Page 1: Service Manual
Datacard CP80™ and CP80™ Plus ® Card Printers Service Manual May 2007 Part No. 539490-002, Rev C...
Page 2 Liability Statement This product has been built to the high standards of Datacard Group. Please do not attempt to operate or repair this equipment without adequate training. Any use, operation, or repair in contravention of this document is at your own risk.
Page 3: Table Of Contents
Contents Chapter 1: Introduction __________________________________________________________ 1-1 Intended Audience_________________________________________________________________ 1-2 Avoiding Electrostatic Discharge ____________________________________________________ 1-2 Symbol Conventions ________________________________________________________________ 1-3 Chapter 2: Theory of Operation___________________________________________________ 2-1 Print Engine Functional Block Diagram _______________________________________________ 2-3 Laminator Functional Block Diagram_________________________________________________ 2-4 Printer Components ________________________________________________________________ 2-5 Sensors _______________________________________________________________________ 2-5 Motors _______________________________________________________________________ 2-6 Miscellaneous ________________________________________________________________ 2-7...
Page 4 Chapter 3: Routine Maintenance _________________________________________________ 3-1 Required Tools and Supplies _________________________________________________________ 3-2 Print Engine Routine Maintenance Procedure ________________________________________ 3-3 Clean the Interior of the Printer ________________________________________________ 3-3 Mechanical Inspection________________________________________________________ 3-5 Laminator Routine Maintenance Procedures _________________________________________ 3-8 Clean the Interior of the Laminator _____________________________________________ 3-8 Mechanical Inspection________________________________________________________ 3-9 Run the Cleaning Cards ______________________________________________________3-10 Chapter 4: Troubleshooting_______________________________________________________ 4-1...
Page 5 General Notes______________________________________________________________________ 5-3 Installing Printer Diagnostics _________________________________________________________ 5-4 Using Printer Diagnostics ____________________________________________________________ 5-6 Parts of the Diagnostics Window _______________________________________________ 5-6 Menu Options ________________________________________________________________ 5-7 Changing Printer Values_______________________________________________________ 5-9 Viewing and Saving Values _____________________________________________5-10 Working With Scripts ____________________________________________________5-11 Setting Printer Value Parameters ______________________________________________5-12 Printer ID_______________________________________________________________5-12 Card Registration Offset ________________________________________________5-12 Card Strip Offset _______________________________________________________5-13...
Page 6 Duplex Vertical Infeed Offset ___________________________________________5-38 MFG Card Registration Baseline _________________________________________5-39 MFG Temperature Baseline _____________________________________________5-39 MFG Patch Registration Baseline ________________________________________5-39 Viewing Laminator Sensors and Enabling Heaters ______________________________5-40 Testing Laminator Motors _____________________________________________________5-41 Network Option Adjustments _______________________________________________________5-42 Software Adjustment Procedures ___________________________________________________5-46 Saving and Restoring a Printer Configuration __________________________________5-46 Start Sentinel Position _________________________________________________________5-49 Card Registration Offset Adjustment __________________________________________5-50 Ribbon Offset Adjustment ____________________________________________________5-51...
Page 7 Cam Motor__________________________________________________________________6-35 Ribbon Motor and Gear ______________________________________________________6-36 Upper Printer Assembly_____________________________________________________________6-38 Transport Assembly___________________________________________________________6-40 Main Control Board __________________________________________________________6-43 Transport Timing Belt _________________________________________________________6-47 Belt Tensioner Pulley and Tension Spring _______________________________________6-48 Drive and Idler Pulleys ________________________________________________________6-49 Cleaning Rocker Assembly ___________________________________________________6-50 Front Rocker Assembly _______________________________________________________6-51 Rear Rocker Assembly________________________________________________________6-52 Ribbon Guide _______________________________________________________________6-53 Pick Roller ___________________________________________________________________6-55...
Page 8 Hand Guard________________________________________________________________6-108 Laminator RFID Antennas ____________________________________________________6-111 Laminator Sensors ________________________________________________________________6-112 Duplex Exit Sensor ___________________________________________________________6-112 Card Exit Sensor_____________________________________________________________6-113 Card Registration Sensor ____________________________________________________6-114 Upper Foil Index Sensor ______________________________________________________6-115 Lower Foil Index Sensor ______________________________________________________6-116 Foil Motion Sensors __________________________________________________________6-117 Heater Home Sensor ________________________________________________________6-118 Laminator Motors _________________________________________________________________6-120 Card Transport Motor _______________________________________________________6-120 Foil Advance Motors ________________________________________________________6-122 Heater Lift Motors ___________________________________________________________6-123...
Page 9 Revision Log Datacard CP80 and CP80 Plus Card Printers Service Manual Revision Date Description of Changes March 2006 First release of this document. June 2006 Updated for RoHS compliance. May 2007 Updated for release of CP80 Plus. Regulatory Compliance Notice for USA (FCC Notice) This equipment generates, uses, and can radiate radio frequency energy.
Page 10 Safety Issues All Datacard products are built to strict safety and reliability specifications in accordance with UL60950-1 and CUL requirements; therefore, safety issues pertaining to operation and repair of Datacard equipment are primarily environmental and human interface. The following basic safety tips are given to ensure safe installation, operation, and maintenance of Datacard equipment and are not to be considered as comprehensive on all matters of safety.
Page 11: Chapter 1: Introduction
Chapter 1: Introduction This chapter provides an introduction to the Datacard® CP80 and CP80 Plus card printers and how they function. Intended Audience______________________________________________________________ 1-2 Avoiding Electrostatic Discharge _________________________________________________ 1-2 Symbol Conventions _____________________________________________________________ 1-3 CP80 and CP80 Plus Service Manual...
Page 12: Intended Audience
Intended Audience This manual is intended for use by authorized representatives of Datacard who are responsible for the maintenance, service, and repair of the CP80 and CP80 Plus card printers. The service representatives must complete an authorized Datacard training course prior to servicing the printers.
Page 13: Symbol Conventions
This symbol indicates a reminder message or other additional information for the technician. Graphic callouts with a colored background provide incidental information about the graphic itself. Graphic leaders with a colored background indicate a direction of movement or similar information. CP80 and CP80 Plus Service Manual...
Page 14 Introduction...
Page 15: Chapter 2: Theory Of Operation
ISO/IEC 7811 (Parts 2 and 6) __________________________________________________________2-24 AAMVA DL/ID-2000 __________________________________________________________________ 2-24 Saflok and Ving______________________________________________________________________2-24 Multiple Record Format (SDS) _________________________________________________________2-25 JIS X 6302 (Type I and Type II Cards) ___________________________________________________2-25 Magnetic Media Locations ___________________________________________________________2-26 Data Track Locations ________________________________________________________________2-27 CP80 and CP80 Plus Service Manual...
Page 16 Summary of Specifications ___________________________________________________________2-28 Character Encoding _________________________________________________________________ 2-29 Smart Card Technology _________________________________________________________ 2-31 Contact Smart Cards ________________________________________________________________2-32 Non-Contact Smart Cards____________________________________________________________2-33 Types of Cards ___________________________________________________________________2-33 Communication _________________________________________________________________2-34 Signal Modulation ________________________________________________________________2-34 Signal Modulation Summary Diagram _____________________________________________2-35 Reader to Card Communication __________________________________________________2-36 Card to Reader Communication __________________________________________________ 2-36 Theory of Operation...
Page 17: Print Engine Functional Block Diagram
Print Engine Functional Block Diagram CP80 and CP80 Plus Service Manual...
Page 18: Laminator Functional Block Diagram
Laminator Functional Block Diagram Theory of Operation...
Page 19: Printer Components
Printer Components Sensors All of the optical sensors in the CP80 and CP80 Plus printers are of the open collector type, and are configured to be active-low with a pull-up resistor on the output. When the sensor is not active (or not connected at all) the control board sees a high voltage (5V) at the Signal input.
Page 20: Motors
Name Function Card Input The card input sensor is an interruption sensor that detects the presence of a card at the entrance of the printer and registers the trailing edge of the card for printing. Magnetic This encoder monitors the rotation of the idler roller in the magnetic stripe Stripe Optical module.
Page 21: Miscellaneous
Most of the communication aspects and the data transfer are controlled by an external software application that is transparent to the printer. The daughter board also provides a connection to control the smart card solenoid. CP80 and CP80 Plus Service Manual...
Page 22: Lcd Service Mode Menu Diagram
LCD Service Mode Menu Diagram Theory of Operation...
Page 23: Laminator Components
The duplex motor drives a gear on the duplex clutch. The clutch permits a single motor to operate the rollers, or to rotate the entire flipper assembly (this is discussed in more detail on page 2-7). CP80 and CP80 Plus Service Manual...
Page 24: Sequence Of Operation
Sequence of Operation Power-on Initialization When the printer is turned on, it begins its initialization routine. As the main control board initializes itself, the status light on the front of the printer will be steady amber. After the control board is initialized, the status indicator will cycle through red, amber, and green.
Page 25 The duplex entry sensor detects the card and determines the position within the flipper. With the magnetic clutch relaxed, the drive rollers pull the card into the module. The clutch is engaged and the motor rotates the flipper to the vertical position. CP80 and CP80 Plus Service Manual 2-11...
Page 26: Lamination Process
The clutch is released, and the motor drives the rollers to move the card down into the lower duplex. Using the same procedure, the lower duplex inserts the card into the laminator transport. Lamination Process The card is moved toward the laminator position at normal transport speed, as the laminate foil is registered.
Page 27: Graphics Printing
Graphics Printing The information presented in the following section is not required for servicing the CP80 and CP80 Plus printers but is presented to augment the customer engineer’s training and knowledge base. The printhead is made up of 672 microscopic heating elements. Each of these thermal elements is made from a printed circuit conductor etched into the printhead substrate (metallic-like foil).
Page 28: Printhead Settings
Printhead Settings A printed card is made up of 1013 discrete vertical (short edge of the card) columns printed across the length of the card. As each column is printed, the printhead circuitry activates the necessary pixels to transfer pigment from the ribbon to the card.
