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Zebra 105940G-230

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1. So O o O O oe de 006 ooo ROSA SEES obara Saba OR ER GRERS d js ej o Q O 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 17 2 6 Installing the Printer Driver Important Do not power the printer with USB attached to your computer at this time The driver will prompt you when it is time to plug in and power up your printer To install the Printer on Windows 2000 Windows XP Windows Server 2003 or Windows Vista operating systems insert the User Documentation and Drivers CD included with your printer into your computer and the InstallWizard will walk you through the required installation steps The InstallWizard will e Automatically install the User Interface when the driver CD is inserted e Start the installation process when the Install Printer Driver menu item is selected from the Main Menu e Allow you to install Ethernet drivers if you plan on networking your card printer e Check to see which operating system you are using e Detect previous versions of the driver and clean up any unnecessary Windows registry entries You must select Remove from the install options to remove any previous driver versions e Install the new driver files e Reboot your computer If your User Documentation and Drivers CD does not load automatically 1 Click on Start the
2. 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 161 Step 8 Slide the Card Cleaning Cartridge into the slots provided at the front of the printer An alignment tab is located on the left side of the Card Cleaning Cartridge to ensure proper installation Step 9 Insert the Ribbon Cartridge with the cleaning roller facing down so the gears on the ends of the rollers fit into the appropriate slots Ribbon Cartridge Step 10 Close the printer lid and push down until you hear an audible click If you can not close the lid the cleaning cartridge or the ribbon cartridge may be installed wrong 162 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Setting Up the Printer Driver Step 1 Open Printers and Faxes click Start then click Printers and Faxes Step 1 Right click the printer for which you want to change settings then click Properties Step 2 Select the Device Settings tab General Sharing Ports Advanced Color Management i Security l Device Settings 7 zebra Pl20i Card Printer Device Settings Printer ModeliFirmware Version Encoder Settings l Tools FY Download Device Information Single Feed About Step 3 Select Single Feed Step 4 Select Enable Single Feed Support Step 5 Click the Apply button Important You can disable Single Feed Support and return to printing cards from the hopper You do not have to re
3. If the LED is flashing GREEN a 100Base link is established and network activity has been detected If the LED is solid ORANGE a 10Base link is established If the LED is flashing ORANGE a 10Base link was established and network activity has been detected Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A LCD Panel Messages LCD Panel messages fall into three categories e Operational Operational Messages are displayed during the Printer s normal operation e Warnings Warnings alert the operator to action that should be taken the printer will generally continue operation e Errors Errors are displayed when a situation causes the printer to stop operating Depending on the cause of the error message restarting the printer or curing the displayed Error may return the printer to operational status or the printer may require troubleshooting and repair Operational INITIALIZING SELF TEST READY DOWNLOADING DATA MAG ENCODING PRINTING MONO PRINTING CYAN PRINTING YELLOW PRINTING MAGENTA PRINTING BLACK PRINTING OVERLAY DOWNLOADING FIRMWARE CLEANING REMOVE RIBBON THEN CLOSE LID EMPTY FEEDER THEN CLOSE COVER FEED LONG CLEANING CARD IN EXIT REMOVE LONG CLEANING CARD INSERT FEEDER CLEANING CARD CLOSE FEEDER DOOR REMOVE FEEDER CLEANING CARD SINGLE CARD READY PRINT OR EJECT INSERT CARD PUSH BUTTON TO CONTINUE 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service
4. Print Engine Right Side 190 Kit Description Model s 105940G 066 KIT PULLEY MOTOR RIBBON P110i P110m P1201 105940G 068 KIT O RING 94 X 2 290 P110i P110m P120i 105940G 116 KIT PLUNGER RIBBON CONT P110i P110m P1201 105940G 058 KIT GEAR 54T 48P CAM P110i P110m P120i Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Kit Description Modells 105940G 060 KIT GEAR COMPD 48T 24T 48P P110i P110m P1201 105940G 061 KIT GEAR COMPD 56T 18T 48P P110i P110m P120i 105940G 065 KIT GEAR PULLEY COMPD 44T 64P P110i P110m P120i 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 191 192 Kit Description Model s 105940G 010 KIT DISC ENCODER P110i P110m P120i 105940G 009 KIT RIBBON MOTOR P110i P110m P120i Han NOE 105940G 121 KIT ESD STRIP 1 69IN LONG P 1101 P110m P120i Zebra P110i P110 m P120i Card Printers Service Manual 980584 001 Rev A Kit Description Model s 105940G 136 K P 1101 P110m P120i 105940G 138 KIT PCBA MAGNETIC SENSOR P110i P110m P120i 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 193 Print Engine Bottom Kit Description Models 194 105940G 003 KIT MOTOR CAM P 1201 P 1101 P110m P120i Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Kit Description Model s 105940G 009 KIT RIBBON MOTOR P110i P110m
5. Step 1 Step 2 42 Open card feeder cover Slide card guide all the way to the right until it locks in place with an audible click Card Feed Cover Card Guide Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Step 3 Remove cellophane wrapper from card stack Note Static charges and edge burrs from the card die cutting process can render individual cards stuck together with significant adhesion force These cards must be physically separated from each other before inserting into the feeder if not separated feeding or printing problems may occur Step 4 Holding the card deck by the sides hold it vertically against a flat surface such as a desktop If the deck is too thick for your hand to hold it comfortably use about half a deck at a time Step 5 Push the stack back and forth to an angle of about 45 from vertical so as to separate all of the cards Step6 Restore the card stack to its original squared off condition and place the cards in the input hopper 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 43 44 Step 7 Place stack of up to 100 cards into card feeder and close the card feeder cover When card feeder cover is closed the card guide locking mechanism will automatically be released Card Feeder Cover Card Stack sy Card Feeder Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Cards with Magnetic
6. the printer Important Do not ship the printer with either the ribbon or the cards in the printer If the original material is lost or damaged a replacement Shipping Kit can be ordered from Zebra Refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer Printer Driver View README gt gt P110i P110m gt gt P120i Install Printer Driver gt gt P110i P110m gt gt P120i gt gt Install Adobe Acrobat gt gt Install ZebraNet Utilities 2006 ZIH Corp Worldwide Support locations are listed in Appendix F Value Line P110 P110m P120 Documentation gt gt View CD README gt gt Warranty gt gt Ethernet FAG Users Manual gt gt P 110i P110m gt gt P120i Reguires Acrobat Support gt gt Register Your Product Media List gt gt P110i gt gt P110m gt gt P120i gt gt Web Site Requires active internet connection 50 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Theory of Operation 3 1 Introduction This section includes five major topics 980584 001 Rev A Card Finn ASI sk n d k d hehe ees hn K 52 Card Pata Ele Wail S AD O T ee EA me Card Movement During Printing 58 Block DIETAMI gon 5 xe ea oe hehe eo kona Ed kA K K ee eae ees 60 CPU PCE A CONN Oesia rreri eaves era 61 Zebra P110 P110m P120i Card Printers
