rear Case screws shown.

Step 2. While lifting the Rear Case and attached Cover up and away, avoid stress on
the Sensor Cable by keeping the Rear Case close to the rear of the printer.

5-2 980327-002
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Step 3. Disconnect the Sensor Cables from the Printer and Laminator CPU Boards.

Step 4. Lift the combined Rear Case and Front Cover free of the printer.

For Cover-Open Sensor Replacement, Continue as follows:

Step 5. On the hinge with the sensor, unhook the spring.

Step 6. On the hinge with the sensor, remove the Hinge Fasteners.

Step 7. Remove the Sensor Fasteners, and the Cover-Open Sensor.

Figure 5-1. Rear Case Fasteners.

980327-002 5-3
CHAPTER 5

5.2.2 Front Case Removal

Refer to Figure 5-2, and proceed as follows:

Step 1. Remove the Rear Case (see Section 5.2.1).

Step 2. Remove the five screws holding the Front Case. Note the Card Flip access.

Step 4. Disconnect the Front Panel connectors from the CPU and Card Flip Boards.

Step 5. While avoiding stress on the cable, slide the Front Case clear of the Printer.

Figure 5-2. Front Case Removal.

5-4 980327-002
 CHAPTER 5

5.2.3 Operator Panel Part Removals

Operator Panel Parts attach to the Front Case. Refer to Figure 5-3, and proceed as follows:

Step 1. Remove the Front Case (see Section 5.2.2).

Step 2. Remove the two Screws and associated Operator Panel Rear Cover Plate.

Step 3. Remove the two screws holding the Operator Panel assembly to the Front
Case.

Step 4. For access to the components under the metal plate of the Operator Panel
assembly, remove the four screws. Note that the LCD Driver IC is socket mounted
for ease of replacement.

Note: When reattaching the Operator Panel Assembly to the Front Case, exercise care in
aligning the LEDs with the associated panel holes.

Figure 5-3. Operator Panel Part Access.

980327-002 5-5
CHAPTER 5

5.2.4 Card Feeder Removal and Part Replacements

Replaceable parts on the Card Feeder include the unit as a whole, the Roller Drive Belt, the
Card Gate Assembly, the Rollers, and the Card Feed Motor. Refer to Figure 5-4, and
proceed as follows:

Belt Replacement:

Step 1. Remove the Rear Case (see Section 5.2.1).

Step 2. Replace the old belt.

Whole Unit Replacement:

Step 1. Remove the Rear and then the Front Case members (see Sections 5.2.1 and
5.2.2).

Step 2. Unplug the Motor Connector.

Step 3. Remove the four screws holding the unit to the Bottom Plate.

Roller Replacement:

Step 1. Remove the Rear Case (see Section 5.2.1).

Step 2. Remove the Belt.

Step 3. Remove the upper Belt Pulley. Note that because the pulley and associated
Push Ring cannot be removed without being damaged, replacements are needed
for reassembly.

Step 4. Remove the screws holding the Roller Bearing Plate, the Plate, and the
Rollers.

Card Gate Replacement:

Step 1. Remove the whole unit (see above).

Step 2. Unplug the Lug that grounds the anti-static brush.

Step 3. Remove the three screws holding the Card Gate Assembly and then the
assembly.

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 CHAPTER 5

Motor Replacement:

Step 1. Remove the whole unit (see above).

Step 2. Remove the three screws holding the motor, the belt, and the motor itself.

Figure 5-4. Card Feeder Replacements.

980327-002 5-7
CHAPTER 5

5.2.5 Card Flip Removal and Part Replacements

Replaceable options for the Card Flip Assembly include:

• Receiver Sensor Board

• Card Flip Circuit Board or Board ICs
• Unit as a whole
• Stepper motors
• Rollers

Receiver Sensor Board Replacement (Figure 5-5):

Step 1. Remove the Rear Case (see Section 5.2.1).

Step 2. Unplug the Card Flip Card Sensor Connector.

Step 3. Loosen the two mounting screws that hold the Card Sensor Assembly to the
Card Flip Assembly, and remove the assembly.

Step 4. Remove the top Cover of the Card Sensor Assembly and then the two screws
holding the circuit board inside.

Step 5. While feeding the cable and connector through the lower cable path, lift the
Sensor Board out at the top.

Figure 5-5. Card Flip Card Sensor.

5-8 980327-002
 CHAPTER 5

Card Flip Circuit Board Replacement (Figure 5-6):

Note: Card Flip Circuit Boards have socketed Controller and Stepper Driver ICs to ease
board-level repairs. Access to the two Stepper Driver ICs does not require a prior removal
of the circuit board. Only unplug the stepper motor connectors for access to these ICs.

Step 1. Remove the Rear Case (see Section 5.2.1)

Step 2. Unplug the five connectors (Operator Panel/CPU Board, Card Feed Motor,
Both Stepper Motors, and Card Flip Sensor).

Step 3. Remove the screw that holds the board to the Card Flip Assembly.

Step 4. Note the chassis tab that grounds the board as well as the rotating portion of
the Flip Assembly that passes through on-board sensors. Then, while tilting the
board to clear these elements, remove the board toward the rear.

Figure 5-6. Card Flip Circuit Board.

980327-002 5-9
CHAPTER 5

Whole Unit Replacement (Figure 5-7):

Step 1. Remove the Rear and Front Cases (see Section 5.2.1 and 5.2.2).

Step 2. Remove the two rear and two front screws.

Step 3. Lift the unit toward the front free from the Bottom Plate.

Figure 5-7. Card Flip Assembly Removal.

Card Flip Stepper Motor Replacements (Figure 5-8):

Note: Two mounting screws secure each stepper motor. A screwdriver clearance path to
the Card Flip Stepper Screws exists from the front of the unit. However, access to the
mounting screws of the Card Transport Stepper requires a prior removal of the Rear Plate.

Step 1. Remove the Card Flip Assembly, and unplug the stepper motor targeted for
replacement (see above).

Step 3. For the Card Flip Stepper Motor, remove the two related screws. Note the
screwdriver access through a notch in the Flip Assembly.

For the Card Transport stepper motor, first remove the Rear Plate of the Card Flip
Assembly and loosen the Circuit Board Screw. Then, while taking care not to lose
the spring that attaches between the motor shaft and the Flip Assembly, remove
the Rear Plate. With access now possible, remove the stepper motor mounting
screws and the motor from the Rear Plate.

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Figure 5-8. Card Flip Stepper Motors.

980327-002 5-11
CHAPTER 5

Roller Replacements

Spring tension holds the Pinch Roller assembly in place, allowing snap-out removals and
snap-in replacements. The roller within this assembly also snaps in or out. In contrast, the
rotating Flip Assembly holds the Drive Roller captive. Access to the Drive Roller requires
splitting apart the Flip Assembly. A drive gear on the roller also requires removal.
Therefore, roller and gear replacements must occur in tandem.

For Pinch Roller replacement, refer to Figure 5-9, and proceed as follows:

Step 1. Lift the Pinch Roller assembly until it snaps free from its shaft.

Step 2. Slide the assembly out from under the spring.

Step 3. Snap out the Roller. Take care during reinstallation to position the spring ends
out of the card path.

Figure 5-9. Card Flip Pinch Roller.

For Transport Roller Replacement refer to Figure 5-10, and proceed as follows:

Step 1. Remove the Rear Plate of the Card Flip Assembly (see above).