Page 29 The strobe setting value is a baseline number for a look-up table that the printer calculates for each printed column. The gray test card is used to detect strobe misadjustment. This test card is available only to the Advanced User in Diagnostics. CP80 and CP80 Plus Service Manual 2-15...
Page 30: Magnetic Cards
Magnetic Cards The information presented in the following section is not required for servicing the CP80 and CP80 Plus printers but is presented to augment the customer engineer’s training and knowledge base. Magnetic Data Principles This discussion is intended to be a primer for those who are not completely familiar with the principles of writing data to and reading data from a magnetic stripe.
Page 31: Magnetic Media
Ampere's Law, it is common practice in discussion to refer to the energy transfer as "induced current." This is appropriate as long as the conductor forms a closed circuit and Ohm's Law can be applied. CP80 and CP80 Plus Service Manual 2-17...
Page 32 Writing Data To write data to the magnetic material on a card, it is necessary to create a magnetic field near the stripe. This aligns all of the magnetic particles nearby in the same orientation (polarity). The Magnetic Write Head contains a small coil of wire wrapped around a semicircular iron core .
Page 33 For this reason, magnetic data is comprised of Transition Points where the polarity of the magnetism reverses, which results in north-to-north or south-to- south polarity. CP80 and CP80 Plus Service Manual 2-19...
Page 34 Magnetic Data The method for recording information on a magnetic stripe is called two- frequency, coherent phase encoding (also known as F/2F). Although the name is complex, the concept is simple: two signals are merged together and written as a single signal.
Page 35: Encoding Format
The record length is the total number of binary words (characters) that can be stored on a magnetic track. Bit density, word length, and the physical length of the stripe determine the maximum record length. CP80 and CP80 Plus Service Manual 2-21...
Page 36 Parity Check A parity check is a method of determining if an error has occurred. This is accomplished by adding one extra bit to the end of a binary character code. The purpose of the parity bit is to make the sum of data bits in a binary word either even or odd.
Page 37 LRC word in the same manner as it would for any other character.) Parity Binary Char Code Name Char Start Sentinel Sample Data Sample Data Field Separator Sample Data Sample Data End Sentinel Pre-LRC Sum Post-LRC Sum CP80 and CP80 Plus Service Manual 2-23...
Page 38: Magnetic Stripe Primary Data Standards
Magnetic Stripe Primary Data Standards The magnetic stripe on a card can store binary data in any form you wish; however, to maintain consistency, national and international standards are followed. A primary data standard is one that specifies how information is stored on a card.
Page 39: Multiple Record Format (Sds)
Type II: A JIS Type II card is a single-track card, and does not have an ISO/IEC equivalent. In the past, this type of card has frequently been referred to as J-Stripe, J-Track, NTT, or simply JIS Type II. (JIS Type II is now preferred.) CP80 and CP80 Plus Service Manual 2-25...
Page 40: Magnetic Media Locations
Magnetic Media Locations The physical location and size of the magnetic stripe on a card follows the specifications outlined in the two drawings below. The first graphic is for a two or three track card (ISO/IEC and JIS Type I). (Note that under the ISO and JIS standards, even if only one of the three tracks is used, the minimum track size follows this specification.) 2-26...
Page 41: Data Track Locations
The positions where data can be recorded on a 3-track stripe are described in the graphic below. This applies to all three of the aforementioned standards, but does not apply to a JIS Type II card. CP80 and CP80 Plus Service Manual 2-27...
Page 42: Summary Of Specifications
Summary of Specifications The preceding sections describe where magnetic data can reside on a card. This section describes the general format of that magnetic data. The following table summarizes the data specifications for the primary standards. ISO/IEC 7811 JIS Type II JIS Type I Parameter Track 1...
Page 43: Character Encoding
These 14 characters ! " & ' * + , : ; < = > @ _ are reserved for hardware control and cannot be part of the data content. (These may or may not be used by various device manufacturers.) Additional reserved characters. S,E,F Reserved characters for Start Sentinel, End Sentinel, and Field Separator. CP80 and CP80 Plus Service Manual 2-29...
Page 44 5-bit Numeric Character Set as Defined by ISO/IEC 7811 Binary Note Char Parity < > Code Description These characters are used to control the hardware and cannot be part of the data content. (These may or may not be used by various device manufacturers.) S,E,F Reserved characters for Start Sentinel, End Sentinel, and Field Separator.
Page 45: Smart Card Technology
Smart Card Technology The information presented in the following section is not required for servicing the CP80 and CP80 Plus printers but is presented to augment the customer engineer’s training and knowledge base. The underlying concept of smart cards is fairly simple: A chip is embedded inside a plastic card—the chip may be microprocessor based, or a simple...
Page 46: Contact Smart Cards
HID Corporation and is shown here for educational purposes. The printed image on the card is an artist’s rendering. Contact Smart Cards A contact smart card needs to connect to an external interface to provide the processor with power and to set up serial communication. The eight terminal contacts are described in the table below.
Page 47: Non-Contact Smart Cards
The Mifare card is fairly common because it is based on an open standard used by many manufacturers. According to the Phillips Corporation this format is fully compliant with the ISO/IEC 14443-A standard. CP80 and CP80 Plus Service Manual 2-33...
Page 48: Communication
Communication Communication with non-contact smart cards is slightly more complicated because there is no physical connection between the interface and the card. The card reader sends out a radio frequency broadcast, which not only provides power to the card, but also establishes communication. This is called inductive coupling, and is similar to the function of a transformer.
Page 49: Signal Modulation Summary Diagram
Phase Modulation: A data transition is signified by a shift in the signal’s phase. In this case, the phase is shifted 180 degrees by inverting the signal. CP80 and CP80 Plus Service Manual 2-35...
Page 50: Reader To Card Communication
Reader to Card Communication The reader communicates with the card by sending an amplitude modulated signal at 13.56 MHz. The modulation variant depends on the class of card. A Type-A card uses 100% Amplitude Shift Keying (ASK100%). A Type-B card uses ASK10% modulation.
Page 51 (inverted). The subcarrier is permitted to invert only at its own transition points (which is why the frequencies are even multiples of each other). CP80 and CP80 Plus Service Manual 2-37...
Page 52 2-38 Theory of Operation...
Page 53: Chapter 3: Routine Maintenance
Print Engine Routine Maintenance Procedure______________________________________ 3-3 Clean the Interior of the Printer ________________________________________________________ 3-3 Mechanical Inspection________________________________________________________________ 3-5 Laminator Routine Maintenance Procedure _______________________________________ 3-8 Clean the Interior of the Laminator_____________________________________________________ 3-8 Mechanical Inspection________________________________________________________________ 3-9 Run the Cleaning Cards______________________________________________________________3-10 CP80 and CP80 Plus Service Manual...
Page 54: Required Tools And Supplies
Required Tools and Supplies The following tools and supplies are needed for routine maintenance procedures. Description Part Number Compressed air (canned) TUL001-018 General purpose, non-abrasive cleaner Lint-free cloth TUL001-020 Isopropanol cleaning pen 557492-001 Isopropanol cleaning card 552141-001 Cleaning sleeve 549288-002 Printer Cleaning Card (isopropanol) 552141-001 Laminator Cleaning Card (sticky card)
Page 55: Print Engine Routine Maintenance Procedure
If the grease on the platen roller shaft has accumulated dirt and debris, wipe off the grease with a dry cloth, and re-grease the surfaces with Molykote DX grease. CP80 and CP80 Plus Service Manual...
Page 56 Use a cloth dampened with water to clean the sensor reflector on the printhead cartridge. Using an isopropanol cleaning pen, clean the thermal printhead by rubbing the isopropanol tip over the printing portion of the printhead. Sp35707s Routine Maintenance...
Page 57: Mechanical Inspection
Inspect the drive pulleys for wear and broken teeth. • Inspect the platen roller gear and pulley for wear and broken teeth. Inspect the ribbon drive gear for wear and broken teeth. Make sure it is securely seated on the motor shaft. CP80 and CP80 Plus Service Manual...
Page 58 Inspect the ribbon cartridge. • Inspect the spindle gear for wear and missing teeth. If the cassette has a plastic encoder wheel, inspect it for scratches and • missing lines. • Check the spindles for proper movement and to be sure the clutches are providing a slight drag.
Page 59 Inspect all sensors to make sure they are properly seated in their mounting locations. Continue with the Laminator Routine Maintenance Procedures listed below. CP80 and CP80 Plus Service Manual...
Page 60: Laminator Routine Maintenance Procedures
Laminator Routine Maintenance Procedures The entire routine maintenance procedure should be completed each time the laminator is serviced. This will help extend the life of the printer. Refer to chapter 6 of this manual for removal and replacement procedures. CAUTION: Do not spray or pour cleaner directly on or into any electrical device.
Page 61: Mechanical Inspection
Wipe the exterior of the printer with a cloth dampened with a non-abrasive, general purpose cleaning solution. Let the printer dry before connecting power. Inspect all sensor to make sure they are properly seated in their mounting locations. CP80 and CP80 Plus Service Manual...
Page 62: Run The Cleaning Cards
Run the Cleaning Cards Connect the printer to the computer and turn on the power. Remove the cleaning roller, print ribbon, laminator cartridges, and any cards from the input hopper. Open the Printer Toolbox Dialog, and click on Clean Laminator. Load the sticky cleaning card in the output hopper just below the static brush.
Page 63: Chapter 4: Troubleshooting
Chapter 4: Troubleshooting This chapter provides information for troubleshooting problems with the CP80 and CP80 Plus card printers. General Notes___________________________________________________________________ 4-3 General Troubleshooting Procedures _____________________________________________ 4-4 Non-Clearing Repetitive Messages_____________________________________________________ 4-4 Troubleshooting Sensors _______________________________________________________________ 4-5 Troubleshooting Motors (Printer)________________________________________________________ 4-7 Testing General DC Motors ________________________________________________________ 4-7...