7. Zebra P110 P110mn P120 Card Printers Service Manual V f Card Printer AN 4 Solutions 980584 001 Rev A Copyright Notice 2007 ZIH Corp This document contains information proprietary to Zebra Technologies Corporation This document and the information contained within is Copyrighted by Zebra Technologies Corporation and may not be duplicated in full or in part by any person without written approval from Zebra While every effort has been made to keep the information contained within current and accurate as of the date of publication no guarantee is given that the document is error free or that it is accurate with regard to any specification Zebra reserves the right to make changes for the purpose of product improvement at any time Trademarks P1107 and P120i are trademarks and Zebra is a registered trademark of Zebra Technologies Corporation Windows and MS DOS are registered trademarks of Microsoft Corp All other trademarks or registered trademarks are marks of their respective holders Product Disposal x Product Disposal Information Do not dispose of this product in unsorted municipal waste This product is recyclable and should be recycled according to your local standards For more information please see our web site at http www zebra com environment Contents 1 General Description s zb 6 hd a D t b RE b 8 tun 1 1 1 DESNO ze add Ev E ba o bos h dok esse 1 1 2
8. A 5 5 Printhead Assembly Electrostatic Discharge Caution The Printhead is extremely susceptible to Electrostatic Discharge ESD damage Do not touch the bottom surface of the Printhead The replacement must be performed at a static free work station an anti static wrist strap must be worn and properly terminated or other appropriate protection must be used Important This procedure describes replacing the Printhead Assembly The Printhead Assembly is supplied with components in correct alignment with each other These alignments are critical to proper operation of the printer Do not deviate from the procedure given here do not loosen or tighten any screws except those specifically noted in this procedure and do not attempt to adjust any part of the Printhead Assembly 3 Note The Printhead Assembly can be replaced without removing any other parts of W the printer Printhead Removal Step 1 Turn the printer off and disconnect the power cord Step 2 Press the access button 1n and raise the Lid Step 3 Locate the Printnead Assembly Printnead Assembly 980584 001 Rev A Zebra P110i P110m P120i Card Printers Service Manual 79 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 80 Push the Printhead Assembly in and upward Lift the Printhead Assembly out of the frame Disconnect the green ground wire With a small flat blade screwdriver loosen and remove the printhead data and power
9. Does not apply overlay in the area of the AFNOR standard Smart Card contacts e Magnetic Stripe Does not apply overlay in the area of the ISO standard Magnetic Stripe 28 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Back Overlay Varnish Feature selection for applying overlay varnish ribbon to back of card Default setting is full edge to edge varnish There are various varnish options A preview pane is shown for each selection Full overlay varnish Applies an edge to edge overlay No overlay Does not apply any overlay Selected Area Applies overlay only in the area selected by user Selected area blank Applies overlay only outside the area selected by user Bitmap based overlay Applies a user defined bitmap in the overlay panel Smartcard ISO Does not apply overlay in the area of the ISO standard Smart Card contacts Smart Card AFNOR Does not apply overlay in the area of the AFNOR standard Smart Card contacts Magnetic Stripe Does not apply overlay in the area of the ISO standard Magnetic Stripe Hologram Overlay Varnish Feature selection for applying hologram overlay varnish ribbon to the front of card Does not apply to this printer There are various varnish options A preview pane is shown for each selection 980584 001 Rev A Full overlay varnish Applies an edge to edge overlay No overlay Does not apply any overlay Selected Area Applies overlay only in the area selected
10. P120i 105940G 034 KIT ROLLER PLATEN ATM P110i P110m P120i 105940G 033 KIT ROLLER PLATEN PRINTHEAD P110i P110m P120i 105940G 119 KIT PLATEN NON MAG P110i P110m P1201 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 195 196 Kit Description Modells 105940G 038 KIT CAP SENSOR ATM P 1101 P110m P120i 105940G 049 KIT SHAFT CAM P 1101 P110m P120i Zebra P110i P110 m P120i Card Printers Service Manual 980584 001 Rev A Print Engine Left Side Kit Description Model s 105940G 030 KIT TENSIOR MAIN DRIVE P 1201 P110i P110m P120i 105940G 151 KIT BELT MXL 110T 6MM WIDE P110i P110m P120i 105940G 154 KIT BELT 2MM PITCH 130T 4MM W P110i P110m P120i 105940G 057 KIT SPRING LEAF PINCH ROLLER P110i P110m P120i 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 197 198 Kit Description Models 105940G 132 KIT INTERUPTOR MULTIPURPOSE P110i P110m P120i 105940G 056 KIT PULLEY COMP MXL 79G 17G P110i P110m P120i 105940G 094 KIT PULLEY GROOVED PPD 7117 P110i P110m P120i Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Kit Description Models 105940G 093 KIT PULLEY GROOVED PPD 55 P110i P110m P120i 105940G 055 KIT PULLEY 17G GT2 P110i P110m P120i 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 199 Shipping Ca
11. Step 1 Locate the Stepper Motor Stepper Motor Step 2 Remove the adjacent roller remove the retaining clip then remove the roller Step 2 Step 3 Step 3 With a TORX T10 driver remove the two screws and washers holding the motor bracket to the frame then remove the bracket 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 143 Step 4 With a5 5 mm Hex driver remove the four nuts with attached lock washers holding the Stepper Motor in place Note that the orange arrows point out the four mounting nuts Step 5 Remove the Stepper Motor 144 Zebra P110 P110m P120 Card Printers Service Manual 980584 001 Rev A Replacement Step 1 Check the Belt Tensioning Tool presets Scale 1 075 and Scale 2 050 Adjust the presets as required Scale 1 Scale 2 Step2 With a TORX T10 driver loosen the three screws indicated in the figure below 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 145 Step 3 Install the belts and associated gears and pulleys The following two figures show the belt path for the two belts removed in this section a Install Belt 1 Belt 1 b Install the Platen Roller Pulley c Install Belt 2 Platen Roller Pulley Belt 2 146 Zebra P110 P110m P120 Card Printers Service Manual 980584 001 Rev A Step 4 Set the Belt Tensioning Tool in place Note that the arrows indicate the alignment
12. Step 9 Remove the Belt Tensioning Tool Step 10 Ensure that the Stepper Motor and associated gears and pulleys rotate freely as the large pulley is turned 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 129 5 28 ATM Card Feed Sensor Step 1 Locate the ATM Card Feed Sensor ATM Card Feed Sensor Step 2 With a TORX T8 driver remove the screw and retainer that hold the sensor in place Step 3 If not already done disconnect the Card Feed Sensor plug from connector J12 on the Main PCBA Step 4 Remove the Card Feed Sensor 130 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 5 29 ATM Pressure Roller 8 Card Drive Roller Assemblies Step 1 Locate the ATM Pressure Roller and Card Drive Roller assemblies ATM Pressure Roller Assembly Card Drive Roller Assembly Step 2 Remove the retaining springs from both sides of the Print Engine Retaining Springs both sides Step 3 Turn the Print Engine over for access from bottom 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 131 132 Step 4 With a TORX T10 driver remove the two screws and disconnect the ground wires Two Ground Wires One Ground Wire Step 5 Turn the Print Engine over for access from top Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Step 6 With a flat blade screwdriver free the locking pins that hold the ATM Pressur