Step 2. Remove the spring and slide off the gear that drives the Drive Roller.

Step 3. If possible, use a Gear Puller to remove the gear from the Drive Roller shaft.
Although the gear is press-fit onto the shaft, the fit is tight, and damage can occur
with removal. If possible, install a new gear during replacement.

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Step 4. Remove the two screws holding the Flip Assembly. Prepare for reassembly by
noting how the Pinch Roller spring and the shafts interface, and then separate the
sections.

Figure 5-10. Card Flip Transport Roller.

980327-002 5-13
CHAPTER 5

5.2.6 Printer Removal

Four Screws hold the Printer to the Bottom Plate. Another screw attaches the Printer to the
Card Flip Assembly. Refer to Figure 5-11, and proceed as follows:

Step 1. Remove the Rear Case (see Section 5.2.1), the Front Case (see Section
5.2.2), the Card Feeder (see Section 5.2.4), and, if installed, the two fasteners
holding the Smart Card Interface Board.

Step 2. Unplug the Power and Host Interface connectors.

Step 3. Remove the five screws holding the Printer to the Bottom Plate and to the
Card Flip Assembly.

Step 4. Lift the Printer off of the Bottom Plate. Note that protrusions in the surfaces
that interface with the bottom plate serve to center the Printer around its mounting
holes.

Figure 5-11. Printer Removal.

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5.2.7 Printer Power Supply Removal

The Printer Power Supply mounts to the Bottom Plate under the Printer. An internal
2-Ampere fuse protects the supply from internal shorts. Be sure to check the fuse prior to a
replacement. Also, make sure to check for excessive loading by a P520 element receiving
power before proceeding with replacement. Refer to Figure 5-12, and proceed as follows:

Step 1. Remove the Rear Case (see Section 5.2.1), the Front Case (see Section
5.2.2), and the Printer (see Section 5.2.6).

Step 2. After removing the four associated screws, remove the Power Supply Shield.

Step 3. Remove the four screws that fasten the Power Supply to the Bottom Plate.

Step 4. Unplug the ac Power Connector from the Power Supply, and lift the Power
Supply free from the Bottom Plate.

Note: ac power to the Power Supply arrives through an ac Power Filter and a Power
Switch. Two screws hold the filter to the Bottom Plate. The switch snaps in place, and its
removal requires retractions of upper and lower tabs. Spade connectors implement
connections to both items. If needed, replacement of either item can proceed after
removal of the Rear Case.

Figure 5-12. Printer Power Supply.

980327-002 5-15
CHAPTER 5

5.2.8 Smart Card Part Removals (Option)

Units equipped for Smart Card Docking have the following components:

• Smart Card Interface Board

• Smart Card Contact Station Board
• Smart Card Lift Solenoid

Smart Card Interface PWB Removal (Figure 5-13):

Step 1. Remove the Rear Case member (see Section 5.2.1).

Step 2. Remove the two DB-9 fasteners and the Board. Note that excessive torque on
these fasteners during installation of a new Board can produce damage. Try to
duplicate the torque required for removal when installing a new board.

Step 3. Disconnect the connectors to the Solenoid, CPU Board, and Contact Station.

Figure 5-13. Smart Card Interface Board.

Smart Card Contact Station Removal (Figure 5-14)

Step 1. Remove the Rear Case (see Section 5.2.1) and the Cleaning Roller Cartridge
(see Section 2.1.6).

Step 2. Remove both the screw holding the Smart Card Station and the cable braid.

Step 3. Unplug the Smart Card Station from the Smart Card Interface Board, and
while feeding the cable, slide the Smart Card Station to the right until free. After
installing a new Smart Card Station, check operation using the Smart Card Test in
the Test Software (see Appendix A).

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Figure 5-14. Smart Card Lift Solenoid.

Smart Card Lift Solenoid (Figure 5-15)

Step 1. Remove the Rear Case (see Section 5.2.1), the Front Case (see Section 5.2.2),
and the Printer (see Section 5.2.3).

Step 2. Remove the two screws holding the Solenoid, followed by the solenoid and
associated Card Lift Bracket.

Step 3. Unplug the solenoid from the Smart Card Interface board.

Step 4. Remove the screw holding the solenoid to the Card Lift Bracket, and attach
the bracket to the new solenoid.

Figure 5-15. Smart Card Contact Station.

980327-002 5-17
CHAPTER 5

5.2.9 Print Head Replacement

Replacement Print Heads arrive in ESD-safe plastic bags. Upon removal, servicing
personnel should exercise extreme care to protect the Print Head from both ESD and
mechanical damage to the delicate internal circuitry and the Print Head Elements. An area
specifically equipped for work on ESD-sensitive devices is strongly advised.

Step 1. As shown in Figure 5-16, loosen the four Torx Head screws on top of the
Print Head Assembly.

Figure 5-16. Print Head Upper Fasteners

Step 2. As shown in Figure 5-17, loosen the screw holding the Ground Lug, and pull
the Lug free.

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Figure 5-17. Print Head Ground Lug

Step 3. As shown in Figure 5-18, unhook the ring holding the lower part of the Print
Head Assembly, and slide the unit away from its mounting. Note that this step may
require some loosening of attached cables.

Figure 5-18. Print Head Assembly Removal

980327-002 5-19
CHAPTER 5

Step 4. Disconnect the two cable connectors from the Print Head Assembly shown in
Figure 5-19. Note that until pushed away, a spring tab prevents removal of the far
connector. The near connector locks onto a connector extension, which releases
with a slight deflection.

Step 5. Note the routing of the Ground Wire through the Print Head Cut Out. Free
the Ground Wire, and separate the Print Head from the Print Head Assembly.

Figure 5-19. Print Head Connectors

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Step 6. Install a new Print Head by reversing the steps used during removal. Before
tightening the Torx Screws, make sure to push the Print Head in as far as possible,
as shown in Figure 5-20. DO NOT adjust the screw that stops the Print Head when
pushing the unit in. All replacement units ship with this screw set to deliver
optimum performance.

First tighten the Torx Screw in the corner nearest to the printer front and closest to
the Fan. Then tighten the screw nearest to the printer back and closest to the Fan.
The remaining two screws may be tightened in any order.

Step 7. Using the Test Software or the Printer Driver, enter the Head Resistance as
marked on the Print Head Label. For example, “!R”resistance¿

CAUTION: Do not print any cards without first entering the Print Head Resistance.

Figure 5-20. Properly Positioned Print Head

980327-002 5-21
CHAPTER 5

5.2.10 Fan Removal

Two self-tapping screws secure both the Fan and the associated Fan Guard. Refer to
Figure 5-21, and proceed as follows:

Step 1. Remove the Rear Case Member (see Section 5.2.1).

Step 2. Disconnect the Fan Connector from the CPU Board, and remove the braid
covering the wires routed to the Print Head.

Step 3. Remove the two self-tapping screws holding the Fan and Fan Guard.

Step 5. Open the Print Head and, while feeding the Fan Wires, pull the Fan and Fan
Guard out through the front side of the Print Head Assembly.

Figure 5-21. Fan Replacement

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5.2.11 Front Belt Removals

Figure 5-23 shows the Front Belts. These belts transport cards downstream from the
Platen Roller. Proceed as follows:

Step 1. Remove the Rear and Front Case Members (see Sections 5.2.1 and 5.2.2).

Step 2. Slide the belt(s) off of the respective pulley(s). Note that the belt on the right
requires removal to gain access to the pulley for the belt on the left.

