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CP80 Plus
DataCard CP80 Plus User Manual
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CP80 and CP8
0 Plus Servi
ce Manual
6-39
5.
From the back of the printer, simultaneously pull out on the side latches and
lift the rear of the printer off the laminator.
6.
With the rear of the printer free, slide the printer back to disengage the front
retaining hook from the laminator chassis.
190
192
Table of Contents
Default Chapter
1
Service Manual
1
Table of Contents
3
Chapter 1: Introduction
11
Intended Audience
12
Avoiding Electrostatic Discharge
12
Plus Card Printers
12
Symbol Conventions
13
Chapter 2: Theory of Operation
15
Print Engine Functional Block Diagram
17
Laminator Functional Block Diagram
18
Printer Components
19
Sensors
19
Motors
20
Miscellaneous
21
LCD Service Mode Menu Diagram
22
Laminator Components
23
Sensors
23
Motors
23
Sequence of Operation
24
Power-On Initialization
24
Default Card Printing Sequence
24
Lamination Process
26
Graphics Printing
27
Printhead Settings
28
Magnetic Cards
30
Magnetic Data Principles
30
Magnetic Media
31
Encoding Format
35
Magnetic Stripe Primary Data Standards
38
ISO/IEC 7811 (Parts 2 and 6)
38
Aamva Dl/ID-2000
38
Saflok and Ving
38
Multiple Record Format (SDS)
39
JIS X 6302 (Type I and Type II Cards)
39
Magnetic Media Locations
40
Data Track Locations
41
Summary of Specifications
42
Character Encoding
43
Smart Card Technology
45
Contact Smart Cards
46
Non-Contact Smart Cards
47
Types of Cards
47
Communication
48
Signal Modulation
48
Signal Modulation Summary Diagram
49
Reader to Card Communication
50
Card to Reader Communication
50
Chapter 3: Routine Maintenance
53
Required Tools and Supplies
54
Print Engine Routine Maintenance Procedure
55
Clean the Interior of the Printer
55
Mechanical Inspection
57
Laminator Routine Maintenance Procedures
60
Clean the Interior of the Laminator
60
Mechanical Inspection
61
Run the Cleaning Cards
62
Chapter 4: Troubleshooting
63
General Notes
65
General Troubleshooting Procedures
66
Non-Clearing Repetitive Messages
66
Troubleshooting Sensors
67
Troubleshooting Motors (Printer)
69
Testing General DC Motors
69
Testing the Ribbon and Pick Motors
70
Testing the Cam Motor
70
Testing the Printhead Fan
71
Testing Transport and Duplex Motors
71
Troubleshooting Motors (Laminator)
71
Troubleshooting Other Devices
71
Testing the Smart Card Solenoid
71
Testing the Duplex Clutch
72
Diagnosing the Duplex Interface Board
73
Diagnosing the Ribbon RFID Antenna
73
Performance Problems
74
Printer Initialization Errors
74
Card Jams at Card Input
75
Card Jams in Printing Area
76
Ribbon Break Errors
77
Card Jams between Upper and Lower Duplex
77
Laminate Problems
78
Error Codes
80
Error Code Prefixes
80
General Notes
80
Driver API (AP)
81
Printer Driver Errors (DR)
82
Input Errors (IS)
84
Duplex Module Errors (DM)
84
System Errors (SY)
85
Magnetic Stripe Errors (MS)
87
Laminator Errors (OP)
92
Print Errors (PR)
96
Smart Card Errors (SC)
98
Chapter 5: Adjustments
99
General Notes
101
Installing Printer Diagnostics
102
Using Printer Diagnostics
104
Parts of the Diagnostics Window
104
Menu Options
105
Changing Printer Values
107
Viewing and Saving Values
108
Working with Scripts
109
Setting Printer Value Parameters
110
Printer ID
110
Card Registration Offset
110
Card Strip Offset
111
Ribbon Type
111
Ribbon Offset
111
Vertical Offset
111
Transport Speed
112
YMC, K, T, & F Strobe Duty
112
YMC, K, T, and F Power and Base Power
113
Duplex Infeed Offset
113
Duplex Home Offset
114
Duplex Print Return Offset
114
Duplex Handoff Offset
114
Smart Card Registration Offset
114
Image Clipping Leading and Trailing
115
Setting Printer Options
116
Viewing Printer Status
117
Testing Motors
118
Testing Motor Functions
119
Setting up Step Tests for the Printer
120
Running a Magnetic Stripe Test Card
121
Configuring the Magnetic Stripe Module
122
Configuring Custom Track Formats