13. power cords for maximum flexibility 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 1 1 2 Features Controls and Indicators The picture below points out some of the printer s external features See Chapter 3 for an interior view Card Feeder Lid Release Cover Ta Button LCD Display Panel Multi Function Control Button Card Entry Exit Slot Covered Card Feeder Opening the Card Feeder Cover gives access to the automatic card feeder The translucent cover allows you to see when the card supply is running low Lid Release Button Pressing the Lid Release Button allows the printer s lid to swing open This gives internal access for changing the Ribbon Cartridge changing Cleaning Rollers and cleaning the printer LCD Display Panel The LCD Display Panel displays printer status information Messages also alert the user of the need for action and indicate certain fault conditions 2 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Multi Function Control Button The Multi Function Control Button initiates several functions these are described in the appropriate sections of this document Card Entry Exit Slot Automatic Card Feeder A card s automatically fed into the printer from the Card Feeder The card will be drawn into the printer printed encoded or decoded as specified by the application program and then be ejected out through the Exit Slot Car
14. 3 Cut the cable ties holding the various wires and connectors going to the Main PCBA Step 4 Disconnect the 2 wire Printhead Fan plug from connector J25 on the Main PCBA Step 5 Remove the Printhead Fan 96 Zebra P110 P110m P120 Card Printers Service Manual 980584 001 Rev A 5 14 Feed Cover Sensor Step 1 Locate the Feed Cover Sensor Feed Cover Sensor Step 2 With a TORX T8 driver remove the screw that holds the sensor in place Mounting Screw Step 3 Cut the cable ties holding the various wires and connectors going to the Main PCBA Step 4 Disconnect the 4 wire sensor plug from connector J8 on the Main PCBA Step 5 Remove the Feed Cover Sensor 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 97 5 15 Linkage Right Side and Left Side Step 1 Locate the Linkage right side Linkage 3 pieces Spring Step 2 Remove the spring Step 3 With a TORX T10 driver remove the two screws and washers holding the Linkage to the frame Step 4 Remove the Linkage 3 pieces M a S Step 5 Repeat Step through Step 4 for the left side 98 Zebra P110 P110m P120 Card Printers Service Manual 980584 001 Rev A 5 16 Ribbon ID PCBA P110 and P120 only Step 1 Locate the PCBA Ribbon ID PCBA behind cover Step 2 With a flat blade screwdriver free the cable from the cable clamp Inner Screws Outer Screws Cable Clamp Step 3 With a TORX T8
15. 4 Card Printer Drivers Nu Y Zebra InstallShield Wizard 44 Zebes P110 Cand Printer Setup is preparing the InstallShield ae ie a ee ces es Bas Step 5 Once the InstallShield Wizard has been installed the Welcome to InstallShield Wizard window will open a ke creme bo the beet eit Meki Wua lin elna PIA Cal Predo Step 6 On the Select Features window you have the option to install USB printer drivers or ethernet internal printer drivers The next two sections detail USB and Ethernet driver installation respectively 20 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 2 6 2 USB Driver Installation Step 1 Select USB and click the Next button Step 2 Observe the License Agreement window If you agree to the License Agreement click the Yes button tema PH Z0I Card Printer 3 40 04 Licence Agreement DETT u iran bs ans sela lu the rte EU eager o ee Step 3 Most users should select the Complete setup type then click the Next button Zebra P1201 Card Printer 3 20 03 Soba Typa Step 4 Select the appropriate Program Folder then click the Next button Zebra P1201 Card Printer 3 270 07 Solect Program Folder 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 21 Step 5 The Install Wizard will show the progress of the installation tebra 1201 Card Printer 3 40 04 Fop Maba Step 6 Read the appropriate information Zebra P
16. 7 Lift the assembly up and out of the Print Engine re m I Step 8 Slide the bearing and the support collar off the roller 152 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Preventive Maintenance 6 1 Cleaning System Caution PROTECT YOUR FACTORY WARRANTY The recommended maintenance procedures must be performed to maintain your factory warranty Other than the recommended cleaning procedures described in this manual N allow only Zebra authorized technicians to service the Printer NEVER loosen tighten adjust or bend etc a part or cable inside the printer NEVER use a high pressure air compressor to remove particles from the printer Your Printer includes a simple cleaning system using Pre Saturated Cleaning Cards provided The regular use of these cards will clean and maintain important parts of your printer that cannot be reached including the Printhead the Transport Rollers and the Magnetic Encoder Station optional feature 6 1 1 When to Clean Clean the Printer when e Print quality has been degraded e The LCD panel displays the message CLEAN PRINTER 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 153 154 6 1 2 How to Clean Step 1 Place the printer power switch in the ON position and then press and hold the Multi Function Control Button for 5 seconds Step2 When the cleaning cycle is initiated the LCD message REMOVE RI
17. Features Controls and Indicators 2 1 3 Specifications 7 1 4 Card Dimensions L nenn 9 Declarations of Conformity 10 ICONS sh a see S S E O ERSA OBEB RO SI L B AS TNE 11 2 Installation and Setup 13 2 1 General Information 13 2 2 Unpacking the Printer 14 2 3 Setting Up the Printer ss dasa basa b 40 1m Hecken ee 15 2 4 Connecting Power 0 cc eee eens 16 2 5 Connecting the Printer to your Computer IZ 2 6 Installing the Printer Driver 18 2 6 1 Print Driver Installatton 19 2 6 2 USB Driver Installatton 21 2 6 3 Ethernet Driver Installation 23 2 7 Changing the Printer Driver Options 25 21 GET NE ee a 26 272 land lab z sro area aa nobena be E Sebe 31 215 o PONOS a aj brod b na i 31 2 7 4 Color Management Tab 32 2 1 5 Security Tab 4 s suis anni im bead wow ns ae m eb b k 32 2 7 6 Advanced Tab 33 2 7 7 Device Settings Tab 33 2 8 Loading Ribbon Cartridge 40 9805
18. Manual 5 Warnings Printer will still operate REMOVE CARD AT EXIT CLEAN PRINTER CHECKING RIBBON ENCODING ERROR INVALID MAGNETIC DATA CHECK RIBBON CLOSE LID FLASH ERROR READING ERROR Errors Printer will not operate OUT OF RIBBON OUT OF CARDS MECHANICAL ERROR COVER OPEN PARAMETERS ERROR COMMAND ERROR LID OPEN OUT OF RIBBON Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 1 3 Specifications General Load N Go drop in ribbon cartridge 16 digit LCD display Driver for Windows 2000 Windows XP Windows Server 2003 and Windows Vista Color Monochrome Printing P110 8 P120 Color dye sublimation or monochrome thermal transfer printing 30 seconds per card full color single sided YMCKO 40 seconds per card full color dual sided YMCKOK P120i only 300 dpi 11 8 dots mm print resolution Monochrome Printing P110m Monochrome thermal transfer printing 300 dpi 11 8 dots mm print resolution Bar Code Code 39 Code 128 B amp C with amp without check digit 2 of 5 amp 2 of 5 Interleaved UPC A EAN 8 amp EAN 13 PDF 417 2D bar code and other symbologies can be printed via Windows drivers The use of Zebra cards will give the best print quality Types PVC PVC Composite Card width length ISO CR 80 ISO 7810 2 12 54mm x 3 38 86mm Magnetic Stripe ISO 7811 Smart Card ISO 7816 Card thickness 30 mil 76mm 10 Card feeder capacity 100 cards 30 mil Card