Figure 5-22. Front Belts.

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5.2.12 CPU and Encoder Board Replacements

See Appendix A for CPU Board tests. For board replacement, refer to Figure 5-23, and
proceed as follows:

Step 1. Remove the Rear Case member (see Section 5.2.1).

For CPU Board:

Step 2. If desired, replace any socketed circuit component(s) most closely related to
the problem.

Step 3. If the problem persists, disconnect the board connectors, and remove the four
screws holding the CPU Board. Then, remove the board itself. Note: After
replacing the board, perform a Printer Setup (see Appendix A).

For Encoder Board:

Step 4. Remove the four screws and the CPU Board and Encoder Head Connectors.
Then remove the board. The Encoder Board has no socketed ICs, making board
level replacement the only option.

Figure 5-23. CPU and Encoder Boards.

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5.2.13 Printer Rear Plate Removal

Rear Plate removal allows access to the Daughter Board and associated motor and sensor
connectors, and their related components. Refer to Figure 5-24, and proceed as follows:

Step 1. Remove the Rear Case (see Section 5.2.1) and unplug the connectors
attached to the circuit boards (see Section 5.2.12).

Step 2. Remove the three screws holding the Rear Plate, followed by the plate itself.
Note that the circuit boards can remain attached.

Step 3. Remove the Cam Follower Rod and Flywheel when required for access to
underlying components. Note rotations for Cam Follower Rod attachment points.

Figure 5-24. Rear Plate Removals.

980327-002 5-25
CHAPTER 5

5.2.14 Printer Daughter Board Removal

Note that this board contains the Print Head Up-Down Sensors and connectors for the
remaining sensors and all motors. Access to this board is a prerequisite for all associated
replacements except for the Card Feed Motor. Refer to Figure 5-25, and proceed as
follows:

Step 1. Remove the Rear Case member (see Section 5.2.1).

Step 2. Unplug connectors on the CPU Board (see Section 5.2.12).

Step 3. Remove the Rear Plate (see Section 5.2.13).

Step 4. Disconnect the six connectors.

Step 5. If necessary, position the disk used for Print Head Up-Down sensing such that
both Print Head Up/Down sensors can pass through the opening.

Step 6. Slide the Daughter Board out toward the rear of the printer.

Figure 5-25. Printer Daughter Board.

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5.2.15 Ribbon Sensor Removal

The four wires of the Ribbon Sensor connect to the Daughter Board. Refer to Figure 5-26,
and proceed as follows:

Step 1. Remove Rear Case, and disconnect the wires from the CPU Board, and if
installed, the Encoder Board (see Sections 5.2.1 and 5.2.12).

Step 2. Remove the Rear Plate with attached circuit boards (see Section 5.2.13).

Step 3. Remove the single screw holding the Ribbon Sensor.

Step 4. Cut the Cable Ties holding the Ribbon Sensor wires.

Step 5. Unplug the Ribbon Sensor Connector from the Daughter Board.

Step 6. Remove the Ribbon Sensor while feeding the associated cable and connector
along the routing path.

Figure 5-26. Ribbon Sensor Removal.

980327-002 5-27
CHAPTER 5

5.2.16 Flag and Head Latch Sensor Board Replacement.

Refer to Figure 5-27, and proceed as follows:

Step 1. Remove the Rear Case Member (see Section 5.2.1).

Step 2. Unplug connectors on the CPU Board and, if installed, the Encoder Board
(see Section 5.2.12).

Step 3. Remove the Rear Plate (see Section 5.2.13).

Step 4. Unplug the Flag and Head Latch Sensor connector from the Daughter Board.

Step 5. Raise the Print Head, and unhook the Print Head Release Spring.

Step 6. Remove the single screw holding the Flag and Sensor Board, and remove the
board and associated cable. Note the cable routing in preparation for installation of
the new assembly.

Figure 5-27. Flag and Head Latch Sensor Board.

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5.2.17 Rear Belt and O-Ring Removal

Figure 5-28 shows the three timing belts that extend stepper motor drive to the Platen and
two rollers that drive cards between the Card Feeder and Platen. The figure also shows the
O-ring that drives the Ribbon Take Up Spindle. Proceed as follows:

Step 1. Remove the Rear Case (see Section 5.2.1).

Step 2. Remove the Rear Plate, Cam Follower, and Flywheel (see Section 5.2.13)

Step 3. Replace the belt(s) and/or O-ring. Note that because two of the rollers have
two pulleys, some replacements require removal of an overriding belt.

Figure 5-28. Rear Belts and O-Ring.

980327-002 5-29
CHAPTER 5

5.2.18 Printer Motor Replacements

Three motors reside in the Printer—the Print Head Up-Down Motor, the Card Transport
Stepper, and the Ribbon Take-Up Motor. Perform the following two steps for all motor
removals:

Step 1. Remove the Printer from the Bottom Plate (see Section 5.2.6).

Step 2. Remove the Rear Plate (see Section 5.2.13).

For Print Head Up-Down Motor Removal (Figure 5-29)

Step 1. Raise the Print Head.

Step 2. Remove the Head Position Disk from the motor shaft.

Step 3. Unplug the motor connector from the Daughter Board and cut the associated
cable tie.

Step 4. Remove the three motor fasteners, and guide the motor out through the
bottom of the Printer.

Figure 5-29. Head Up-Down Motor Removal.

For Stepper Motor Removal (Figure 5-30)

Step 1. Remove the timing belt that drives the Platen Roller.

Step 2. Unplug the Stepper Motor Connector from the Daughter Board, and cut the
associated cable tie.

Step 3. Remove the three screws that hold the motor, and guide the motor out
through the bottom of the Printer. Note that proper belt tensioning must be
reestablished during installation of a new motor (see Section 6.3.1).

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Figure 5-30. Stepper Motor Removal.

For Ribbon Take-Up Motor Removal (Figure 5-31)

Step 1. Remove the O-ring and the Take-Up Motor Pulley.

Step 2. Unplug the Ribbon Take-Up Motor Connector from the Daughter Board.

Step 3. Remove the three motor fasteners, and guide the motor out through the
bottom of the Printer.

Figure 5-31. Ribbon Take-Up Motor Removal.

980327-002 5-31
CHAPTER 5

5.2.19 Encoder Head Replacement

Two Encoder Head configurations exist—the standard below-the-card-path

configuration and an optional above-the-card-path configuration.

For Common Requirements:

Step 1. Remove the Rear Case (see Section 5.2.1).

Step 2. Remove the Encoder Station Shroud (see Figure 5-32).

Figure 5-32. Encoder Station Shroud.

For Above-the-Card-Path Configurations (Figure5-33):

Step 1. Unplug the Encoder Head Connector from the Encoder Board, and Remove
the Rear Plate (see Sections 5.2.12 and 5.2.13).

Step 2. Remove the two screws holding the Encoder Head, and while feeding the
cable along the routing path, remove the Encoder Head.

Figure 5-33. Encoder Head (Above-the-Card-Path).

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For Below the Card Path Configurations:

Step 1. Remove the Front and Rear Case members (see Sections 5.2.1 and 5.2.2),
and the Encoder Board (see Section 5.2.12).

Step 2. Remove the screw and washer holding the Pressure Roller Support Rod that
overlies the Encoder Head (see Figure 5-34).

Figure 5-34. Encoder Station Pressure Roller Rod.