124
Running Magnetic Stripe Diagnostics
125
Testing the Smart Card Option
126
Setting Laminator Values
128
Laminator Parameter Dependencies
129
Temperature
130
Patch Size
130
Foil Advance Offset
131
Card Registration Offset
132
Debow Enable
132
Roller down Distance
133
Transport Apply Speed
133
Foil Control 1(Foil Strip Distance)
134
Foil Control 2 (Foil Apply Speed Ratio)
134
Foil Control 3 (Foil Registration Speed)
135
Duplex Handoff Offset
135
Duplex Home Offset
135
Duplex Flipped Offset
135
Duplex Reject Offset
136
Duplex Debow Offset
136
Duplex Horizontal Infeed Offset
136
Duplex Vertical Infeed Offset
136
MFG Card Registration Baseline
137
MFG Temperature Baseline
137
MFG Patch Registration Baseline
137
Viewing Laminator Sensors and Enabling Heaters
138
Testing Laminator Motors
139
Network Option Adjustments
140
Software Adjustment Procedures
144
Saving and Restoring a Printer Configuration
144
Start Sentinel Position
147
Card Registration Offset Adjustment
148
Ribbon Offset Adjustment
149
Updating the Printer Firmware
150
Upper Duplex Rotational Adjustment
151
Lower Duplex Rotational Adjustment
152
Chapter 6: Removal and Replacement
153
General Notes
156
Symbols
156
Required Tools
156
Screw Torque Specifications
157
Print Engine Front Wire Routing Diagram
158
Print Engine Duplex and Printhead Wire Routing Diagram
159
Laminator Front Wire Routing Diagram
160
Laminator Rear Wire Routing Diagram
161
Power Supply Wire Routing Diagram
162
Print Engine Cable Connection Diagram
163
Laminator Cable Connection Diagram
164
Enclosure Components
165
Swingarm Cover
165
Main Enclosure
167
Input Hopper
169
LCD Display
171
Output Hopper
174
Swingarm Assembly
175
Printhead Fan
176
Printhead Spring
177
Upper Printer Sensors
178
Card Input Sensor
178
Swingarm Sensor
179
Ribbon Motion Sensor
180
Ribbon Index Sensor
181
Cam Sensor
182
Card Hopper Empty Sensor
183
Upper Printer Motors
184
Transport Motor
184
Pick Motor
185
Cam Motor
187
Ribbon Motor and Gear
188
Upper Printer Assembly
190
Transport Assembly
192
Main Control Board
195
Transport Timing Belt
199
Belt Tensioner Pulley and Tension Spring
200
Drive and Idler Pulleys
201
Cleaning Rocker Assembly
202
Front Rocker Assembly
203
Rear Rocker Assembly
204
Ribbon Guide
205
Pick Roller
207
Cleaning Drive Roller
209
Front Drive Roller
211
Rear Drive Roller
213
Platen Roller
216
Printhead Cam
217
Printhead Lifter
218
Front Card Guide
219
Rear Card Guide
220
RFID Antenna
222
Upper Duplex Module
223
Duplex Entry Sensor
225
Duplex Home Sensor
227
Duplex Interface Board
228
Duplex Entry Rocker
229
Duplex Motor
230
Magnetic Clutch/Spring Clutch/Duplex Rollers
232
Magnetic Stripe Option
236
Magnetic Stripe Circuit Board
236
Magnetic Stripe Registration Sensor
237
Magnetic Stripe Head
238
Magnetic Stripe Rocker Assembly
240
Smart Card Option
241
Smart Card Interface Board
241
Solenoid Assembly/Solenoid Link
242
Smart Card Contact
244
Contactless Smart Card Coupler
247
Laminator Transport Assembly
249
Power Supplies
250
Upper Laminator Transport Rollers
251
Lower Laminator Transport Rollers
253
Intermediate Transport Rollers and Card Guide
255
Upper Platen Roller
257
Lower Platen Roller
258
Rear Cooling Fan
259
Hand Guard
260
Laminator RFID Antennas
263
Laminator Sensors
264
Duplex Exit Sensor
264
Card Exit Sensor
265
Card Registration Sensor
266
Upper Foil Index Sensor
267
Lower Foil Index Sensor
268
Foil Motion Sensors
269
Heater Home Sensor
270
Laminator Motors
272
Card Transport Motor
272
Foil Advance Motors
274
Heater Lift Motors
275
Major Subassemblies
276
Upper Heater Assembly
276
Lower Heater Assembly
277
Upper Foil Drive Assembly
278
Lower Foil Drive Assembly
280
Heating Element/Heated Roller/Thermocouple
281
4
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DataCard CP80 Plus Specifications
General
Brand
DataCard
Model
CP80 Plus
Category
Printer
Language
English
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