19. P120i Card Printers Service Manual 980584 001 Rev A Firmware Update Important Before starting the Firmware Update refer to the Test Card you printed prior to removing and replacing the Main PCBA You will need the Head Resistance the X and Y Step 1 Go to start gt Printers and Faxes Step 2 Step 3 Step 4 Step 5 Offsets and the End of Text value to update the firmware on the replacement Main PCBA a If for any reason you were unable to print the Test Card contact Zebra Technical Support to obtain the above values From the Printers and Faxes list right click the Card Printer and select Properties from the pop up menu The Printer Properties window will open Click on the Device Settings tab Click on Tools gt Properties This brings up the Tools display Type the command here Command ta send to printer Print Test Card Cleaning Standard w Printer only bad Offset setting Front x Front a Direct encoding a dm Oss I Note See Appendix D for the complete list of commands 980584 001 Rev A Zebra P110i P110m P120i Card Printers Service Manual then click the Execute button 93 Step 6 From the information on the Test Card update the printer s firmware PLASTIC CARD PRINTER PRINTER P120i Serial N P120i 060376 Firmware V1 10 16 USB 300 dpi A TEST CARD Head resistance 1568 AU A Ofset XO7 05 V 24 a In the Comman
20. Service Manual 51 3 2 Card Printing Basics This section provides an overview description of how images are printed on plastic cards Printhead The Printhead Assembly mounts in the Printhead Bracket which holds the Printhead at a right angle to the card s long surface The Printhead is a thin film device that consists of a row of individually addressable heating elements Each heating element is approximately 0 0033 inch 0 08 mm wide giving a print resolution of 300 dots per inch There are a total of 672 heating elements Since the width of the plastic card is 2 125 inches 54 mm 638 elements provide full width coverage The extra 34 elements 17 on either side of the card s nominal width are present to support programmable image centering and full bleed imaging even if a card is slightly oversize 52 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Printing Technologies and Ribbons There are two types of printing technology used in the P1107 and P120i Printers Dye Sublimation and Thermal Transfer The technology to use is determined by the type of dye or ink on the ribbon Monochrome Ribbons have a single color ink on the length of the ribbon the Printer is programmed to use Thermal Transfer printing for monochrome ribbons The P110m Printer uses only thermal transfer printing Multi Panel Ribbons have a repeating sequence of panels of different dye i Series True Colours Mu
21. already done disconnect the Card Feeder Motor plug from connector J13 on the Main PCBA Step 8 Pull the card feeder cable and connector out of the access hole 980584 001 Rev A Zebra P110i P110m P120i Card Printers Service Manual 111 112 Step 9 Remove the Card Feeder Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 5 24 Flipper Module Step 1 Locate the Flipper Module Flipper Module Step 2 Remove the clip holding the pulley in place Slip the belt off the pulley Slide the pulley off the shaft Mounting Screw 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 113 114 Step 3 With a TORX T10 driver remove the screw holding the Flipper Module to the frame Step 4 With a TORX T10 driver remove the screw on the opposite side holding the Flipper Module to the frame Step 5 With a TORX T10 driver remove the two top mounting screws Mounting Screws Zebra P110 P110m P120 Card Printers Service Manual 980584 001 Rev A Step6 Cutthe cable ties holding the various cables and connectors Cable Tie Cable Tie Step 7 If not already done disconnect the Flipper Motor plug from connector J2 the Card Load Sensor plug from connector J10 and the Flipper Position Sensor from connector J11 on the Main PCBA Step 8 Remove the Flipper Module 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 115 5 25
22. by user Selected area blank Applies overlay only outside the area selected by user Bitmap based overlay Applies a user defined bitmap in the overlay panel Smartcard ISO Does not apply overlay in the area of the ISO standard Smart Card contacts Smart Card AFNOR Does not apply overlay in the area of the AFNOR standard Smart Card contacts Magnetic Stripe Does not apply overlay in the area of the ISO standard Magnetic Stripe Zebra P110 P110m P120i Card Printers Service Manual 29 30 Head Settings Setting for heat adjustments on the print head Adjustments can be made to the Contrast and Intensity Head settings can be changed to adjust the monochrome contrast color intensity and color contrast Changes made to head settings will change color quality of printed images These adjustments directly affect the heating levels used by the printer for each of the individual panels on a print r bbon e Contrast adjusts the black and overlay contrast from 0 to 10 e Color Intensity adjusts the intensity of each color from 0 to 10 e Color Contrast adjusts the contrast of each color from 0 to 10 e Click on Restore Defaults button to reset the settings to the factory default values Printing Mode Feature selection for type of printing required e Print only e Print and Encode e Encode Only Use this when magnetic encoding is the only function desired printing and or laminating will not occur Copies Default nu
23. continue printing Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 6 2 Cleaning the Printhead Use of the cleaning cards will normally do an adequate job of cleaning the printer However a separate Printhead cleaning using swabs can remove more stubborn deposits when print anomalies persist To avoid deposits only use foam tipped swabs Caution Never use a sharp object to scrape deposits from the printhead Permanent damage to the printhead will result Step 1 Place the printer power switch in the OFF 0 position Step 2 Open the printer lid by pressing the cover release button Open the cover fully to reveal the Printhead mounted to the inside of the cover Step 3 Clean the Printhead by moving an alcohol moistened swab tip side to side across Printhead elements Only use moderate force Step 4 Allow two to three minutes for the Printhead to dry before placing the printer power switch in the ON position Step 5 To reorder swabs refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 155 6 3 Magnetic Encoder Cleaning Use the standard cleaning card process as described in Section 6 1 2 This cleans the most important parts of the printer including the Printhead Transport Roller and Magnetic Stripe Encoder 156 Zebra P110 P110m P120i Card Printers Service Manu
24. driver remove the two outer screws holding the PCBA cover to the frame Step 4 With a TORX T8 driver remove the two inner screws holding the PCBA cover to the standofts 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 99 Step5 Remove the cover Step 6 Slide the two springs off their respective standoffs Step7 Slide the PCBA of the standoffs Step 8 If not already done disconnect the Ribbon ID PCBA plug from connector J18 on the Main PCBA Step9 Remove the Ribbon ID PCBA 100 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 5 17 Lid Sensor Step 1 Locate the Lid Sensor Lid Sensor Mounting Screw Step 2 With a TORX T8 driver remove the screw holding the Lid Sensor to the frame Step 3 If not already done disconnect the Lid Sensor plug from connector J7 on the Main PCBA Step 4 Remove the Lid Sensor 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 101 5 18 Right Side Cover Step 1 Locate the two screws that hold the Right Side Cover in place Screws Step 2 With a TORX T10 driver loosen the two screws Step 3 Remove the Right Side Cover 102 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 5 19 Ribbon Flag Position Sensor Step 1 Locate the Ribbon Flag Position Sensor Ribbon Flag Position Sensor behind cover Step 2 With a TORX T8 driver remove the two scre