980327-002 5-33
CHAPTER 5

Step 3. Snap the Front Pressure Roller free of the rod by applying pressure to the
right side while holding the left side stationary (see Figure 5-35).

Figure 5-35. Encoder Head Pinch Roller Removal.

Step 4. By applying force to the area previously occupied by the Pressure Roller,
work the Pressure Roller Rod toward the front. Then, when possible, pull the rod
free (see Figure 5-36). Note the positions of the remaining parts on the roller,
which can fall off and scatter onto underlying surfaces.

Figure 5-36. Pressure Roller Rod Removal.

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Step 5. Remove the two screws holding the Encoder Head Assembly. Then, while
feeding the associated cables through the Rear Plate cutout, Remove the Encoder
Head (see Figure 5-37).

Figure 5-37. Encoder Head Fasteners.

Step 6. Install the new Encoder Head, and replace the overlying parts previously
removed. Feed cables through the plastic frame, and to the Encoder Board (see
Figure 5-23). Note that new Encoder Heads have a protective tape cover (see
Figure 5-38). To avoid possible Encoder Head damage, postpone tape removal
until just before replacement of the Shroud. After reassembly, optimize Encoder
performance using the Encoder Test in the Test Software (see Appendix A).

Figure 5-38. Encoder Head Protective Tape.

980327-002 5-35
CHAPTER 5

5.2.20 Ribbon Supply Spindle and Clutch Replacements

Figure 5-39 shows the Ribbon Supply Spindle and associated Clutch Assembly.
Replacement options include any of the parts that appear in the exploded view.

Step 1. Remove the Rear Case (see Section 5.2.1) the Front Case (see Section 5.2.2)
and the Rear Plate (see Section 5.2.13).

Step 2. Remove the Flag and Head Latch Sensor Board (see Section 5.2.16).

Step 3. Unhook the springs attached to the Print Head Latch Assembly.

Step 4. Remove the two fasteners holding the Print Head Latch Assembly.

Step 5. Remove the screw and captive washer holding the Supply Spindle, and slide
the spindle off of the rod.

Step 6. Slide the clutch and flag assembly toward the rear until free of the printer.

Note: At this point, reassembly can occur with a new Clutch and Flag Assembly, a new
Spindle, or both. Also, with further disassembly, individual Clutch parts can be replaced
(note the items in the exploded view). However, any new Clutch Pads require a burn-in
followed by a torque test. Normally two washers are used on the side closest to the Rear
Plate to create the proper torque. Added washers increase torque while washer removal
decreases torque. A torque of from 185 to 250 centimeter grams produces the required
clutch friction.

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Figure 5-39. Supply Spindle Assembly

980327-002 5-37
CHAPTER 5

5.2.21 Ribbon Take Up Spindle Replacements

Figure 5-40 shows the Ribbon Take Up Spindle. Replacement options include any of the
parts that appear in the exploded view.

Step 1. Remove the Rear Case (see Section 5.2.1) the Front Case (see Section 5.2.2)
and the Rear Plate (see Section 5.2.13).

Step 2. Remove the o-ring belt from the Spindle Pulley.

Step 3. Remove the screw and captive washer holding the Take Up Spindle, and slide
the spindle off of the rod.

Step 4. To replace any parts still attached to the rod, slide the assembly toward the
rear until free of the printer.

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Figure 5-40. Ribbon Take Up Spindle

980327-002 5-39
CHAPTER 5

5.2.22 Laminator Station Removal

Four screws hold the Laminator Station to the Bottom Plate. Refer to Figure 5-41, and
Proceed as follows:

Step 1. Remove the Front and Rear Case members (see Sections 5.2.1 and 5.2.2).

Step 2. Unplug the Power Supply and CPU Interconnect Connectors.

Step 3. Remove the four screws holding the Laminator Station to the Bottom Plate,
and the single screw at the Card Flip. Then, lift the Station free.

Figure 5-41. Laminator Station Removal.

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5.2.23 Laminator Heater Removal

Refer to Figure 5-42, and proceed as follows:

Step 1. Remove the two screws holding the protective shield.

Step 2. Remove the screw holding the Heater Element. Note that the Heater serves as
a bearing for the Lamination Roller.

Step 3. Cut away the shrink wrap tubing from the heater wires.

Step 4. Disconnect the two wires, and pull the Heater free from the Roller.

Figure 5-42. Laminator Heater Removal.

980327-002 5-41
CHAPTER 5

5.2.24 Laminator Front Belt Replacement

Refer to figure 5-43, and proceed as follows:

Step 1. Remove Rear and Front Case members (see Sections 5.2.1 and 5.2.2).

Step 2. Remove the desired belt. Note that the right belt requires removal to access
the left belt. Also note that the belts hold the idler pulleys in place. If possible, avoid
loosening the Idler Pulley Brackets and an associated adjustment of belt tension.

Figure 5-43. Laminator Front Belts.

5.2.25 Laminator Fan Removal

Figure 5-44 shows the fastener that holds the Fan Bracket to the Laminator Head.
Proceed as follows:

Step 1. Remove the Back and Front Case members (see Sections 5.2.1 and 5.2.2).

Step 2. Remove the Laminator Station from the Bottom Plate (see Section 5.2.22).

Step 3. Remove the single screw holding the Laminator Fan Bracket and raise the
Lamination Head. With the screw removed, tilt the upper bracket edge forward.
Then move the assembly away from the Laminator Head toward the Card Flip. To

5-42 980327-002
 CHAPTER 5

replace the Fan, remove the four fan fasteners, and unplug the fan from the CPU
Board.

Figure 5-44. Laminator Fan Removals.

980327-002 5-43
CHAPTER 5

5.2.26 Laminator Spindle Removals

Set screws fasten the Laminator Spindles to underlying shafts. Refer to Figure 5-45 and
proceed as follows:

Step 1. For the Supply Spindle (shown), first unfasten and move the Laminator Head
Fan clear of the Laminator Head (see Section 5.2.25).

Step 2. For either spindle, loosen the two or three set screws that fasten the spindle to
the underlying shaft.

Step 3. Slide the spindle free of the shaft. When reinstalling spindles, note that two set
screws tighten against the flat on the shaft. Also note that a 0.030-inch (0.76mm)
gap between the spindle and the middle plate should be reestablished. A 30-mil
card can be used as a Feeler Gage.

Also note that the Take-up Spindle has a set screw that keys Take-up Ribbon
Cores to the spindle to prevent slippage.

Figure 5-45. Laminator Spindle Removal.

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5.2.27 Laminator Head Sensor Access

Figure 5-46 shows the fasteners holding the Ribbon Sensor Assembly to the Lamination
Head, along with the sensor circuit boards that become accessible with the Ribbon Sensor
Assembly removed. Note that for a better camera angle, the figure shows a Lamination
Head removed from the Lamination Station. However, sensor access should not require
this removal. Also note that replacement or repositioning of the temperature-sensing
thermistor can change the Laminator temperature.

Step 1. Remove the Laminator Fan and Laminator Ribbon Supply Spindle as described
previously.

Step 2. After allowing for a suitable cool-down, remove the two Allen-head screws
holding the Ribbon Sensor Assembly.

Step 3. Cut the ties holding the sensor wires, and slide the Ribbon Sensor Assembly away
from the Lamination Head. Find a position that allows a convenient access to the sensor
circuit board being replaced.

Step 4. Remove the single fastener holding the sensor circuit board being replaced.