Page 64 Magnetic Stripe Errors (MS) ___________________________________________________________4-25 Laminator Errors (OP)_________________________________________________________________ 4-30 Print Errors (PR) _______________________________________________________________________4-34 Smart Card Errors (SC)________________________________________________________________4-36 Troubleshooting...
Page 65: General Notes
To open Info Central, click on the icon installed to the desktop when the SmartDriver was installed on the computer. • If Info Central was not installed, insert the printer driver CD, click on User Information and then CP Series Info Central and e-Guide to install CP80 and CP80 Plus Service Manual...
Page 66: General Troubleshooting Procedures
General Troubleshooting Procedures CAUTION: This section is intended only for a fully trained technician. Performing these procedures in an inappropriate manner will damage the printer. Even a trained technician should use care in applying these procedures to avoid permanent damage to the printer. The following procedures serve as a rough guideline for isolating the cause of a failure.
Page 67: Troubleshooting Sensors
• If a spare sensor is not available, you can use an adjacent sensor from within the printer. (Except for the ribbon motion sensor, all sensors are electrically compatible.) CP80 and CP80 Plus Service Manual...
Page 68 • The sensor does not need to be the same type. For example, a transmissive sensor can be used in place of a reflective sensor. (The transmissive sensor is easier to block and unblock.) If the replacement sensor functions, then the original sensor is defective. Verify this by reconnecting the original sensor.
Page 69: Troubleshooting Motors (Printer)
• If the LED turns on regardless which motor is operating, then it is more likely that the main control board is faulty. CP80 and CP80 Plus Service Manual...
Page 70: Testing The Ribbon And Pick Motors
Testing the Ribbon and Pick Motors Because the ribbon and pick motors are identical, swapping the two motors can isolate whether the motor is faulty or the control board is faulty. Remove the wires from both motors. Take the two wires from the operable motor and connect them to the motor to be tested.
Page 71: Testing The Printhead Fan
To verify that the solenoid itself is functioning, plug it into the cam motor’s connector. CAUTION: Do not attempt to connect the solenoid into the printhead fan’s connector, as this may damage the fan’s driving circuitry. CP80 and CP80 Plus Service Manual...
Page 72: Testing The Duplex Clutch
Testing the Duplex Clutch CAUTION: Connecting or disconnecting the duplex interface cable from the main control board with the printer powered on may result in immediate damage to the main control board. Never make modifications to the interface board with the printer powered on. The driving circuitry for the duplex clutch is located on the duplex interface board.
Page 73: Diagnosing The Duplex Interface Board
If the printer cannot read any ID tag, first check the cable leading to the main control board. If the cable is connected properly, then the main control board is likely at fault. CP80 and CP80 Plus Service Manual 4-11...
Page 74: Performance Problems
Performance Problems Printer Initialization Errors Symptom Comments The printer initializes but reports a • Check the operation of the card input sensor using the card stuck in the transport, and sensor screen in Printer Diagnostics. If the sensor is always the transport runs more than blocked, it is either disconnected or not fully seated expected.
Page 75: Card Jams At Card Input
(obscured by part of the chassis). • If the sensor never blocks, either the cable has a short circuit, or the sensor is not seated at all (outside of the card track). CP80 and CP80 Plus Service Manual 4-13...
Page 76: Card Jams In Printing Area
Card Jams in Printing Area Symptom Comments • Clean the printer. Card stops prior to reaching the platen roller. • Increase the card registration distance. • Check the front rocker assembly springs for damage. • Check the front card guide and spring for damage. •...
Page 77: Ribbon Break Errors
The cards are not being handed assemblies. off properly between the upper duplex and lower duplex. • Verify that there are no obstructions on the interstage platform that block the opening, such as lost cards. CP80 and CP80 Plus Service Manual 4-15...
Page 78: Laminate Problems
Laminate Problems Symptom Comments • Check the card stock for quality problems. Cards are consistently scratched. • Check the laminate supply for quality problems. • Check the card gate in the input hopper for burrs. • Inspect the entire card path for burrs or debris. •...
Page 79 • Inspect the capstan roller for wear or build-up of debris. • Make sure the backup roller loading spring is in place and not distorted (applying pressure to the capstan roller). • Make sure the loading gate is fully closed and engaged. CP80 and CP80 Plus Service Manual 4-17...
Page 80: Error Codes
Error Codes When an unexpected or undesired event occurs, the printer and/or software will generate an error code to be displayed on the monitor. Many times the error code is intended to be informational to instruct the operator to perform a required or routine task.
Page 81: Driver Api (Ap)
AP 00805 data entered or the format selected. AP 00806 AP 00808 The application used a Datacard printer Select the CP80 or CP80 Plus printer. function with a printer other than the Datacard printer.
Page 82: Printer Driver Errors (Dr)
Printer Driver Errors (DR) Error Message text Comments Code • Make sure the printer status light is showing DR 00901 The printer is not responding. Check steady green. the printer and USB cable connections. • Check the cables. • Make sure the computer’s USB port is functioning.
Page 83 • Pause the printer before powering it off. DR 00921 A printer has been identified. Please wait while the driver reads the printer. CP80 and CP80 Plus Service Manual 4-21...
Page 84: Input Errors (Is)
Error Message text Comments Code DR 00924 The driver does not support the connected printer. Connect a supported printer or install the driver for this printer. DR 00925 The user does not have the required Log in with Administrator privileges. permissions for the printer.
Page 85: System Errors (Sy)
EEPROM flash data error. Obtain a new download an updated firmware update update file. utility. Make sure to use the correct firmware update utility for the specific ERR_SYS_FLASH_DATA printer. • Main control board problem. CP80 and CP80 Plus Service Manual 4-23...
Page 86 Error Symptom Comments Code SY-01312 EEPROM flash size error. A logo loaded into flash memory is too large. ERR_SYS_FLASH_SIZE SY-01314 Warning! EEPROM flash write error. Do Main control board problem. not power off the printer. RETRY the NOTE: Do not power off the printer. Try to update file.
Page 87: Magnetic Stripe Errors (Ms)
• Run the Calibrate MS Head in Diagnostics. • Check the magnetic stripe head. • Check the magnetic stripe optical encoder. • Check the magnetic stripe daughter board. CP80 and CP80 Plus Service Manual 4-25...
Page 88 Error Symptom Comments Code MS-01410 Start Sentinel error reading data An error was encountered at the beginning of the data record. If this occurs frequently: MS-01411 track 1, 2, or 3. • Run a cleaning card. MS-01412 • Try different card stock. MS_T1_SS_ERR •...
Page 89 • Check the operation of the card input and MS_MOVE4_ERR magnetic stripe sensors. • Check the front and magnetic stripe rockers for proper spring pressure and roller movement. • Check the transport for proper operation or obstructions. CP80 and CP80 Plus Service Manual 4-27...
Page 90 Error Symptom Comments Code MS-01421 A card was lost when The card was never detected by either the attempting to read or write magnetic stripe or card input sensors. magnetic stripe data on card. • Check the card input and magnetic stripe sensors for operation.
Page 91 • Check the magnetic stripe configuration settings MS-01434 Magnetic stripe module settings using Diagnostics. EEPROM write error. • Try the operation again. MS_FAC_WRITE_ERR • Power cycle the printer. If the error continues, replace the main control board. CP80 and CP80 Plus Service Manual 4-29...
Page 92: Laminator Errors (Op)
Error Symptom Comments Code • The main or magnetic stripe control board may MS-01435 The magnetic stripe module is be defective. not installed or detected. Make sure the card creation • Power cycle the printer. application does not send If the error continues, replace the main or magnetic stripe data if no magnetic stripe control board.
Page 93 • Replace the foil with a new spool. The RFID tag OP 01622 The printer cannot identify the may be defective. supply material in the L1 laminator. Install a different roll • Inspect the RFID antenna and cable. of material. ERR_OPT1_SUPPLY_TYPE CP80 and CP80 Plus Service Manual 4-31...
Page 94 Error Symptom Comments Code OP 01623 Hardware problem in the This is reported if the ambient temperature is out of laminator. range or if the board voltage is out of range. • If the board voltage is out of range, it is likely that ERR_OPT1_HARDWARE_ERR the second power supply (B0) on a dual laminator board is disconnected.
Page 95 OP 01674 A card is lost in the L2 The card was not seen by the card exit sensor. laminator. • Make sure the sensor is fully seated in the chassis. • Replace the sensor. ERR_OPT2_CARD_LOST CP80 and CP80 Plus Service Manual 4-33...
Page 96: Print Errors (Pr)
Print Errors (PR) Error Symptom Comments Code • Check the printhead cam sensor. The printhead cam is not in the 01703 correct position to print. • Inspect the cam gear for damage. • Test the cam motor. ERR_PRN_HEAD_POSITION The card is lost in the print area. The card was not seen by a sensor when it was 01705 expected.
Page 97 • Check antenna cable. ribbon or click OK to print one- • If the ribbon is a new type, the printer's firmware color (K) cards. may need to be updated to recognize it. ERR_PRN_RIBBON_TYPE CP80 and CP80 Plus Service Manual 4-35...
Page 98: Smart Card Errors (Sc)
Smart Card Errors (SC) Error Message text Comments Code • Verify that the smart card option is enabled using The smart card module is not Diagnostics. 01804 installed or detected. Make sure the card creation • Check the smart card assembly. Possible failed application does not request components are the sensor, the cable, and the smart card programming.
Page 99: Chapter 5: Adjustments
Setting Up Step Tests for the Printer ____________________________________________________5-22 Running a Magnetic Stripe Test Card__________________________________________________5-23 Configuring the Magnetic Stripe Module ______________________________________________ 5-24 Configuring Custom Track Formats ____________________________________________________5-26 Running Magnetic Stripe Diagnostics__________________________________________________5-27 Testing the Smart Card Option________________________________________________________5-28 CP80 and CP80 Plus Service Manual...