25. eee ene 77 94 TEMIN erso ann Ener ee MR BO wean ans 78 5 5 Printhead Assembly s szobbos bU ban n bi br ek ooh een 79 5 6 Cleaning Roller 84 Of o EN BREUER 85 98 LED Display PODA 22554250 440 BE 87 5 9 BOOM COVEI e z m ad obd kA o o B B ini 88 5 10 RearCOVer eee eee eee eens 89 5 11 Man RA 244 AO OD Bc ne NE O NB ae 90 Sale Le SIJE COVE een Zak np k Oey ba S bo aro ke bj 95 9 13 Fimhead Fin po bav ek adsts a DE es s nger 96 5 14 Feed Cover SeNSOr LLLL eens 97 5 15 Linkage Right Side and Left Side 98 5 16 Ribbon ID PCBA P110i and P120i only 99 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 5 17 LA SEeNSOr 40064405065 AE AK k eee aa HR 101 5 18 Right Side COVE s s o 5 5a ob Shan dod BSE b 102 5 19 Ribbon Flag Position Sensor 103 5 20 Encoder Wheel 105 5 21 Front COVE past ine b r po o r hn ee eee eee ed 106 5 22 Motor and Roller Locations 107 5 23 Card Feeder and Lid 109 5 24 Flipper Module eee nenn 113 5 25 Card Sync Sensor ee ee eee 116 5 26 Pressure Roller 117 O27 ER ROIG obs ee oe cae ne De
26. guide posts Step 5 With a TORX T10 driver tighten the two motor mount screws Step 6 Rotate the Belt Tensioning Tool 180 degrees 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 147 Step 7 Set the Belt Tensioning Tool in place Note that the arrows indicate the alignment guide posts Step 8 With a TORX T10 driver tighten the single screw Step 9 Remove the Belt Tensioning Tool Step 10 Ensure that the Stepper Motor and associated gears and pulleys rotate freely as the large pulley is turned 148 Zebra P110 P110m P120 Card Printers Service Manual 980584 001 Rev A 5 35 Main Drive Roller Step 1 Locate the Main Drive Roller Main Drive Roller Step 2 With a TORX T10 driver remove the two screws holding the Main Drive Roller support collar to the frame va m ni l sa R 4 ka Ss i e 12 al 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 149 Step 3 With a TORX T10 driver remove the two screws holding the side of the support collar to the frame Step 4 Slide the collar over the roller 150 Zebra P110 P110m P120 Card Printers Service Manual 980584 001 Rev A Step 5 With a Phillips screwdriver carefully push the Main Drive Roller shaft out of its right side mounting hole Step 6 Slide the roller assembly into the large hole 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 151 Step
27. of Copies 1 e Collate Unchecked e Print What Document e Print All pages in range e Pages per sheet 1 page e Scale to paper size No Scaling Print eee 21x Printer Name 4 Zebra P110i USB Card Printer Properties Status Idle Type Zebra P110i USB Card Printer where LPTI Print to file Comment Page range Copies all Number of copies 1 Current page Selection Pages LP Collate Enter page numbers and or page ranges separated by commas For example 1 3 5 12 Zoom Print what Document Pages per sheet 1 page v Print fan pages in range Scale to paper size No Scaling v Options Close Click the OK button The printer will feed in a card and start printing The data download time will vary depending on complexity of the card design and the computer s processing speed Once the printing is completed the card will be ejected from the printer into the printed card hopper Remove the sample card from the card output hopper and check for any discrepancies If the sample card is correct your printer is ready to produce more cards Zebra P110 P110m P120 Card Printers Service Manual 49 2 12 Packing the Printer for Shipment If the printer is to be shipped use the original printer packing and shipping material for shipping the printer only It is important to use the original packing and shipping material to prevent damage to
28. the Partner Zone on www zebracard com for the latest spare parts kits listing The Spares List is arranged in the following categories A stne EINE O NE PM O94 k ooo rar 176 Prclosute A CONEIS 24454404445 490 40455 ONA KRE ENA a 179 BE na EEA REN oe ane ER RT KN nea 182 POPS BE PORE EN ANE PE PE RI RANE EE da mmm 183 Print Engine Transport s 44 4 aussen Ka AA ee a ba eee kt aa xd 188 Prot no ine Reli o da on a Sa O k Soda ib k 190 Print Engine BOOM sos are vna sa rk se oka deh k kaka ke kA 194 Print En ine Len SUC ud s d dd esdasSsd Sa S 197 Shipping CaO 4644 nab k KK tk b n h o k ko 6 200 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 175 Assemblies Kit Description Models 105940G 230 KIT PCBA NO ENET w MAG P 1101 P110i P110m 105940G 139 KIT PCBA NO ENET w MAG P120I P120i 105940G 248 KIT PCBA ENET P1XX P110i P110m P120i 176 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Kit Description Model s 105940G 140 KIT PCBA LCD P120I P110i P110m P120i Ei IF N 105940G 165 KIT PCBA CRYPTOGRAPHIC P120I P110i P120i 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 177 178 Kit Description Models Je F d ARE A A Mail l M sA F an 4 ak aa nen me Fr EEE ia sli i al SP vr 105925G 002 KIT POWER SUPPLY P2XX P110i P110m P120i Zebra P110 P110m P120i Card Printers Service Ma
29. un printed areas For dual sided printing the card is now moved back to the Card Flipper where the card is turned over rotated into the 180 position The card is moved into the Print Engine passing the Cleaning Roller this cleans dust or dirt particles from the back of the card The card is printed same as Step 4 When printing is completed the card is moved to the Card Exit where it falls into the Output Hopper Zebra P110 P110m P120i Card Printers Service Manual 59 3 5 Block Diagram Most of the circuitry in the Printer is on the CPU PCBA Since the CPU PCBA is nota serviceable unit circuit analysis to the component level is pointless Below is a block diagram of the functional circuits of the Printer the block diagram also shows how signals are passed to and from the CPU PCBA to the rest of the Printer CPU PCBA Ribbon and ICard Transport Motors Ethernet Option Components FI zj A SN mam ee m Ethernet Ethernet Ethernet A D Circuitry Printserver Extension el Connection hee for Optical s nn wi Jj Board A Board Circuitry Sensors i j cn USB USB Port Da an Sensor LoL Calibration Circuitry Printhead IN Z Z IM 7777707 Ribbon Core nee LCD Display I and Panel ae J Clock Button iz RE i Ws Ribbon RFID Circuitry Panel i Circuitry Button AC Voltage Power 24 VDC Power Magnetic ad I Supply Control Encoder 1 60 Zebra P110
30. 120I Card Printer 3 20 02 Congratulations on mabaling the printer diners Step 7 Driver installation is now complete Click the Finish button debra P1201 Card Printer J 20 07 haa hal hor W zani Urajilcie Step 8 After installing the Driver restart your computer When you apply power to the printer the Windows New Hardware Found wizard will find the printer 22 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 2 6 3 Ethernet Driver Installation Step 1 Select Ethernet and click the Next button Step 2 Observe the License Agreement window If you agree to the License Agreement click the Yes button Zebra P1 20 Card Printer 3 20 04 Licence Agreement r cov En RE reve poje jen en Step 3 Most users should select the Complete setup type then click the Next button tebra P120 Card Printer 3 70 07 Soba Typa letali H Step 4 Specify the IP address then click the Next button febra P120I Card Printer 3 20 03 Enter Taxi 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 23 Step5 Select the appropriate Program Folder then click the Next button Zebra PTDI Card Printer 3 20 02 pment Program Folder Step6 The Install Wizard will show the progress of the installation febra PUZOl Card Printer 3 20 07 Fop Maba Step 7 Driver installation is now complete Click the Finish button debra P1201 Card F bmi