Figure 5-46. Lamination Head Sensors.

Step 5. Note that a replacement Temperature Sensor must ride on the Lamination
Roller such that contact occurs along the entire length of the thermistor body. Also,
for proper heat detection, this sensor must not contact the overlying Ribbon Sensor
Assembly. To adjust the Sensor Bracket position, see Section 6.3.5.

980327-002 5-45
CHAPTER 5

5.2.28 Cleaning Roller Spring Clip Removal

Figure 5-47 shows the Clip that holds the Cleaning Roller in place. Proceed as follows:

Step 1. Remove the Rear and Front Case Members (see Sections 5.2.1 and 5.2.2).

Step 2. Remove the Cleaning Roller.

Step 3. Remove the two screws holding the Cleaning Roller Spring Clip.

Figure 5-47. Cleaning Roller Spring Clip

5.2.29 Laminator Power Supply Removal

The Laminator Power Supply mounts to the Bottom Plate beneath the Laminator. An
internal 2-Ampere fuse protects the supply from excessive current drain. Be sure to check
the fuse prior to a supply replacement. Also, be sure to check for excessive loading by a
P520 element receiving supply power before proceeding with replacement. Refer to
Figure 5-48, and proceed as follows:

Step 1. Remove the Rear and Front Case members (see Sections 5.2.1 and 5.2.2)
and the Laminator Assembly (see Section 5.2.22).

Step 2. After removing the four associated screws, remove the Power Supply Shield.

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Step 3. Remove the four screws that fasten the Power Supply to the Bottom Plate.

Step 4. Unplug the ac Power Connector from the Power Supply, and lift the Power
Supply free from the Bottom Plate.

Note: ac power to the Laminator Power Supply arrives through the same ac Power Filter
and a Power Switch as feeds the Printer Supply (see Section 5.2.7).

Figure 5-48. Laminator Power Supply

980327-002 5-47
CHAPTER 5

5.2.30 Laminator Station CPU Board Replacement

Adjustments on a new CPU may not match those on the old. See Appendix A for
adjustments. Refer to Figure 5-49, and proceed as follows:

Step 1. Remove the Rear Case member (see Figure 5.2.1).

Step 2. If desired, replace the circuit component(s) most closely related to the
problem. Note that the Stepper Motor Driver IC has a heat sink.

Step 3. If the problem persists, disconnect the board connectors, and remove the four
screws holding the Main Circuit Board. Then, remove the board itself.

Figure 5-49. Main Circuit Board or Board Component Removals.

5.2.31 Laminator Bottom-Accessible Component Replacements

Bottom-Accessible Components include the Daughter Board, the Cooling Station Fan,
and the Card Sensor. Refer to Figure 5-50, and proceed as follows:

For all removals:

Step 1. Remove the Laminator Station Assembly (see Section 5.2.22).

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For the Cooling Station Fan:

Step 2. Unplug the Fan Connector from the Daughter Board, remove the two screws
holding the Fan Bracket, and remove the fan and attached bracket.

Step 3. Remove the four screws that hold the fan to the bracket.

For the Card Sensor:

Step 4. Unplug the Card Sensor Connector from the Daughter Board.

Step 5. Remove the single nut holding the Card Sensor, and remove the sensor. Take
care not to lose the spacer that positions the sensor over holes in the card path.

For the Daughter Board:

Step 6. Unplug all the connectors identified in the figure.

Step 7. Remove the four screws (one at each corner) holding the board, and remove
the board.

Figure 5-50. Laminator Bottom-Accessible Components.

980327-002 5-49
CHAPTER 5

5.2.32 Laminator Rear Plate Removal

Three screws hold the Rear Plate to standoffs attached to the Middle Plate. All three are
accessible without removal of the Laminator CPU Board. Removal of the plate gives
access to underlying motors, sensors, and belts. Refer to Figure 5-51, and proceed as
follows:

Step 1. Remove the Rear and Front Case members (see Sections 5.2.1 and 5.2.2)
and the Laminator Assembly (see Section 5.2.22).

Step 2. Unlatch the Laminator Head, and tape the Release Latch in place.

Step 3. Unplug the connectors that supply dc power and data to the Daughter Board.

Step 4. Remove the three screws holding the Rear Plate, and then remove the Rear
Plate.

Figure 5-51. Laminator Rear Plate Removal.

5-50 980327-002
 CHAPTER 5

5.2.33 Laminator Middle Plate Sensor Replacements

Removal of the Rear Plate of the Laminator gives access to the Flag and Laminator Head
Latch optical sensors and Laminator Head Position switch sensors. Refer to Figure 5-52,
Remove the Rear Plate, and proceed as follows:

For each Optical sensor, remove the single mounting screw, and unplug the associated
connector from the Daughter Board.

For the switch sensors, remove the two screws that hold both in place, and unplug the
connector from the Daughter Board.

Figure 5-52. Mid-Plate-Mounted Sensors.

980327-002 5-51
CHAPTER 5

5.2.34 Laminator Motors and Rear Belts

Figure 5-53 shows the Rear Belts, Motor Fasteners and motor connections to the Daughter
Board.

Stepper Motor and Associated Belt:

Two screws hold the Stepper Motor in place. Servicing personnel should only secure the
motor by tightening the screws with the belt under proper tension (see Section 6.3.2).

Ribbon Take Up and Roller Transport Belts:

Two belts extend the control of the Stepper Motor to the two rollers that deliver cards to the
Platen Roller. Because of the pulley arrangement, a belt replacement may require the
removal of one or more other belts that lie in the way. To access a belt, servicing personnel
may need to remove either the large pulley on the Platen Roller or the screws securing the
Stepper Motor. A belt replacement accomplished without disturbing the Stepper Motor
avoids the use of the Belt Tensioning Procedure.

Dc Motors:

Dc motors drive the Ribbon Take Up Spindle and the cam that raises and lowers the
Laminator Head. Three screws secure each dc motor. Replacement also requires removal
of either the pulley or the cam, depending on the motor being replaced. Both the Pulley
and the Cam are positioned 0.063 inches (2.60 mm) from the Middle Plate.

5-52 980327-002
 CHAPTER 5

Figure 5-53. Printer Station Middle Panel Parts

980327-002 5-53
CHAPTER 5

5.2.35 Ribbon Supply Spindle and Clutch Replacements

Figure 5-54 shows the Ribbon Supply Spindle and associated Clutch Assembly.
Replacement options include any of the parts that appear in the exploded view.

Step 1. Remove the Laminator Assembly and its Rear Plate (see Sections 5.2.22 and
5.2.32).

Step 2. Remove the Flag Sensor Bracket.

Step 3. Unhook the two springs attached to the Laminator Head Latch Assembly.

Step 4. Remove the Laminator Head Latch Assembly after first removing the
associated nut and e-ring.

Step 5. Remove the Supply Spindle after first loosening the set screws.

Step 6. Slide the Spindle free of the rod and slide the remaining Flag and Clutch parts
away from the Printer Station.

Note: At this point, reassembly can occur with a new Clutch and Flag Assembly, a new
Spindle, or both. Also, with further disassembly, individual Clutch parts can be replaced
(note the items in the exploded view). However, any new Clutch Pads require a burn-in
followed by a torque test. Normally two washers are used on the side closest to the Middle
Plate to create the proper torque. Added washers increase torque while washer removal
decreases torque. A torque of from 185 to 250 centimeter grams produces the required
clutch friction.

