DataCard CP80 Plus Manuals

Manuals and User Guides for DataCard CP80 Plus. We have 1 DataCard CP80 Plus manual available for free PDF download: Service Manual

DataCard CP80 Plus Service Manual (286 pages)

Card printers

Brand: DataCard | Category: Printer | Size: 30.09 MB

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
Chapter 4: Troubleshooting

63
- General Notes
  
  65
- General Troubleshooting Procedures
  
  66
- 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

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DataCard CP80 Plus Manuals

DataCard CP80 Plus Service Manual (286 pages)

Table of Contents

Chapter 1: Introduction

Chapter 2: Theory of Operation

Print Engine Functional Block Diagram

Laminator Functional Block Diagram

Printer Components

Laminator Components

Sequence of Operation

Graphics Printing

Magnetic Cards

Magnetic Stripe Primary Data Standards

Smart Card Technology

Chapter 3: Routine Maintenance

Required Tools and Supplies

Print Engine Routine Maintenance Procedure

Chapter 4: Troubleshooting

General Notes

General Troubleshooting Procedures

Performance Problems

Error Codes

Chapter 5: Adjustments

General Notes

Installing Printer Diagnostics

Using Printer Diagnostics

Network Option Adjustments

Software Adjustment Procedures

Chapter 6: Removal and Replacement

General Notes

Enclosure Components

Swingarm Assembly

Upper Printer Sensors

Upper Printer Motors

Upper Printer Assembly

Upper Duplex Module

Magnetic Stripe Option

Smart Card Option

Laminator Transport Assembly

Laminator Sensors

Laminator Motors

Major Subassemblies

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