31. 84 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual lil 2 9 Loading CardS 0 cc eee eens 42 2 10 Printing a Test Gard 3 5 6a be e16 s van d n th r vvid pu bile a i 47 2 11 Printer Operation ee eens 48 2 12 Packing the Printer for Shipment 50 de Theory of Operation u vecina eee Bot ok a re 51 3 1 Introduction 000 51 3 2 Card Printing Basics 52 3 3 Cal Pain Elements s 80e kva d nenne 57 3 4 Card Movement During Printing 58 3 0 BIOCK Diagrami nu susanne K on a o 60 3 6 CPU PCBA Connections 61 4 Troubleshooting 66 zavaro see Re ar da 63 4 1 INIKOOWELON 2 22025 ae ea 22 Soe see oes re p ba a No 63 4 2 Troubleshooting Procedures 64 4 2 1 General ISSUES 2 mn men 64 4 2 2 Print Quality Issues 65 4 3 Troubleshooting the Ethernet Connection and Adapter 71 4 3 1 Ethernet Adapter Status Indicator 71 4 3 2 Network Status Activity Indicator 73 4 3 3 Resetting to Factory Defaults 74 5 Replacement Procedures 75 9 1 INIOOLUCHON E sa se bane 6d na een en dendo 75 Se MONO 100s Zaren nen ee na ee een 76 5 3 Removal Sequence 2 ce eee
32. BBON THEN CLOSE LID will display Multi Function Feeder Cleaning Card LCD Panel Feeder Multi Function Control Button Path Cleaning Card Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 Cover ae After the ribbon is removed and the lid is closed the message EMPTY FEEDER THEN CLOSE COVER will display If the lid is opened and closed without removing the ribbon the REMOVE RIBBON THEN CLOSE LID message will remain Once the cover is closed the firmware will eject any card inside the printer The message EJECTING CARD will display The LCD will then display FEED LONG CLEANING CARD IN EXIT When the card sensor registers the presence of the cleaning card the rollers should take the card into the printer When the cleaning process is done the printer will eject the cleaning card If the card sensor still senses the cleaning card the message REMOVE LONG CLEANING CARD will display Once the long cleaning card is no longer sensed by the exit card sensor the message INSERT FEEDER CLEANING CARD will display Open the feeder cover and insert the feeder cleaning card When the feeder cleaning card has been sensed by the feeder card sensor the message CLOSE FEEDER COVER will display When feeder cleaning is complete the message REMOVE FEEDER CLEANING CARD will display After the card is removed the LCD will display READY You may now reload the ribbon and cards and
33. Card Sync Sensor Step 1 Locate the Card Sync Sensor Card Sync Sensor Step 2 With a TORX T8 driver remove the screw and retainer that hold the sensor in place Step 3 If not already done disconnect the Card Sync Sensor plug from connector J9 on the Main PCBA Step 4 Remove the Card Sync Sensor 116 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 5 26 Pressure Roller Step 1 Locate the Pressure Roller Pressure Roller Step 2 Turn the Print Engine over Pressure Roller 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 117 Step 3 Carefully apply pressure to the roller to pop it loose Step 4 Remove the Pressure Roller 118 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 5 27 Exit Roller Stepl Remove the belts a Locate the two belts Retainer Clip Belt 1 Belt 2 b Remove the retainer cl p on the Platen Roller c Slide the Platen Roller pulley off the shaft this releases the belt then remove the belt d Remove the second belt accessible with the Platen Roller pulley removed 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 119 Step2 Remove the rocker assembly a Locate the two springs Note that the orange arrows point out the two springs 120 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A c With a TORX T10 driver re
34. Main PCBA see Section 5 11 Step 3 Detach the Fan from the old Main PCBA Step 4 Connect the Ethernet PCBA to the Main PCBA Lint LPC Et ee Mi O ga r Nylon Standoffs Step 5 Use two 2 56 Panhead Screws to attach the two Nylon Standoffs to the Main PCBA 166 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Step 6 Use two TORX T10 screws and lockwashers to attach the Fan removed in Step 3 to the Grounding Plate Step 7 Remove the plastic plug shown below from the Rear Cover Step 8 Slide the Main PCBA onto the Grounding Plate 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 167 Step 9 Use two 2 56 Panhead Screws to secure the Main PCBA to the Grounding Plate These screws go into the Nylon Standoffs attached in Step 5 Mounting Screws Step 10 Connect the Fan plug to connector J21 on the Main PCBA Step 11 Re attach the Main PCBA to the underside of the Print Engine Step 12 Re attach the Rear Cover and the Bottom Cover 168 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A APPENDIX D Software Introduction This section lists software commands to initiate check or adjust various system functions parameters and variables Detailed information on the use of these commands are given in the EPCL Programmer s Guide Zebra document 980415 001 which can be downloaded from the Zebra Card Print
35. Note that the Cleaning Roller snaps in and out of place Carefully grasp the roller and lift it up and out of the printer Cleaning Roller 84 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 5 7 Top Cover Step 1 Press the access button in and raise the Lid Access Button Step2 With a TORX T10 driver remove the four screws that hold the Top Cover to the Lid as shown below Note that the Printhead has been removed for clarity Step 3 Lower but do not latch the Lid 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 85 86 Step 4 Step 5 Step 6 With one hand grasp the front lip of the Top Cover With the other hand press down and to the rear with enough force to pop the Top Cover loose Remove the Top Cover Set the Top Cover aside Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 5 8 LCD Display PCBA Stepl Locate the LCD Display PCBA LCD Display PCBA Step 2 Carefully remove the 10 wire plug from the connector on the LCD Display PCBA 10 Wire Plug Mounting Screws Step3 With a TORX T10 driver remove the two screws that hold the LCD Display PCBA to the frame Step4 Remove the LCD Display PCBA 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 87 5 9 Bottom Cover Step 1 Turn the printer over bottom side up Step 2 With a flat blade screwdriver care
36. P110m P120i 184 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Kit Description Modells 105940G 070 KIT TOP CARRIER CARD FLIPPER P120i 105940G 072 KIT ARM PLATEN FLIPPER P110i P110m P120i 105940G 073 KIT PLATEN FLIPPER P110i P110m P120i 105940G 074 KIT GEAR DRIVE PLATEN FLIPPER P110i P110m P120i 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 185 Kit Description Modells 105940G 129 KIT C A FLIPPER SENSORS P110i P110m P1201 105940G 079 KIT GEAR 50T 48P P110i P110m P1201 105940G 075 KIT GEAR DRIVE FLIPPER P110i P110m P1201 186 Zebra P110 P110m P120 Card Printers Service Manual 980584 001 Rev A Kit Description Models 105940G 155 KIT BRNG FLNG 10MM ID IGLIDUR P 1101 P110m P120i 105940G 168 KIT BRNG FLNG 5 16 ID IGLIDUR P110i P110m P120i 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 187 Print Engine Transport Kit Description 7 Modelle 105912G 201 KIT REFLECTIVE TAPE 10 KIT P110i P110m P1201 E a u 105940G 125 KIT CLEANING ROLLER P110i P110m P120i 188 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Kit Description Models 105940G 014 KIT PRESSURE ROLLER MAG P 1101 P110m P120i 105940G 159 KIT ROLLER PLATEN MAG P 1101 P110m P120i 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 189