5-54 980327-002
 CHAPTER 5

Figure 5-54. Supply Spindle Assembly

980327-002 5-55
CHAPTER 5

5.2.36 Laminator Ribbon Take Up Spindle Replacements

Figure 5-55 shows the Ribbon Take Up Spindle. Replacement options include any of the
parts that appear in the exploded view.

Step 1, Remove the Laminator Assembly and its Rear Plate (see Sections 5.2.22 and
5.2.32).

Step 2. Remove the timing belt from the Spindle Pulley.

Step 3. Loosen the set screws holding the Spindle to the Spindle Rod.

Step 4. Pull the Spindle away from the Spindle Rod toward the front.

Step 5. Pull the Spindle Rod and attached parts away from the Middle Plate toward
the rear.

Step 6. Replace any part(s) shown in the exploded view.

5-56 980327-002
 CHAPTER 5

Figure 5-55. Laminator Ribbon Take Up Spindle

980327-002 5-57
CHAPTER 5

5-58 980327-002
 CHAPTER 6
MAINTENANCE AND ADJUSTMENTS

This chapter contains procedures for Cleaning and Adjustments. A more thorough
cleaning than the Cleaning Card procedure offered in Chapter 2 appears in this chapter.
Other than roller, Heat Sink, and Print Head cleaning, no other regular maintenance
requirements exist. Under no circumstances should anyone ever apply either a lubricant
or any other unprescribed material to a component inside a P520 printer. To minimize any
chance of a residue, use only 99-percent pure or better cleaning solutions. Moreover,
users must maintain a printing and laminating environment essentially free of
contaminants that could migrate onto cards or Card Path elements.

Adjustments initially made at the factory typically remain operative for an extended period
and have no associated time- or use-based schedule for their employment. Adjustments
typically occur in response to a part replacement, a printer upgrade, or an operational
anomaly. Chapters four and five contain most of the referrals to the adjustments contained
here.

980327-002 6-1
CHAPTER 6

6.1 CLEANING MATERIALS

Figure 6-1 shows a Cleaning Kit swab.

Figure 6-1. Cleaning Swabs

6.2 CLEANING

This Section describes a manual cleaning of the Print Head and Card Transport Rollers.
For Encoder-equipped models, Encoder Heads require a cleaning using the Cleaning
Cards (see Cleaning Alert—Sections 2.2.6 and 2.2.11).

6.2.1 Card Transport, Platen, and Cleaning Rollers

Refer to Figure 6-2, and proceed as follows:

Step 1. Turn off power, open the Cover, raise the Print Head and remove the shroud
covering the card path down stream from the Print Head. Also remove any Card
and Ribbon media and the Cleaning Roller Cartridge.

Step 2. For recently operated systems, Print Head elements may remain hot. If so,
allow about five minutes to pass before proceeding.

Step 3. Select a suitable fiber-free cleaning media. For ordinary foam-tipped swabs
moisten with alcohol, For Eltron-supplied swabs, bend the foam tip until the
underlying plastic breaks and releases alcohol into the tip.

Step 4. For Transport Rollers, rub the Swab over all roller surfaces. Initiate brief card
feeds to expose initially hidden areas.

6-2 980327-002
 CHAPTER 6

Step 5. Before installing the Cleaning Roller Cartridge, remove and discard the
Cleaning Roller; clean the Rollers in and below the Cartridge, and replace the
Cleaning Roller (see Sections 2.1.4 through 2.1.6).

Step 6. Clean the Laminator Cleaning Roller with water or by rolling the roller over a
label with a slightly more tacky surface.

Ribbon Cleaning
Take Up Print Head Roller
Latched Flag
Magnetic Sensor
Encoder
(Option) Ribbon
Print Head Sensor Card
Sensor
Card Feed
Hopper

Card Feed
Transport and Roller
Card Platen Rollers
Path (Both Stations)
Smart Card Head
Station Up/Down
Daughter (Option)
Board Sensors

Cam Follower (Raises Encoder Station Pinch Card Feed and Printer Stations

Ribbon Laminator Ribbon Cleaning Card Card-Flip

Shroud Position Assembl
Sensor Station Supply Rollers

Card
Catcher

Flip
Rotatio
n
Card
Cooling Head Up/Down
Cam (Both Stations)

Card
Reject LED
Transmitter

Card Flip and Laminator Stations

Figure 6-2. Card Transport Rollers.

980327-002 6-3
CHAPTER 6

6.2.2 Cleaning the Print Head

Refer to Figure 6-3, and proceed as follows:

Step 1. Turn off power, and allow about five minutes for a cool down.

Step 2. Open the cover, raise the Print Head, and remove any ribbon installed.

Step 3. Using an alcohol-moistened swab and moderate pressure, clean the Print
Head elements. Check the condition of the swab. If necessary, finish with a clean
swab.

Figure 6-3. Print Head Cleaning.

6-4 980327-002
 CHAPTER 6

6.3 OBTAINING AND INSTALLING FIRMWARE UPDATES

P520 Firmware resides in Flash Memory. Those needing an update or reload can get the
latest version of the firmware from the Eltron Web Site (www.eltroncards.com). Once
there, selection of firmware and then the printer model produces a dialog box with the
related file already selected. At this point, all that is needed is a place to put the file. For a
P520 printer and a Firmware Version of 2.51, file name should appear as follows:

P310Cfirmware_v2_51.exe

From the dialog, complete the download by specifing any desired temperary location on
the C: Drive from which to execute the file (e.g., C:\Temp).

From DOS, run the downloaded file. This creates a C:\P520FW directory and places an
unzipped version of the Firmware File inside.

To change to the created directory, type CD\P520FW.

Make sure the PC is connected to the Printer using a Parallel Port (e.g., LPT1). Then type
P_FLASH_V2_P51.BIN and press <Enter>.

Note the Status Messages as the update progresses and finally, upon completion, ACK.

980327-002 6-5
CHAPTER 6

6.4 ADJUSTMENTS

Adjustments exist for the following:

• Stepper Belt Tension

• Image Centering
• Peel Bar and Laminator Sensor Bracket Positions

No specific adjustment interval exists. Some adjustments must occur after a part
replacement. Service personnel should wait for a deterioration in performance.

6.4.1 Printer Stepper Belt Tension

Three screws fasten the Stepper Motor to the rear chassis casting. For belt tensioning
purposes, two of the screws hold the motor through slotted holes. The remaining screw
feeds through a non-slotted hole that serves as a pivot point for motor position
adjustments. Refer to Figure 6-4, and proceed as follows:

Step 1. Remove the Printer Assembly and its rear plate (see Sections 5.2.6 and
5.2.13).

Step 2. Loosen the three screws holding the Stepper Motor just enough to allow the
motor to be repositioned. A half to three-quarter turn should suffice.

Figure 6-4. Printer Stepper Motor Fasteners.

6-6 980327-002
 CHAPTER 6

Step 3. Attach the Printer Belt Tensioning Fixture (C011) between the Stepper and
Platen pulleys (see Figure 6-5). Note that two cutouts on the fixture attach to the
platen and stepper pulley shafts, respectively, and that the post between these
cutouts must bear on the right side of the stepper belt. Also, the flat of the platen
shaft must face the flat on the fixture.

Figure 6-5. Stepper Motor Belt Tensioning Fixture (Part No. 900116-001).