Page 100 Setting Laminator Values _____________________________________________________________5-30 Laminator Parameter Dependencies ______________________________________________5-31 Temperature _____________________________________________________________________5-32 Patch Size _______________________________________________________________________5-32 Foil Advance Offset ______________________________________________________________5-33 Card Registration Offset __________________________________________________________5-34 Debow Enable ___________________________________________________________________5-34 Roller Down Distance_____________________________________________________________5-35 Transport Apply Speed ___________________________________________________________5-35 Foil Control 1(Foil Strip Distance)___________________________________________________5-36 Foil Control 2 (Foil Apply Speed Ratio) _____________________________________________5-36 Foil Control 3 (Foil Registration Speed) _____________________________________________5-37 Duplex Handoff Offset ____________________________________________________________5-37 Duplex Home Offset ______________________________________________________________5-37...
Page 101: General Notes
General Notes This document is organized sequentially for the customer engineer who is encountering an CP80 or CP80 Plus printer for the first time, and begins with installing the diagnostic software, navigating and using the software, and concludes with specific adjustment procedures for the printer.
Page 102: Installing Printer Diagnostics
Installing Printer Diagnostics Before you begin, confirm that the printer driver has been installed on the computer. Diagnostics will not run without the print driver. Procedure Insert the printer driver CD into your CD drive. The CD should run automatically and display the following window. If the CD does not auto start, run the setup.exe file from the CD.
Page 103 You will then be asked to which program group the icon should be added. Make no changes and click Next. The program performs the installation and informs you when it is completed. Click on Finish. CP80 and CP80 Plus Service Manual...
Page 104: Using Printer Diagnostics
Using Printer Diagnostics The first time you use the Printer Diagnostics you may be required to select the printer model. Make sure the printer is connected and powered on, and then click on the appropriate printer. Next, select User Properties from the File menu to change the logon level. Select Advanced User from the list and press OK.
Page 105: Menu Options
Printer | Flash Update This option provides a method for manually updating the printer’s firmware. This feature is used only with *.fls files, and does not function with the flash update found in the driver software. CP80 and CP80 Plus Service Manual...
Page 106 Option Purpose Printer | Motor Tests This option allows you to operate each of the motors in the printer for a specified duration as described in Testing Motors. Printer | Motor Cycle Tests This option is for selecting a motor to test by having it complete a full cycle of operation as described in Testing Motor Functions.
Page 107: Changing Printer Values
If the changes are not acceptable, either reset the printer or turn it off. If the changes are acceptable, click on the Save current values to Power-on button to store the changes permanently. You will be prompted for a password. Enter 42360. CP80 and CP80 Plus Service Manual...
Page 108: Viewing And Saving Values
Viewing and Saving Values The buttons on the right of the Printer Values dialog box are used to choose what values are listed in the current values window. Current values Displays the current parameter values. View current values Select to display the values that are currently loaded in the printer’s non-permanent memory.
Page 109: Working With Scripts
The script can then be loaded into another printer for batch processing a series of printers. Click on Clear list if you want to clear the scripting window. CP80 and CP80 Plus Service Manual 5-11...
Page 110: Setting Printer Value Parameters
Setting Printer Value Parameters The following sections describe how to modify the printer parameters. Please note the following: • Just because a parameter is listed and explained here does not mean it should be altered. Those parameters that should not be altered are so noted in the description.
Page 111: Card Strip Offset
Viewing Printer Status. This will provide the ribbon type number as well as the Datacard part number. Ribbon Offset This parameter tells the printer how far to advance the print ribbon after the index mark is detected by the ribbon index sensor.
Page 112: Transport Speed
This value is best modified in the printer driver interface under the Edge to Edge tab. Range -15 to 15 Increase Value The printed image moves toward the right on a portrait- oriented card. Decrease Value The printed image moves toward the left on a portrait- oriented card.
Page 113: Ymc, K, T, And F Power And Base Power
If this value is incorrectly set, the card may bind as the duplex rotates. Range 1 to 80 Increase Value The card travels further into the duplex. Decrease Value The card travels less distance into the duplex. CP80 and CP80 Plus Service Manual 5-15...
Page 114: Duplex Home Offset
Duplex Home Offset This parameter controls where the duplex flipper stops when in the home position. Refer to the Upper Duplex Rotational Adjustment procedure (p. 5-53). Range 1 to 40 Increase Value The index pointer moves toward the lower letters (see the adjustment procedure).
Page 115: Image Clipping Leading And Trailing
Frequent ribbon breaks at the leading or trailing edge of a card. • Increase the image clipping to prevent the printhead from overheating the ribbon before printing should begin. CP80 and CP80 Plus Service Manual 5-17...
Page 116: Setting Printer Options
Setting Printer Options The Printer Options window controls various aspects and features of the printer. Option Description Enable duplex module Enable or disable the duplex module for printers so equipped. Enable speaker audio Enable or disable the speaker output of the printer. Enable mag stripe Enable or disable the magnetic stripe capabilities of the printer.
Page 117: Viewing Printer Status
Select this option and click Query to display the type of ribbon detected by the printer in the display window Laminate information This option is available only for the CP80 and CP80 Plus printers. CP80 and CP80 Plus Service Manual...
Page 118: Testing Motors
Testing Motors This dialog box allows you to operate each of the motors in the printer for a specified duration. Procedure Select from this list of available motor tests: • Transport Motor (fast, slow, forward, or reverse) • Ribbon Motor •...
Page 119: Testing Motor Functions
Click Start to begin the test (Stop ends the test before it completes all the cycles). Click Reset Printer as it is a good practice to reset the printer before returning to card production. CP80 and CP80 Plus Service Manual 5-21...
Page 120: Setting Up Step Tests For The Printer
Setting Up Step Tests for the Printer The Printer Step Test dialog box offers a series of routines from the printer’s firmware. Each routine can be run individually or as a procedure of successive routines. Buttons that are appropriate for the printer model are selectable; the others are grayed out.
Page 121: Running A Magnetic Stripe Test Card
Encode and print Click on this button to encode the card and print test graphics on the card. The printing on the card duplicates the character data encoded on the card. CP80 and CP80 Plus Service Manual 5-23...
Page 122: Configuring The Magnetic Stripe Module
Configuring the Magnetic Stripe Module This option is available only with the Advanced User login. Start sentinel adjustment The Track # boxes show the current start sentinel values and the format defined for the track. This allows for adjusting the start sentinel position to a custom location. Refer to the Start Sentinel Position adjustment procedure on page 5-49 for further information.
Page 123 Custom track formats The options on the right side of the screen open a separate dialog box for customizing the magnetic stripe formatting. Refer to Configuring Custom Track Formats on page 5-26. CP80 and CP80 Plus Service Manual 5-25...
Page 124: Configuring Custom Track Formats
Configuring Custom Track Formats The purpose of the Custom Track Format dialog box is to permit the customer engineer the ability to set up a custom format to meet the specific needs of the end user. This dialog box is available only with the Advanced User login. Further information about magnetic data formats is located in the Theory of Operation chapter of this manual.
Page 125: Running Magnetic Stripe Diagnostics
• Click on Start in the Mag stripe encoder test to cause the transport motor to turn for about half a second and report the number of encoder interrupts in the display box. CP80 and CP80 Plus Service Manual 5-27...
Page 126: Testing The Smart Card Option
Testing the Smart Card Option The smart card test is a built-in routine to simulate smart card personalization. A card is picked from the hopper, personalized, and transported to the smart card module. The module issues the Reset command to the card, and the card responds by sending its ATR (Answer To Reset) signal.
Page 127 If necessary, perform additional testing on the card using the customer software application. Click on the Smart card continue button to eject the card and display the results in the status window. CP80 and CP80 Plus Service Manual 5-29...
Page 128: Setting Laminator Values
Laminator Values parameters. Please note the following: • Descriptions indicate which parameters should not be altered. Do not modify these parameters without contacting Datacard first. • Some of the offsets have links to specific procedures for setting the values.
Page 129: Laminator Parameter Dependencies
Duplex Debow Offset Duplex Horizontal Infeed Offset Duplex Vertical Infeed Offset MFG Card Registration Baseline* MFG Temperature Baseline* MFG Patch Registration Baseline* * These parameters are available only when logged in as an Advanced User. CP80 and CP80 Plus Service Manual 5-31...
Page 130: Temperature
Temperature The Temperature setting controls the operating temperature of the heated roller while it is applying the laminate material to the card. Range 50 to 210 °C Increase Value Increases the temperature of the heated roller. Decrease Value Decreases the temperature of the heated roller. Symptom/Solution Laminate not adhering to the card.
Page 131: Foil Advance Offset
• Decrease the foil advance offset. Patch material is too far from the leading edge of the card. • Decrease the foil advance offset. * Note that this can also be caused by an improper Card Registration Offset. CP80 and CP80 Plus Service Manual 5-33...
Page 132: Card Registration Offset
Card Registration Offset This setting determines the card’s position when the heated roller is lowered. This offset is relative to the MFG Card Registration Baseline setting. • If the MFG Card Registration Baseline is properly adjusted, setting the Card Registration Offset to zero should position the leading edge of the card directly under the nip of the rollers.
Page 133: Roller Down Distance
Unless the printer is exhibiting signs of resonance during the laminating process (such as excessive noise), this value should remain at the factory default setting. Range 100 to 1800 (steps/sec.) Symptom/Solution The transport motor stalls. • Decrease the apply speed. CP80 and CP80 Plus Service Manual 5-35...
Page 134: Foil Control 1(Foil Strip Distance)
Foil Control 1(Foil Strip Distance) The Foil Control 1 setting determines how far the foil is pulled after the heated roller is lifted. Pulling on the foil causes it to separate from the card. Range 0 to 1500 (mils) Increase Value Increases the distance the foil is pulled at the end of the lamination process.
Page 135: Foil Control 3 (Foil Registration Speed)
• Adjust the Duplex Handoff Offset, and then set this value to be 60 units smaller than the Handoff Offset. Range 1 to 100 (steps) Value Duplex Handoff Offset minus 60 CP80 and CP80 Plus Service Manual 5-37...