37. P110m P120i Card Printers Service Manual 980584 001 Rev A 3 6 CPU PCBA Connections Most of the circuitry in the Printer is on the CPU PCBA Since the CPU PCBA is not a serviceable unit circuit analysis to the component level is pointless but a bas c understanding of how the CPU PCBA connects to the rest of the Printer helps to better understand the Printer J2 J6 J23 J3 J12 Flip Ribbon Mag Cam ATM Motor Flag Encoder Motor Card Position Head amp Feed Sensor Sensor Sensor J14 USB Port lg J8 Feed Cover Sensor ER ee Maui s J16 Ribbon Motor J11 Flipper Position M ii 2 g EEA KU kun uti Sensor J21 Auxiliary Fan J10 Card Load Sensor J7 Lid Sensor J13 Feeder Motor J26 Platen Motor J19 DC Power Supply J25 J28 J24 J5 J9 J18 Print Printhead LCD Color Card Ribbon Head Display Ribbon Sync ID PCBA Fan Sensor Sensor Motor 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 61 62 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 4 Troubleshooting 4 1 Introduction The objective of troubleshooting is to relate a problem to an associated assembly or system function in order to most efficiently isolate and repair the problem Typically this involves determining the failure symptom and then checking one or more possible causes of the failure Only a symptom related list of possibilities appears In genera
38. Stripe stripe cards The magnetic stripe must be flush to the surface of the card to work properly Caution ONLY USE cards that comply with ISO 7810 8 7811 standards for magnetic A Never use cards which have taped on magnetic stripes The magnetic encoder is a factory installed item with the read write head positioned below or above the card path Note that the magnetic encoder is settable via the driver for HiCo or LoCo encoding When loading cards with magnetic stripes into the card feeder please ensure that the magnetic stripe is facing the left side of the printer and closest to the bottom edge of the card feeder as shown below Magnetic Stripe Note Zebra approved HiCo and LoCo PVC cards are available 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 45 46 Card Output Hopper Step 1 Raise the printer lid and pull the output hopper down to place it in its functional position Step 2 When not using the printer place the card output hopper back in its closed position to protect the printer from dust Card Output Hopper Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 2 10 Printing a Test Card With ribbon cartridge and cards loaded your printer s ready to print To check the operation of the printer you sh
39. Zebra FESO Digital Photo Pri 5 Enable bidirectional support Enable printer pooling 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 31 32 2 7 4 2 7 5 Color Management Tab Use the Color Management tab to add remove or change printer color profiles Zebra P120i USB Card Printer Properties General Sharing Ports Advanced Color Management j Security Device Settings These settings let you associate color profile s with your color printer Color profiles control the color on your printer based on the type of media being used and the printer configuration 6 Automatic Windows will automatically select the best color profile fram the list of associated color profiles Recommended O Manual Manually select the default color profile for all output from this device from the list of associated color profiles Default color profile lt None gt Color Profiles currently associated with this printer Security Tab Use the Security tab to change permissions for the printer General ri Advanced Color Management Device Settings Group or user names f Administrators 01PRAIN Gw ALD Administrators 45 CREATOR OWNER fi Ewemone fl Power Users 074 PRARING WALD Power Users Remove Permissions for Administrators Deny Print Manage Printers Manage Documents Special Permissions For special permissions or for advanced settings cli
40. al 980584 001 Rev A APPENDIX A Model Numbers The Zebra Product Number tells a story Here is a quick review of the Zebra Card Printer Series numbering and lettering system to help you 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 157 Model numbers include identifiers that specify options using lettering conventions as follows PART NUMBER DESCRIPTION Base Printer P110 Single Sided Color Card Printer P110m Single Sided Monochrome Card Printer P1207 Dual Sided Color Card Printer Magnetic Encoder None Yes select defaults below Magnetic Encoder Defaults None Stripe Down HiCo LoCo Interface USB Only USB and Ethernet Power Cords U S and Europe U K and Australia Windows Drivers and User Documentation are included on one CD Software amp Documentation Package containing multi language documentation English Spanish French German Chinese Italian and Portuguese Starter Kit No Starter Kit Starter Kit including 200 30 mil PVC cards and one YMCKOK ribbon part number 800015 948 EXAMPLE P120i OM10A IDO P1201 Printer Magnetic Encoder Stripe Down HiCo LoCo Standard Memory USB Interface U S and Europe Power Cords Windows Driver and User Documentation CD No Starter Kit DESCRIPTION Card Sense single card feed upgrade kit Cleaning Kit includes 4 print engine cleaning cards and 4 feeder cleaning cards 158 Zebra P110 P110m P120i Card Printers S
41. am Intensity CHECK Return Checksum CLEAN Set Cleaning Card Sequence CLN Check Due for Cleaning Parameters CLNCARD Set Cleaning Parameters CLCD Set LCD Contrast CV Adjust Clear Varnish Intensity C vC Write Box Monochrome ID Move Print Head Down D vD Draw Diagonal Line Monochrome Overlay E Retransmit Last Response amp E Write Single Track 980584 001 Rev A 980584 001 Rev A KE Write Track Buffers EC End of Print F Clear Color Image Buffers IF Move Motor IFA Move Ribbon IFE Set Ribbon Color Seguence EP Clear Specified Bit Maps F vF Clear Monochrome Image Buffers GS Download Color Graphic G vG Initialize Monochrome Graphic B W HEAD Get Print Head Serial Number I Print Monochrome Panel IH Print Hologram Overlay IM Print Color Test Card IMB Print Gray Test Card IS Print Card Panel ISERIES 1 Series Printer Test IV Print Clear Varnish J Print Multiple Monochrome Cards IL Check Status of Printer Sensors L Draw a Horizontal Line Rectangle in a Color Buffer L Read Single Track L Adjust Specified Color Intensity LLCD Set LCD Intensity LD Initialize a Color Buffer to a Specified Intensity Level L vL Draw Horizontal Line Monochrome Overlay IM Move Print Head Up MB Return Card To Card Feeder MC Clear Media Path ME Exit Card To Output Hopper MF Flip Card P120i only MI Move Card Into Print Ready Position MIB Move Card Back To Print Ready Position MM Move Card Through Printer M m Multiple Command MO Move Card To Ou
42. anual 980584 001 Rev A Step 4 Step 5 Step 6 980584 001 Rev A The card is printed Dye Sublimation Printing P1107 and P120 only The leading edge of the card is moved under the Printhead over the Platen Roller and the Printhead is lowered Lowering the Printhead reduces the space between the Printhead the ribbon and the card which produces sharper images The last time the Lid was opened and closed the ribbon was automatically synchronized bringing the leading edge of the yellow ribbon panel for a YMCKO or YMCKOK ribbon under the Print Head As the card and ribbon move along each element of the Printhead receives a pulse of variable width a wider pulse results in a hotter element which melts a larger amount of yellow dye onto that particular spot on the card After this yellow pass is completed the Printhead is raised the card is moved back and printing continues with the Magenta ribbon panel then the Cyan panel then the Black panel if present then an Overlay panel Thermal Transfer Printing P110i P110m and P1207 If using a monochrome ribbon used when printing a bar code on a card the card makes a single pass under the Printhead The Printhead elements are energized to either on or off The on level actually transfers the spot of resin under the Printhead element to the card This results in the sharpest possible images for bar codes you want the sharpest edges and highest contrast between dark and