980327-002 6-7
CHAPTER 6

Step 6. As shown in Figure 6-6, use a screwdriver as a pry-bar to move the Stepper
Motor to a position where the edge of the tension indicator on the fixture centers
between the stationary tabs.

Step 7. While holding the position established in Step 6, tighten the Stepper Motor
Screws. Then, manually flex the fixture a few times to verify a return to a proper
indication as specified in Step 6.

Step 8. Remove the fixture, and manually turn the larger pulley to verify a smooth
operation of all the stepper-driven pulleys and belts.

Step 9. Reassemble the printer, and print a card. Check for evidence of uneven card
feeds, such as, lines across the y axis.

6-8 980327-002
 CHAPTER 6

Figure 6-6. Stepper Belt Tensioning.

980327-002 6-9
CHAPTER 6

6.4.2 Print Head Tilt Adjustments

Print Head Tilt adjustments serve to position the imaging elements with reference to the
Platen Roller. Two alignments exist. The adjustment that tilts the Print Head relative to the
high point of the Platen Roller determines image brightness. The adjustment that aligns
the Print Head parallel across the Platen Roller removes any image fading across the short
axis of the card. Proceed as follows:

Step 1. Using either the Printer Driver or the Test Software, send the IM command.

Step 2. Check the Test Card produced by this command against the cards shown in
Figure 6-7 to determine any needed adjustments. Note that the faded stripes are used to
check for proper Print Head alignment relative to the Platen High Point. Edge voids signal
the need for Print Head lowering on the associated card side.

Figure 6-7. Head Alignment Test Cards.

For improper brightness, proceed as follows:

6-10 980327-002
 CHAPTER 6

Step 3. Unlatch the Print Head, and loosen the four Head Fasteners shown in Figure
6-11.

Step 4. Adjust the Brightness Adjustment Screw by either loosening or tightening.

Remember the amount and direction of adjustment. If loosening, push the Head
Assembly until the adjustment screw again bears against the Print Head Yoke.

Step 5. Tighten the Head Fasteners in the sequence shown.

Step 6. Print another Test Card. Then compare the cards. Any improvement in
brightness signals a proper direction of adjustment. Conversely, any deterioration
in brightness indicates that the adjustment should have been in the opposite
direction or possibly that too great an adjustment placed the Print Head beyond
the optimum point.

Step 7. Repeat Steps three through six until an optimum brightness is achieved.

Figure 6-8. Image Brightness Adjustment.

980327-002 6-11
CHAPTER 6

For an adjustment to make the Print Head parallel to the Platen Roller, continue as follows:

Step 8. Unlatch and raise the Print Head.

Step 9. Slightly loosen the Print Head fasteners shown in Figure 6-9. However, try to
maintain a tightness just sufficient to leave the Print Head position undisturbed.

Step 10. Examine the last Test Card printed to determine which side has a reduced
brightness. Then, slightly lower the corresponding side of the Print Head, and
tighten the screws.

Step 11. Perform a Peel Bar adjustment (see Section 6.3.3).

Step 12. Latch down the Print Head, and print another Test Card, Note the result of
the repositioning.

Step 13. Repeat Steps eight through 12 until a proper result is achieved.

Figure 6-9. Lower print Head Fasteners.

6-12 980327-002
 CHAPTER 6

6.4.3 Print Head Peel Bar Position Adjustment

Figure 6-10 shows the two screws that fasten the Peel Bar to the Print Head assemblies.
Slotted holes allow Peel Bar positioning. Peel Bars control ribbon flow over the Heads to
establish a centered take up without wrinkling or off-spindle travel. Proceed as follows:

Step 1. Open the Cover, raise the Head, and remove any ribbon.

Step 2. Connect the power and host I/O cables, lower the Cover, Latch down the
Printer and Laminator Heads, and turn power on.

Step 3. Position a 0.02-inch thick card in the card path under the Peel Bar such that
the card resides in Card Guides on both the leading and trailing edges.

Step 4. Latch down the Head, and issue a Head Down command (!D) from the
Window’s print driver or the Test Software (see Appendix A).

Step 5. Sufficiently loosen the two screws securing the Peel Bar to give the bar
freedom of movement. Note that the lower two screws secure other components
and do not interfere with this adjustment.

Step 6. Push down on the Peel Bar until both sides rest on the card.

Step 7. While holding this position, tighten the screws. Afterwards, check for any
displacement from the position established in Step 5.

Step 7. Issue a Head Up command (!M) from the Window’s print driver or the Test
Software, remove the card placed in Step 2, install a ribbon, and print one or more
cards while checking for an even ribbon take up.

Figure 6-10. Peel Bar Fasteners.

980327-002 6-13
CHAPTER 6

6.4.4 Image Centering

Centering establishes x- and y-offset values. The x offset determines when a Print Head
lowers and raises, between which printing occurs. The y offset determines which group of
Print Head elements produce images.

If the Print Head lowers too soon, the leading card edge in encountering an already
lowered Print Head can shear the ribbon. Another ribbon shear condition can occur if the
Print Head remains lowered past the trailing edge of the card, where the head can abruptly
drop below card level. Centering should be checked by printing a full-bleed image.

Proceed as follows:

Step 1. From the Window’s print driver, or Test software issue the “Print Test Card”
command (A). Note that the resulting printed card includes x- and y-offset values
(e.g., Offset X - Y 008-006.

Step 2. Create and print a full-bleed image using a suitable graphic application and
the Eltron-provided Window’s print driver).

Step 3. Check for the conditions below.

Result Remedy
Image Centered on Card None; Skip Remaining Steps
Ribbon Sheared (No Image), or Excessive Border at Trailing Edge Increase x Offset
Excessive Border at Leading Card Edge; Ribbon Shear Possible Decrease x Offset
Excessive Border at Card Edge Nearer Front of Printer. Increase y Offset
Excessive Border at Card Edge Nearer Back of Printer. Decrease y Offset

Probable starting points for Offsets are at or near:

Image Corner Controlled by Offset Values
X-offset = 0
Subtract X Add

Y-offset = 0
Subtract

Card Feed Direction

Y
Add

6-14 980327-002
 CHAPTER 6

Step 4. Either measure or estimate any departure from a centered image, and convert
the result to dots. Note that at 300 dpi, the distance between dots measures
0.00333... inches. Also, 300 dpi converts to 11.81 dots per millimeter, and the dot
spacing measures 0.085 millimeters.

Step 5. Either add or subtract (per the Remedy prescribed in table above) the Step-4
value(s) from the associated value(s) found on the Test Card printed in Step 1.

Step 6. Enter the new x and y offsets calculated in Step 5 using either the Window’s
print driver, or the Test Software, as follows:

For x values, enter:

O value

For y values enter:

OY value

Where:

value = new offset in dots (a <Space> separates the Command from the value).

980327-002 6-15
CHAPTER 6

6.4.5 Laminator Stepper Belt Tension

Three screws fasten the Stepper Motor to the Middle Plate. For belt tensioning purposes,
the lower screw holds the motor through an enlarged hole. The upper screw serves as a
pivot point for motor position adjustments. Refer to Figure 6-11, and proceed as follows:

Step 1. Remove the Laminator Assembly and its rear plate (see Section 5.2.32).

Step 2. Loosen the two screws holding the Stepper Motor just enough to allow the
motor to be repositioned. A half to three-quarter turn should suffice.

Figure 6-11. Laminator Stepper Motor Fasteners.