Page 136: Duplex Reject Offset
Duplex Reject Offset The Duplex Reject Offset controls where the duplex flipper stops when in the reject position. • Adjust the Duplex Handoff Offset, and then set this value to be 26 units larger than the Handoff Offset. Range 1 to 200 (steps) Value Duplex Handoff Offset plus 26 Duplex Debow Offset...
Page 137: Mfg Card Registration Baseline
• • If the MFG Patch Registration Baseline is properly adjusted, setting the Foil Advance Offset to zero should position the leading edge of the patch directly under the nip of the rollers. CP80 and CP80 Plus Service Manual 5-39...
Page 138: Viewing Laminator Sensors And Enabling Heaters
Viewing Laminator Sensors and Enabling Heaters The Laminator Sensor Display dialog box displays information about the laminator sensors. It also allows you to enable or disable the heaters. 5-40 Adjustments...
Page 139: Testing Laminator Motors
Duplex Clutched (rotates the flipper) • Enter the number of seconds to run the test. Click Start to begin the test. Click Reset printer. It is good practice to reset the printer before returning to card production. CP80 and CP80 Plus Service Manual 5-41...
Page 140: Network Option Adjustments
The MAC Address is a unique identifier for the physical printer. The first 6 digits of the MAC address are assigned to Datacard and cannot be changed. The remaining 6 digits are assigned to each individual printer. The MAC Address shown on the LCD display should match the address printed on the chassis.
Page 141 If DHCP is selected, the IP Addresses submenu will no longer be visible. • If Static IP is selected, you will automatically be brought into the IP Addresses submenu before the printer reboots. CP80 and CP80 Plus Service Manual 5-43...
Page 142 To change any of the IP Addresses, enter the IP Addresses submenu. The image below shows the options under the IP Addresses menu. Use the Up or Down arrow to select the address to change and press the Enter key. Use the Up or Down arrow to change the value in each field, and press the Enter key to move the cursor to the next field.
Page 143 Enter key to move to the next field. After the value has been changed, press the Enter key to apply the settings and reboot the printer. CP80 and CP80 Plus Service Manual 5-45...
Page 144: Software Adjustment Procedures
Software Adjustment Procedures Saving and Restoring a Printer Configuration Procedure Notes If the control board is not being replaced with a new board, it is important to keep the existing serial number as described in step 1.B on page 5-47. If this procedure is being completed because the main control board was replaced, note the following items: •...
Page 145 Using a text editor (Notepad), open the original configuration script you saved in step 3 above and make the following changes: Delete the header from the file ("Printer Values Datacard Card Printer Printer Offsets"). Locate the entry Printer ID: xxxxx.
Page 146 If this procedure resulted in a duplicate instance (Null serial number) of the driver, the only way to fully remove this instance is to uninstall ALL Datacard printers from the PC, at which time the Clean-up Utility removes leftover files.
Page 147: Start Sentinel Position
If the customer requires a custom start sentinel position, alter the numeric entries for each track in the entry boxes. Since this is custom, you will have to refer to the customer’s procedure for this setting. CP80 and CP80 Plus Service Manual 5-49...
Page 148: Card Registration Offset Adjustment
Card Registration Offset Adjustment Use the Card Registration Offset adjustment to set the distance a card travels after being detected by the Card Input sensor. Procedure In Printer Diagnostics, click on the Printer menu and select Values. Record the current customer settings for image clipping, and then set both values to zero.
Page 149: Ribbon Offset Adjustment
Verify the settings with a new ribbon and also with a near-empty ribbon, as the spool diameters may impact the results. Click Save to Power-on defaults to store the new value permanently. Enter 42360 in response to the password prompt. CP80 and CP80 Plus Service Manual 5-51...
Page 150: Updating The Printer Firmware
• If Datacard has provided you with a flash update file that is newer than the firmware utility in the printer driver. Update the firmware using Diagnostics if an *.fls file is used. After selecting the *.fls file, the rest of the procedure is automated.
Page 151: Upper Duplex Rotational Adjustment
Handoff offset should be 77 units larger than the Home offset. Parameter Change Sample Duplex Home Offset Baseline Duplex Print Return Offset Add 6 Duplex Handoff Offset Add 77 Save the values to Power-on defaults. CP80 and CP80 Plus Service Manual 5-53...
Page 152: Lower Duplex Rotational Adjustment
Lower Duplex Rotational Adjustment This adjustment sets the Lower Duplex Handoff offset. Other duplex position offsets are adjusted based on the resulting value of the Duplex Handoff offset. Adjustment Procedure From Diagnostics, select Printer and then Step Test. Click on the Move lower duplex to handoff position button. The flipper will rotate and re-register at the handoff position.
Page 153: Chapter 6: Removal And Replacement
Chapter 6: Removal and Replacement This chapter provides instructions for removal and replacement of assemblies and parts in the CP80 and CP80 Plus card printers. General Notes___________________________________________________________________ 6-4 Symbols ______________________________________________________________________________ 6-4 Required Tools ________________________________________________________________________ 6-4 Screw Torque Specifications ___________________________________________________________ 6-5...
Page 154 Ribbon Motor and Gear______________________________________________________________6-36 Upper Printer Assembly _________________________________________________________ 6-38 Transport Assembly __________________________________________________________________6-40 Main Control Board __________________________________________________________________6-43 Transport Timing Belt _________________________________________________________________6-47 Belt Tensioner Pulley and Tension Spring _______________________________________________6-48 Drive and Idler Pulleys ________________________________________________________________6-49 Cleaning Rocker Assembly ___________________________________________________________6-50 Front Rocker Assembly _______________________________________________________________6-51 Rear Rocker Assembly _______________________________________________________________6-52 Ribbon Guide _______________________________________________________________________6-53 Pick Roller ___________________________________________________________________________6-55...
Page 155 Foil Advance Motors ________________________________________________________________6-122 Heater Lift Motors ___________________________________________________________________6-123 Major Subassemblies __________________________________________________________ 6-124 Upper Heater Assembly _____________________________________________________________6-124 Lower Heater Assembly _____________________________________________________________6-125 Upper Foil Drive Assembly ___________________________________________________________6-126 Lower Foil Drive Assembly ___________________________________________________________6-128 Heating Element/Heated Roller/Thermocouple _______________________________________6-129 CP80 and CP80 Plus Service Manual...
Page 156: General Notes
General Notes • After completing replacement procedures, always perform the routine maintenance procedures in chapter 3 of this manual. • Verify that the printer functions correctly after replacing parts by performing and/or observing a limited customer production run. • Some photographs use light-colored components for clarity and high contrast. Symbols Chapter 1 of this manual provides a complete listing of symbol conventions.
Page 157: Screw Torque Specifications
Magnetic stripe encoder set screw 1.2±0.1 Magnetic stripe encoder mounting screws 0.9±0.1 Laminator transport motor 8±0.8 Heater lift motor 8±0.8 Swingarm cover screws (locking option) 12±1.2 Key lock barrel nut 16±1.6 Key lock cam nut 12±1.2 CP80 and CP80 Plus Service Manual...
Page 158: Print Engine Front Wire Routing Diagram
Print Engine Front Wire Routing Diagram Removal and Replacement...
Page 159: Print Engine Duplex And Printhead Wire Routing Diagram
Print Engine Duplex and Printhead Wire Routing Diagram CP80 and CP80 Plus Service Manual...
Page 160: Laminator Front Wire Routing Diagram
Laminator Front Wire Routing Diagram Removal and Replacement...
Page 161: Laminator Rear Wire Routing Diagram
Laminator Rear Wire Routing Diagram CP80 and CP80 Plus Service Manual...
Page 162: Power Supply Wire Routing Diagram
Power Supply Wire Routing Diagram 6-10 Removal and Replacement...
Page 163: Print Engine Cable Connection Diagram
Print Engine Cable Connection Diagram CP80 and CP80 Plus Service Manual 6-11...
Page 164: Laminator Cable Connection Diagram
Laminator Cable Connection Diagram 6-12 Removal and Replacement...
Page 165: Enclosure Components
If the printer is equipped with locking covers, you will need to remove the two security screws from the inside of the swingarm just below the printhead fan. Place your fingertips under the back of the cover and pull back to release the retaining tab. CP80 and CP80 Plus Service Manual 6-13...
Page 166 Push the cover toward the swingarm latch, and then rotate it upward to release the forward retaining tab. Pull the cover back and lift it off the swingarm. 6-14 Removal and Replacement...
Page 167: Main Enclosure
Gently pry down on the two locking tabs and separate the two halves of the enclosure slightly. Press down on the upper locking tab (located behind the input hopper) and separate the two halves of the chassis. CP80 and CP80 Plus Service Manual 6-15...
Page 168 Release the retaining latches between the interstage platform and the enclosure by pressing up on each corner of the interstage platform. Release the retaining tabs from the output hopper by flexing the enclosure inward, and then tilting the enclosure away from the printer. Replacement Notes •...
Page 169: Input Hopper
Main Enclosure (page 6-15). Press in on the transport chassis locking tabs, and lift up on the back of the transport assembly. Disconnect the LCD display’s data cable from the main control board. CP80 and CP80 Plus Service Manual 6-17...
Page 170 Simultaneously pull back on the transport chassis and forward on the input hopper. Remove the hopper from the chassis. 6-18 Removal and Replacement...
Page 171: Lcd Display
Remove the Main Enclosure (page 6-15). Press in on the transport chassis locking tabs, and lift up on the back of the transport assembly. Disconnect the LCD cable connector from the main control board. CP80 and CP80 Plus Service Manual 6-19...
Page 172 Remove the card hopper by simultaneously pulling back on the transport chassis and forward on the card hopper. Remove the Lower cover from the hopper: Place your fingertips between the main hopper body and the rear edge of the lower cover (see “Lift Here” below). Gently pry up on the edge of the cover slightly.
Page 173 Replacement Note When replacing the lower cover, line up the guide rails and slide the two pieces together. CP80 and CP80 Plus Service Manual 6-21...
Page 174: Output Hopper
Output Hopper Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15). Press up on the hopper retaining latches (one on either side of the hopper) and pull the hopper straight out to remove it.
Page 175: Swingarm Assembly
Unhinge the swingarm by pulling each side off the hinge pins. Replacement Note Replace the cable tie if it was cut free. • • Refer to the Print Engine Duplex and Printhead Wire Routing Diagram on page 6-7. CP80 and CP80 Plus Service Manual 6-23...
Page 176: Printhead Fan
Printhead Fan Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15) and the Swingarm Cover (page 6-13). Unplug the fan from the main control board. To remove the fan, press in on the two retaining tabs and lift the fan out from the top of the swingarm.
Page 177: Printhead Spring
Press in on the printhead release lever and remove the printhead. Pull up firmly on the printhead spring to unhook it from the retaining pin on the swingarm latch. Remove the other end of the spring from the printhead release lever. CP80 and CP80 Plus Service Manual 6-25...
Page 178: Upper Printer Sensors
Upper Printer Sensors Card Input Sensor Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15). Gently press the side of a screwdriver against the tip of the sensor (removal access slot shown below) and push it out of the chassis.
Page 179: Swingarm Sensor
• Refer to the Print Engine Front Wire Routing Diagram Print Engine Cable Connection Diagram for replacement details. • Use the sensor display in Diagnostics to verify that the sensor is functional. CP80 and CP80 Plus Service Manual 6-27...
Page 180: Ribbon Motion Sensor
Ribbon Motion Sensor Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15). Remove the sensor: Insert a screwdriver under the sensor's circuit board and gently twist to free the sensor from the retaining pin.
Page 181: Ribbon Index Sensor
Refer to the Print Engine Front Wire Routing Diagram Print Engine Cable Connection Diagram for replacement details. • Use the sensor display in Diagnostics to verify the sensor changes state as the ribbon is advanced. CP80 and CP80 Plus Service Manual 6-29...
Page 182: Cam Sensor
Cam Sensor Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15). Remove the Upper Printer Assembly from the interstage platform (page 6- 38). Close and lock the swingarm, and turn the printer upside down. Rotate the printhead cam until the cam flag is clear of the sensor.
Page 183: Card Hopper Empty Sensor
CAM Motor. Pull the wire free from the printer. Unclip the sensor bracket from the card input hopper. Sensor Bracket Sensor Replacement Notes Use Diagnostics to verify that the sensor is working properly. CP80 and CP80 Plus Service Manual 6-31...
Page 184: Upper Printer Motors
Upper Printer Motors Transport Motor Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15). Remove the Upper Printer Assembly from the interstage platform (page 6- 38).
Page 185: Pick Motor
To access the motor mounting screws, it is necessary to remove the Input Hopper (page 6-17). Unsnap the rear transport feet from the base. Slide the transport chassis back, and simultaneously pull forward on the input hopper. Remove the card hopper. CP80 and CP80 Plus Service Manual 6-33...
Page 186 Remove the two screws that secure the pick motor to the transport chassis, and remove the motor. Replacement Procedure Place the pick roller in the transport chassis. While positioning the pick motor, rotate the pick roller until the shaft-flat lines up with the flat on the roller. Tighten the mounting screws to 8 in-lbs.
Page 187: Cam Motor
Tighten the mounting screws to 8 in-lbs. • Refer to the Print Engine Cable Connection Diagram for replacement details. • Run the Printhead Cam Test in Diagnostics to verify that the motor is functional. CP80 and CP80 Plus Service Manual 6-35...
Page 188: Ribbon Motor And Gear
Ribbon Motor and Gear Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15). Unhinge the swingarm by pulling back on the hinge tab. Using pliers, pull the gear off the motor shaft. (During replacement, make sure to line up the shaft flats.) Remove the two screws that secure the motor to the transport chassis, and remove the motor.
Page 189 Print Engine Cable Connection Diagram for replacement details. • Run the ribbon motor test in Diagnostics to verify the motor is functioning. • Print several test cards to verify the motor operates under a load. CP80 and CP80 Plus Service Manual 6-37...
Page 190: Upper Printer Assembly
Upper Printer Assembly This is a general procedure for separating the upper printer and interstage platform from the lower laminator section. Removal Procedure Turn off the printer and unplug the power cord. Remove both halves of the Main Enclosure (page 6-15). Unplug the print assembly’s power supply connector from the main control board and pull the wire back out of the interstage platform.
Page 191 From the back of the printer, simultaneously pull out on the side latches and lift the rear of the printer off the laminator. With the rear of the printer free, slide the printer back to disengage the front retaining hook from the laminator chassis. CP80 and CP80 Plus Service Manual 6-39...
Page 192: Transport Assembly
Transport Assembly This is a general procedure for removing the transport assembly from the printer. This procedure is a prerequisite to many other procedures. If you are performing this procedure to access a component, you may want to consider disconnecting only those cables necessary to turn the transport on its side.
Page 193 When the tabs on the chassis are clear of the openings, lift the chassis (and control board) out of the base. Pull back on the duplex assembly and lift it off the transport chassis. Disconnect all cable connectors from the main control board. CP80 and CP80 Plus Service Manual 6-41...
Page 194 Cable Replacement Procedure Some of the cables described below are optional and may not be present on all printers. With the printer laying on its side and the control board placed next to it, begin connecting the cables that will reach. Magnetic stripe registration sensor Magnetic stripe optical encoder cable (disconnect the other end from the encoder)
Page 195: Main Control Board
From the Printer menu, select Values. Click on the Save as button. Name the file with a unique name using the printer serial number and current date (for example, F50123-01-31-04.txt). Exit from Diagnostics but leave the printer running. CP80 and CP80 Plus Service Manual 6-43...
Page 196 Record the Printer Network Settings Press the Enter key on the display to enter the status menu. Repeatedly press the Enter key to scroll through the network settings and record each one as it is displayed. • Address Mode • Data Format •...
Page 197 Click on the Run All button. Click on the Save to Power-on Defaults button. Restore the Network Settings Simultaneously press the Up and Down arrows on the LCD display until the display shows “Service Enabled.” CP80 and CP80 Plus Service Manual 6-45...
Page 198 Press the Up or Down arrow until the Configuration menu is displayed, and press the Enter key to access the menu. Update the settings. (The image below shows the MAC Address screen as an example.) Press the Up or Down arrow to locate each setting, and press the Enter key one or more times to access the Change Value screen.
Page 199: Transport Timing Belt
Release the belt tension, and remove the transport belt. Replacement Notes Follow the belt routing shown below. • • Print a couple of test cards to verify that the printer is functioning properly. CP80 and CP80 Plus Service Manual 6-47...
Page 200: Belt Tensioner Pulley And Tension Spring
Belt Tensioner Pulley and Tension Spring Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15). Release the belt tension, and remove the transport belt. Lift the release tab and slide the tensioner down as far as it will go, and remove the spring.
Page 201: Drive And Idler Pulleys
Replacement Notes • After slipping the pulley onto the shaft, rotate it until the square key slips into the square keyway. • Print several test cards to ensure there are no transport problems. CP80 and CP80 Plus Service Manual 6-49...
Page 202: Cleaning Rocker Assembly
Cleaning Rocker Assembly When replacing the rocker assembly, it is a good idea to replace the springs as well. Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Push the rocker mount one direction and the rocker arm the other direction and pull up and out.
Page 203: Front Rocker Assembly
Be careful not to lose the springs. Replacement Note Make sure the springs are seated in the pockets of the transport chassis, and on the alignment pins of the rocker assembly. CP80 and CP80 Plus Service Manual 6-51...
Page 204: Rear Rocker Assembly
Rear Rocker Assembly This procedure is for printers without the magnetic stripe option. For the Magnetic Stripe Rocker Assembly, refer to page 6-88. When replacing the rocker assembly, it is a good idea to replace the springs as well. Removal Procedure Turn off the printer and unplug the power cord.
Page 205: Ribbon Guide
This releases the small locking nibs on the ends of the ribbon guide (see inset photo below). Slowly lift the ribbon guide straight up. If necessary, remove the index sensor from the ribbon guide by lifting it off the mounting post. CP80 and CP80 Plus Service Manual 6-53...
Page 206 Replacement Notes Route the cable through the ribbon guide as shown below. • Refer to the Print Engine Front Wire Routing Diagram Print Engine Cable • Connection Diagram for replacement details. Use the sensor display in Diagnostics to verify the sensor changes state as the •...
Page 207: Pick Roller
Press in on the transport chassis locking tabs, and lift up on the back of the transport assembly. Slide the transport chassis back, and simultaneously pull forward on the card hopper. Remove the card hopper. CP80 and CP80 Plus Service Manual 6-55...
Page 208 Remove the two screws that secure the pick motor to the transport chassis, and remove the motor and roller. Replacement Procedure Place the pick roller in the transport chassis. While positioning the pick motor, rotate the pick roller until the shaft-flat lines up with the flat on the roller.
Page 209: Cleaning Drive Roller
Remove the pulley from the shaft by squeezing the end of the shaft, and slipping the pulley off. The pulley's flange is permanently adhered to the pulley. Do not try to remove the flange. CP80 and CP80 Plus Service Manual 6-57...
Page 210 Remove the drive roller: Lift the pulley-end of the shaft up. Slide the shaft out the side. Lift the opposite end of the shaft and remove the roller. 6-58 Removal and Replacement...
Page 211: Front Drive Roller
Remove the pulley from the shaft by squeezing the end of the shaft and slipping the pulley off. The pulley's flange is permanently adhered to the pulley. Do not try to remove the flange. CP80 and CP80 Plus Service Manual 6-59...
Page 212 Lift the pulley-end of the shaft, slide it out until the roller touches the sidewall, and lift the other end out of the chassis. Follow-up Procedure Print several test cards to ensure there are no transport problems. 6-60 Removal and Replacement...