6-16 980327-002
 CHAPTER 6

Step 3. Attach the Belt Tensioning Fixture (C790) between the Stepper and Platen
pulleys (see Figure 6-12). Note that two cutouts on the fixture attach to the platen
and stepper pulley shafts, respectively, and that the bracket between these cutouts
must bear on the right side of the stepper belt. Also, the flat of the platen shaft must
face the flat on the fixture.

Figure 6-12. Laminator Stepper Motor Belt Tensioning Fixture.

980327-002 6-17
CHAPTER 6

Step 6. As shown in Figure 6-13, use a screwdriver as a pry-bar to move the Stepper
Motor to a position where the fixture pointer centers between on the marker.

Step 7. While holding the position established in Step 6, tighten the Stepper Motor
Screws. Then, manually flex the fixture a few times to verify a return to a proper
indication as specified in Step 6.

Step 8. Remove the fixture, and manually turn the larger pulley to verify a smooth
operation of all the stepper-driven pulleys and belts.

Step 9. Reassemble the printer, and print a card. Check for evidence of uneven card
feeds and Patch applications.

Figure 6-13. Laminator Stepper Belt Tensioning.

6-18 980327-002
 CHAPTER 6

6.4.6 Laminator Head Sensor and Peel Bar Adjustments

Step 1. With power off and ribbon removed, remove the Laminator Head Shield (see
Figure 6-14).

Figure 6-14. Laminator Head Shield.

Step 2. Connect the power and host I/O cables, lower the Cover, Latch down the
Printer and Laminator Heads, and turn on power.

Step 3. Open the Cover, and insert the C037 followed by the C177 Fixtures, both
under the Head as far as possible (see Figure 6-15). Avoid touching the hot
Lamination Roller.

Figure 6-15. Laminator Head Adjustment Fixtures.

980327-002 6-19
CHAPTER 6

Step 4. Send a Head Down Command to the Laminator (# 1 !D) using the Printer
Driver or Test Software (see Appendix A).

Step 5. Loosen the Peel Bar and Sensor Bracket Fasteners just enough to allow
repositioning (see Figure 6-16).

Step 6. While holding the C177 Fixture against the Print Head, position the Sensor
Bracket down against the Fixture. Make sure that both sides of the Sensor Bracket
touch the Fixture, and then tighten the Sensor Bracket Screws.

Step 7. With the Peel Bar pushed down against the C037 Fixture, tighten the Peel Bar
Screws.

Figure 6-16. Laminator Head Sensor Bracket and Peel Bar Fasteners.

Step 8. Issue a Head Up Command (# 1 !M), remove the fixtures, and reinstall the
Laminator Head Shield.

Step 9. Close the Cover and print some cards while checking for even ribbon take up.

6-20 980327-002
 APPENDIX A
TEST SOFTWARE

Test Software supports factory checks that contribute to a functioning Printer.

Because of the intuitive nature of the software, this appendix only calls attention to some
Typical Test Software operations. Service personnel should explore the selections
available to expand their ability to test and exercise assemblies within the Printer.

NOTE: This software operates in a DOS environment and may not always operate
properly under Windows 95/98 or NT.

A.1 INSTALLATION

Unzip a Copy the Test Software into a folder on the C drive or any other mapped volume.

A.2 OPERATION

Characteristically, the Test Software has a tree structure. A program launch produces a list
of selections. Selection of items in this list can either produce another list of related
selections or allow entry of a setup parameter. In any case, selection of an item from the
first list begins a path that leads—often via sub lists—to a desired result related to operation
of a P520 Printer.

The presentation here presumes a printer familiarity consistent with the information
contained in other sections of this manual. Therefore, with this information available,
servicing personnel should have no trouble interpreting listed items.

Begin by preparing the Printer for operation by attaching the cables (see Section 2.1.8).

980327-002 A-1
APPENDIX A

A.2.1 Launching the Card Printer Test Software

With DOS operating and the prompt set to the volume and folder containing the Test
Software (e.g., C:\PNTRTST). Enter the following to launch the executable file in
the folder:

p323v2p1

Note that the previous string may not launch later releases of the software. If not, check the
contents of the folder for a similar but perhaps different executable file name.

Note that a successful launch produces a screen similar to the following:

A-2 980327-002
 APPENDIX A

Selection of Item 3 from the previous screen (and entry of the code requested) produces the
following screen:

980327-002 A-3
APPENDIX A

Particularly note the following:

• A selection results by typing a list item number followed by <Enter>.

• Selection of Exit returns the DOS prompt.
• Selection of “Change of COM port” should always follow the program launch to
establish the port that has the Printer attached.
• Typing <Esc> usually returns the previous screen.

A.2.2 Changing the COM Port

Note the following screen, which appears with selection of Item 3. Change of COM PORT
offers three choices—two serial (COM 1 and COM 2) and one parallel (LPT 1). Item 3,
LPT1, is required when the PC is attached to the printer.

A-4 980327-002
 APPENDIX A

A.2.3 Operating in Terminal Mode

The following screen appears following selection of item 4, Terminal Mode, from the
second screen. Terminal Mode offers a convenient means for sending commands to the
printer. This screen allows entry of all applicable commands found in the Programmer’s
Manual. Before altering any of the parameters basic to printer operation, servicing
personnel should record the current printer configuration (see “Printer Configuration” in
second screen). This record can then serve as a basis both for subsequent changes and for
reestablishing any parameters that return the printer to a previous starting point.

980327-002 A-5
APPENDIX A

A.2.4 Typical Sub List

Selection of Item 2, Mechanic Test, from the second screen produces the following screen,
which offers related selections. Note that some items in this list produce an end result,
while others lead to another screen.

A-6 980327-002
 APPENDIX A

A.2.5 Sensor Test Selection

The following screen appears after selection of item 2, Sensors Test, from the previous
screen.

980327-002 A-7
World Wide Sales and Support
Zebra Technologies Corporation
Eltron Card Printer Products
1001 Flynn Road
Camarillo, CA 93012-8706 USA
Phone: +1 (805) 579 1800
FAX: +1 (805) 579 1808
Toll Free in US: (800) 452 4056
e-mail: [email protected]
Zebra Technologies Corporation
Eltron Card Printer Products (Europe, Middle East, Africa)
The Valley Centre, Gordon Road, High Wycombe
Buckinghamshire HP13 6EQ, UK
Phone: +44 (0) 870 241 1527
FAX: +44 (0) 870 241 0765
e-mail: [email protected]
Zebra Technologies Corporation
Eltron Card Printer Products, France
50, 56 rue Marcel Dassault
92100 Boulogne-Billancourt, France
Phone: +33 1 55 20 93 93
FAX: +33 1 55 20 93 99
e-mail: [email protected]
Zebra Technologies Corporation
Eltron Card Printer Products, Latin America
6175 NW 153rd Street #121
Miami Lakes, FL 33014 USA
Phone: +1 (305) 558 8470
FAX: +1 (305) 558 8485
e-mail: [email protected]
Zebra Technologies Corporation
Eltron Card Printer Products, Asia/Pacific
1 Sims Lane # 06-11
387355, Singapore
Phone: +65 84 20 322
FAX: +65 84 20 514
e-mail: [email protected]
CORPORATE HEADQUARTERS
Zebra Technologies Corporation
333 Corporate Woods Parkway
Vernon Hills, IL 60061-3109 USA
Phone: +1 (847) 634 6700
FAX: +1 (847) 913 8766
e-mail:[email protected]

980327- 002