Page 213: Rear Drive Roller
If present, partially remove the smart card contact carrier: Insert a screwdriver between the carrier and the left mounting tab. Twist the blade to pry the carrier out of the mounting tab. It is not necessary to fully remove the carrier. CP80 and CP80 Plus Service Manual 6-61...
Page 214 Remove the rear card guide: Remove the bias spring from the card guide. This will reduce the chance of the spring flying loose when the guide is removed. Pull up on the card guide. Remove the Transport Timing Belt (page 6-47). Remove the pulley from the shaft by squeezing the end of the shaft and slipping the pulley off.
Page 215 Lift the opposite end of the shaft and remove the roller. Follow-up Procedure Print several test cards to ensure there are no transport problems. CP80 and CP80 Plus Service Manual 6-63...
Page 216: Platen Roller
Platen Roller Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15). Remove the Transport Timing Belt (page 6-47). Grasp the manual advance knob on the platen roller and lift the roller up and out through the side wall of the transport chassis.
Page 217: Printhead Cam
Using a screwdriver, pry the flag-side of the cam out of the transport chassis. Gently lift the cam out of the chassis, taking care not to bind the gears. Follow-up Procedure Run the Printhead Cam Test in Diagnostics to verify that the motor is functional. CP80 and CP80 Plus Service Manual 6-65...
Page 218: Printhead Lifter
Printhead Lifter Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15). Depending on the configuration of the printer, remove either the Rear Rocker Assembly (page 6-52) or the Magnetic Stripe Rocker Assembly (page 6-88).
Page 219: Front Card Guide
Remove the front card guide: Remove the bias spring from the card guide. This will reduce the chance of the spring flying loose when the guide is removed. Pull up on the card guide. CP80 and CP80 Plus Service Manual 6-67...
Page 220: Rear Card Guide
Rear Card Guide Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Depending on the configuration of the printer, remove either the Rear Rocker Assembly (page 6-52) or the Magnetic Stripe Rocker Assembly (page 6-88).
Page 221 Remove the rear card guide: Remove the bias spring from the card guide. This will reduce the chance of the spring flying loose when the guide is removed. Pull up on the card guide. CP80 and CP80 Plus Service Manual 6-69...
Page 222: Rfid Antenna
RFID Antenna Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15). Disconnect the cable connector from the bottom of the antenna board. With the tip of your finger or a screwdriver, pull back slightly on the bottom of the circuit board, and lift the board out of the slots.
Page 223: Upper Duplex Module
Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15). Press in on the transport chassis locking tabs, and lift up on the back of the transport assembly. CP80 and CP80 Plus Service Manual 6-71...
Page 224 Disconnect the interface cable from the duplex interface board. Pull back on the duplex assembly and lift it off the transport chassis. 6-72 Removal and Replacement...
Page 225: Duplex Entry Sensor
Remove the Main Enclosure (page 6-15). Disconnect the duplex interface cable from the interface board. Remove the Upper Duplex Module (page 6-71) from the printer. Disconnect the entry sensor connector from the interface board. CP80 and CP80 Plus Service Manual 6-73...
Page 226 Remove the Duplex Entry Rocker from the module (page 6-77). Push the sensor out of the duplex chassis. Replacement Notes • When pushing the sensor into the duplex chassis, do not push against the wires or crush them. • Print a test card to verify that the duplex is functioning properly. 6-74 Removal and Replacement...
Page 227: Duplex Home Sensor
Replacement Notes • When pushing the sensor into the duplex chassis, do not push against the wires or crush them. • Print a test card to verify that the duplex is functioning properly. CP80 and CP80 Plus Service Manual 6-75...
Page 228: Duplex Interface Board
Duplex Interface Board Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15). Disconnect all connectors from the duplex interface board. Lift the edge of the board slightly and slide it off the retaining pins. Remove the board.
Page 229: Duplex Entry Rocker
Repeat the step for the other side, and remove the rocker. Replacement Note It is easiest to replace the rocker first and add the springs afterward. Insert the spring over the guide pin. Compress the spring and slide it into the receiving socket. CP80 and CP80 Plus Service Manual 6-77...
Page 230: Duplex Motor
Duplex Motor Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15). Disconnect the duplex interface cable from the interface board. Remove the Upper Duplex Module (page 6-71) from the printer.
Page 231 Simultaneously press in on the locking tabs, and rotate the motor to remove Replacement Notes When inserting the motor into the duplex chassis, make sure the gears mesh • properly. • Print several test cards to verify that the duplex is functioning properly. CP80 and CP80 Plus Service Manual 6-79...
Page 232: Magnetic Clutch/Spring Clutch/Duplex Rollers
Magnetic Clutch/Spring Clutch/Duplex Rollers These three procedures require the same preliminary steps and are grouped together for convenience. Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15).
Page 233 Tilt the flipper assembly up and remove the whole assembly. Take care not to break the stabilizing tab. Pull it away from the clutch as needed. Slide the magnetic clutch off the center pin of the flipper. CP80 and CP80 Plus Service Manual 6-81...
Page 234 Squeeze the ends of the spring clutch and pull it off the boss. To remove the idler rollers, spread the sidewalls of the flipper, and pull the roller out one side at a time. 6-82 Removal and Replacement...
Page 235 Verify that the clutch is properly engaged. When properly engaged, the • flipper will rotate in only one direction. If necessary, adjust the duplex home offset. • • Print several test cards to verify that the duplex assembly is functioning properly. CP80 and CP80 Plus Service Manual 6-83...
Page 236: Magnetic Stripe Option
Magnetic Stripe Option Magnetic Stripe Circuit Board Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15). Remove the Upper Printer Assembly from the base (page 6-38). Unplug the magnetic stripe head and encoder cables from the magnetic stripe board.
Page 237: Magnetic Stripe Registration Sensor
Be careful not to damage the wires when pushing the sensor into position. • Make sure the sensor is fully seated. • Using the Diagnostics in chapter 5, calibrate the magnetic stripe head as described in Start Sentinel Position. CP80 and CP80 Plus Service Manual 6-85...
Page 238: Magnetic Stripe Head
Magnetic Stripe Head Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15). Remove the Upper Printer Assembly from the interstage platform (page 6- 38). Unplug the magnetic head from the magnetic stripe board. Remove the Magnetic Stripe Rocker Assembly (page 6-88).
Page 239 The long pin on the head points toward the front of the printer (fits only one • direction). Using the Diagnostics in chapter 5, calibrate the magnetic stripe head as • described in Start Sentinel Position. CP80 and CP80 Plus Service Manual 6-87...
Page 240: Magnetic Stripe Rocker Assembly
Magnetic Stripe Rocker Assembly Removal Procedure Turn off the printer and unplug the power cord. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (page 6-15). Using a screwdriver, pry the rocker's pivot pin out of the mounting tab on the chassis.
Page 241: Smart Card Option
Squeeze the locking tab on one standoff and lift the board up slightly. Repeat for the other standoff. Gently pry the board off the connector. Follow-up Procedure Using Diagnostics, perform the Smart Card Test Card procedure as described in chapter 5 of this manual. CP80 and CP80 Plus Service Manual 6-89...
Page 242: Solenoid Assembly/Solenoid Link
Solenoid Assembly/Solenoid Link Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-15). Using a screwdriver carefully pry out the solenoid release tab, and pull the solenoid out just slightly from the mounting pocket. •...
Page 243 To remove the solenoid link, rotate it 90 degrees and pull it off the rocker. Follow-up Procedure Using Diagnostics, perform the Smart Card Test Card procedure as described in chapter 5 of this manual. CP80 and CP80 Plus Service Manual 6-91...
Page 244: Smart Card Contact
Smart Card Contact Removal Procedure Unplug the printer. Remove the ribbon cartridge and cleaning roller. Remove the Main Enclosure (p. 6-15). Remove the Upper Printer Assembly from the base (p. 6-38). Disconnect the interface cable from the smart card interface board. Refer to Print Engine Cable Connection Diagram (p.
Page 245 Replacement Notes • Make sure the contact is fully seated in the carrier. • Make sure the wires are not routed under the motor. Route wire out through the side of the chassis. • CP80 and CP80 Plus Service Manual 6-93...
Page 246 • Route the wires around the solenoid and connect it to the smart card interface board. • Using Diagnostics, perform the Smart Card Test Card procedure as described in chapter 5 of this manual. 6-94 Removal and Replacement...
Page 247: Contactless Smart Card Coupler
Main Enclosure (p. 6-15). Remove the Upper Printer Assembly from the base (p. 6-38). Use a screwdriver to press the plastic locking tabs out of the chassis. Remove the coupler bracket or plastic cover. CP80 and CP80 Plus Service Manual 6-95...
Page 248 Replacement Notes Snap the coupler back into the chassis using the four mounting bracket locking tabs. Orientation is important for reading the smart card. Connect the three connectors. Follow-Up Procedure Using Diagnostics, perform the Smart Card Test Card procedure as described in chapter 5 of this manual.
Page 249: Laminator Transport Assembly
Disconnect the cable connectors from the control board as necessary to perform further work on the laminator. Replacement Notes • Refer to the laminator wiring diagrams beginning on page 6-8. • Print several test cards to verify operation. CP80 and CP80 Plus Service Manual 6-97...
Page 250: Power Supplies
Power Supplies The same procedure is used for all three power supplies. Refer to the Power Supply Wire Routing Diagram (page 6-10) for power supply placement, connections, and wire routing information. Removal Procedure Turn off the printer and unplug the power cord. Remove the Main Enclosure (page 6-15).
Page 251: Upper Laminator Transport Rollers
(as viewed in the photograph). When the tip of the shaft clears the pocket in the chassis, lift the shaft out. Be careful not to pull so hard on the chassis wall that you break the chassis. CP80 and CP80 Plus Service Manual 6-99...
Page 252 Remove the laminator entry and exit drive rollers: Open the retaining flap above the roller. Lift the gear-end of the roller, and pull it out the side of the chassis. Follow-up Procedure • Refer to the Laminator Cable Connection Diagram Laminator Rear Wire Routing Diagram for replacement details.
Page 253: Lower Laminator Transport Rollers
(as viewed in the photograph). When the tip of the shaft clears the pocket in the chassis, lift the shaft out. Be careful not to pull so hard on the chassis wall that you break the chassis. CP80 and CP80 Plus Service Manual 6-101...
Page 254 Loosen but do not remove the Upper Foil Drive Assembly (page 6-126). The assembly needs to be just loose enough to reach the intermediate roller’s drive gear, so it isn’t necessary to remove the wires from the assembly. Pull outward on the intermediate roller drive gear so it disengages from the other transport gears.
Page 255: Intermediate Transport Rollers And Card Guide
(as viewed in the photograph). When the tip of the shaft clears the pocket in the chassis, lift the shaft out. Carefully lift up on the card guide to remove it and the bias spring. CP80 and CP80 Plus Service Manual 6-103...
Page 256 Remove the intermediate drive roller: Open the retaining flap above the roller. Pull outward on the drive gear so it disengages from the other transport gears. Lift the gear-end of the roller, and pull it out the side of the chassis. Follow-up Procedure •...
Page 257: Upper Platen Roller
Make sure the washer is between the platen roller and the transport chassis. Put a thin film of Molykote DX grease (Part No. 807421-001) on the shaft at the • ® locations shown. Print several test cards to check print quality. • CP80 and CP80 Plus Service Manual 6-105...
Page 258: Lower Platen Roller
Lower Platen Roller Removal Procedure Turn off the printer and unplug the power cord. Remove the Main Enclosure (page 6-15) and the Upper Printer Assembly (page 6-38). Remove the Upper Foil Drive Assembly (page 6-126). Remove the Upper Heater Assembly (page 6-124) from the laminator.
Page 259: Rear Cooling Fan
Simultaneously press outward on the two retaining tabs and lift the fan out. Replacement Notes • Route the wires according to the two pictures below. • Use the Laminator Motor Tests in Diagnostics to test the fan. CP80 and CP80 Plus Service Manual 6-107...
Page 260: Hand Guard
Hand Guard This is a prerequisite procedure for other procedures, so it is assumed that the laminator transport chassis (and its prerequisites) has been removed from the printer. Only a dual laminator printer will have a hand guard. Removal Procedure Attempting to remove the hand guard in any sequence other than that described below will complicate the procedure and may even damage the retaining posts.
Page 261 Lift the corner (only the corner) of the guard past the edge of the chassis. Remove the guard from the lower-rear post. CP80 and CP80 Plus Service Manual 6-109...
Page 262 Finish removing the guard by freeing it from the slotted retainer: Bend the guard in the middle. Move the back edge of the guard past the sensor pocket. Continue to rotate the guard until it is free from the retaining slot. 6-110 Removal and Replacement...
Page 263: Laminator Rfid Antennas
Laminator Front Wire Routing Diagram Laminator Cable Connection Diagram for replacement details. • Go to the advance setup in the printer tool box to verify that the printer properly identifies the laminate supply. CP80 and CP80 Plus Service Manual 6-111...
Page 264: Laminator Sensors
Laminator Sensors Duplex Exit Sensor The duplex exit sensor is located next to the rear fan and below the duplex interface board. Removal Procedure Turn off the printer and unplug the power cord. Remove the Main Enclosure (page 6-15). Remove the Upper Printer Assembly (page 6-38).
Page 265: Card Exit Sensor
• Refer to the Laminator Front Wire Routing Diagram Laminator Cable Connection Diagram for replacement details. Print several laminate test cards to verify that the sensor is functional. • CP80 and CP80 Plus Service Manual 6-113...
Page 266: Card Registration Sensor
Card Registration Sensor Removal Procedure Turn off the printer and unplug the power cord. Remove the Main Enclosure (page 6-15). Remove the Upper Printer Assembly (page 6-38). Disconnect the sensor cable from the laminator control board. Gently push against the tip of the sensor to free it from the chassis. Replacement Notes •...
Page 267: Upper Foil Index Sensor
Make sure the sensor is fully seated and locked into position. • Refer to the Laminator Front Wire Routing Diagram Laminator Cable Connection Diagram for replacement details. • Print several laminate test cards to verify that the sensor is functional. CP80 and CP80 Plus Service Manual 6-115...
Page 268: Lower Foil Index Sensor
Lower Foil Index Sensor This sensor is located on the underside of the laminator chassis about midway between the upper and lower laminator platen rollers. Removal Procedure Turn off the printer and unplug the power cord. Remove the Main Enclosure (page 6-15).
Page 269: Foil Motion Sensors
• Refer to the Laminator Front Wire Routing Diagram Laminator Cable Connection Diagram for replacement details. • Print several laminate test cards to verify that the sensor is functional. CP80 and CP80 Plus Service Manual 6-117...
Page 270: Heater Home Sensor
Heater Home Sensor Removal Procedure Turn off the printer and unplug the power cord. WARNING: The heated roller can become hot enough to cause serious burns. Allow the printer to cool at least 30 minutes before beginning this procedure. Remove the Main Enclosure (page 6-15) and the Upper Printer Assembly...
Page 271 Compress the heater slide until the cam lines up with its retaining points. Insert the cam into its retaining points. Follow the replacement notes for the Upper Heater Assembly (page 6-124) or Lower Heater Assembly (page 6-125) procedures. CP80 and CP80 Plus Service Manual 6-119...
Page 272: Laminator Motors
Laminator Motors Card Transport Motor Removal Procedure Turn off the printer and unplug the power cord. Remove the Main Enclosure (page 6-15) and the Upper Printer Assembly (page 6-38). Remove the Upper Foil Drive Assembly (page 6-126). Remove the Upper Heater Assembly (page 6-124) from the laminator.
Page 273 Refer to the Laminator Cable Connection Diagram Laminator Rear Wire Routing Diagram for replacement details. • Use the laminator motor tests in Diagnostics to verify the motor is functioning properly. • Print several test cards. CP80 and CP80 Plus Service Manual 6-121...
Page 274: Foil Advance Motors
Foil Advance Motors The same procedure is used for both upper and lower motors. The graphic below shows the different cable routing. Removal Procedure Turn off the printer and unplug the power cord. Remove the Main Enclosure (page 6-15). Disconnect the motor from the laminator control board. Press in on the two retaining tabs and rotate the motor counterclockwise to remove it.
Page 275: Heater Lift Motors
The polarity is shown above. • The upper heater lift motor uses the yellow and blue wires, while the lower heater lift motor uses the red and black wires. CP80 and CP80 Plus Service Manual 6-123...
Page 276: Major Subassemblies
Major Subassemblies Upper Heater Assembly Removal Procedure Turn off the printer and unplug the power cord. Remove the Main Enclosure (page 6-15). Remove the Upper Printer Assembly (page 6-38). Disconnect the heater, thermocouple, and lift home sensor wires from the laminator control board.
Page 277: Lower Heater Assembly
Make sure the motor wires are connected properly. Reversing the wires will reverse the rotation of the motor. The polarity is shown above. • Refer to the Laminator Cable Connection Diagram Laminator Rear Wire Routing Diagram for replacement details. • Print several test cards. CP80 and CP80 Plus Service Manual 6-125...
Page 278: Upper Foil Drive Assembly
Upper Foil Drive Assembly Removal Procedure Turn off the printer and unplug the power cord. Remove the Main Enclosure (page 6-15). Disconnect the foil advance motor connector from the laminator control board. Free up the following cables from the cable guides on the face of the drive assembly: Heater Lift Motor •...
Page 279 The plastic gears are not retained on their shafts. Make sure the gear train is • replaced according to the image below. Re-route the wires according to the image above and the Laminator Rear Wire • Routing Diagram. CP80 and CP80 Plus Service Manual 6-127...
Page 280: Lower Foil Drive Assembly
Lower Foil Drive Assembly Removal Procedure Turn off the printer and unplug the power cord. Remove the Main Enclosure (page 6-15). Disconnect the foil advance motor connector from the laminator control board. Free up the heater wires from the cable guide on the face of the drive assembly.
Page 281: Heating Element/Heated Roller/Thermocouple
(note the orientation of the cam in the photo below). Lift the gear-end of the cam out of the pocket. Slide the shaft out of the assembly, and slowly release the heater slide until it is clear of the frame and spring. CP80 and CP80 Plus Service Manual 6-129...
Page 282 Free the heater and thermocouple wires from the heater assembly frame. In order to fit the connectors through the cable guides, you need to rotate the connector so the connector latch is in-line with the opening as shown. Remove the heater wires. (Hint: If you temporarily leave one of the two wires in place, the heater will not fall loose in step 8.) Slide the connectors off the heater’s terminals.
Page 283 Separate the two halves of the heater slide slowly. When the two halves are separated, all of the components are free to fall loose. Repeat this for the other latch and separate the two halves completely. CP80 and CP80 Plus Service Manual 6-131...
Page 284 If the thermocouple needs to be replaced, slide it out of the mounting slot and install the new thermocouple at this time. Inspect the wiper pad. • At a minimum, clean debris from the wiper pad. If the pad contains flashing debris (laminate materials), then the wiper •...
Page 285 Insert the stripper bar and wiper into the heater slide. Slide the second half of the heater slide over the heater, heated roller, and stripper bar. Snap the two halves together. Feed the first heater wire back through the heater slide. CP80 and CP80 Plus Service Manual 6-133...
Page 286 Connect the wire to the heater, and take the slack back out of the wire (the loop of wire in the previous photo). Repeat the previous two steps for the other wire. Replace the heater slide: Place the spring over the spring boss. Without stretching the heater and thermocouple wires, place the slide assembly over the end of the spring.

This manual is also suitable for:

Cp80 Sp75

DataCard CP80 Plus Service Manual

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

Quick Links

Service Manual

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for DataCard CP80 Plus