43. arting position whenever the Lid is opened and then closed For a YMCKOK ribbon the starting position is with the leading edge of a Yellow Panel at the Printhead location 54 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A The following figure shows how the r bbon and card move relative to each other during the printing process This obviously does not apply to the P110m Printer Printhead at Fixed Position 2 Card is Fed to Printing Position Under the Printhead 3 Card and Ribbon Move Together as Yellow Panel is Printed N om 4 Card and Ribbon Stop at End of Yellow Panel nm am 5 Ribbon is Stationary Card is Moved Back to Printing Position ft EM ina 6 Card and Ribbon Move Together as Magenta Panel is Printed m iim Note that before printing the second K Resin black panel the card would be moved back to the card flipper flipped over and then advanced to the Printhead 1 Ribbon Moves Yellow Panel into Position at Printhead 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 55 Dye Sublimation Printing P110 and P120 only In Dye Sublimation Printing each Printhead heating element is applied voltage at one of a number of pulse widths A wider pulse results in the element getting hotter which converts more of the dye at that pixel location to a gas and diffuses it into the surface of the card a wider pulse gives more i
44. bon Storage Information above e Storage Humidity 20 to 70 non condensing e Ventilation Free air Options e Magnetic encoder 30 mil cards only 3 track HiCo LoCo e CardSense single card feed mode e Cleaning Kit 1 cleaning card and cleaning swab Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 1 4 Card Dimensions ISO standard dimensions for plain card 2 125 0 002in 53 98 0 050mm Bi 375 0 01 u 0 125in 0 009 0 034in 0 23 0 84mm i ISO standard dimensions for magnetic stripe card 0 623in 15 82mm min 0 218in 5 54mm max 0 0 115 in 2 92 mm MAGNETIC STRIPE 0 0 115in 2 92mm 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual Declarations of Conformity Declarations of Conformity 89 336 EEC EMC Directive EN 55022 1998 RF Emissions control modified by en l EMC Directive EN 301489 3 V1 4 1 RF Emissions and Immunity for radio 92 31 EEC and equipment 93 68 EEC EMC Directive EN55024 2001 Immunity to Electro Magnetic Disturbances 73 23 EEC modified Low voltage EN 60950 1 2001 Product safai by 93 68 EEC Directive y 1999 5 CE R amp TTE Directive EN300330 2 V1 1 1 Radio Frequency Interferences For a formal certificate please contact the Compliance Office at Zebra s Camarillo facility EUROPE Norway Only This product is also designed for IT power system with phase to phase voltage 230V Earth ground
45. bra P120i USB Card Printer Features Color Yes Paper available Double sided es 86mmx54mm Card Staple No Speed Unknown Maximum resolution 300 dpi Printing Preferences Print Test Page Click on Tools gt Properties amp Zebra P120i USB Card Printer Properties General Sharing Parts Advanced Color Management Security Device Settings x Zebra P120i Card Printer Device Settings Printer Model Firmware Version Zebra P120i Card Printer Encoder Settings Fi Download Device Information Single Feed About gt Zebra P110i P110m P120i Card Printers Service Manual 980584 001 Rev A Step5 This brings up the Tools display Type the command h Command to send to printer th ere A en click the Print Test Card Cleaning button Offset setting Front gt lt Front r P fee Direct encoding Dwa SY ta ZZ a Note The Print Head Resistance command is R See Appendix D for the complete list po 7 of commands Step 6 In the Command to send to printer field type the Print Head Resistance command a space and the resistance of the replacement Printhead Assembly e g R 1234 Step7 Click the Execute button Step 8 The firmware update is complete 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 83 5 6 Cleaning Roller Step 1 Locate the Cleaning Roller Cleaning Roller Step2
46. cable Disconnect the 4 wire Color Ribbon Sensor Do not let the 4 wire connector go into the access hole it is difficult to retrieve Note that this sensor connects to J5 on the Main PCBA Remove the Printhead Assembly Zebra P110 P110m P120 Card Printers Service Manual 980584 001 Rev A Printhead Replacement Printhead Installation Stepl Record the resistance of the new Printhead Assembly Printhead Resistance Step2 Connect the 4 wire Color Ribbon Sensor Step 3 Connect the printhead data and power cable Note that the connector is keyed Use a flat blade screwdriver to guide the connector into place Step 4 Connect the green ground wire Step 5 Push the printhead alignment pin into the alignment hole Alignment Pin Alignment Hole Step 6 Press in and downward lowering the Printhead Assembly into place Step 7 The Printhead installation is complete 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 81 82 Firmware Update Step 1 Go to start gt Printers and Faxes Step 2 Step 3 Step 4 From the Printers and Faxes list right click the Card Printer and select Properties from the pop up menu The Printer Properties window will open Click on the Device Settings tab amp Zebra P120i USB Card Printer Properties Color Management Security add Device Settings Sharing Ports Advanced Location Comment Model Ze
47. card com 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 203 204 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A
48. ck Advanced Zebra P110i P110m P120i Card Printers Service Manual 980584 001 Rev A 2 7 6 Advanced Tab On the Advanced tab you can choose various printer properties install different printer drivers and change default printer settings Color Management Security General Sharing Ports 8 Always available O Available from Priority Driver Zebra P120i USB Card Printer F 6 Spool print documents so program finishes printing faster O Start printing after last page is spooled 6 Start printing immediately O Print directly to the printer C Hold mismatched documents Print spooled documents first C Keep printed documents Enable advanced printing features Printing Defaults Separator Page 2 7 7 Device Settings Tab On the Device Settings tab you can change settings for a Magnetic Encoder and change to or from single feed mode Zebra P120i USB Card Printer Properties PR General Sharing Forts Advanced Color Management Secui Device Settings Er zebra Pl20i Card Printer Device Settings Printer ModeliFirmware Version Encoder Settings Tools FY Download Device Information Single Feed about 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 33 Printer Model Firmware Version Gives the printer model and firmware version E
49. d out in each step as appropriate Important When removing any of the nylon or plastic pulleys or gears the use of a gear puller is strongly recommended If a gear puller is not available use pliers and or a flat blade screwdriver to pry the gear or pulley off its shaft In either case remove any Loctite residue from the shaft and the gear pulley Inspect the old gear pulley very carefully If any teeth have burrs are missing or are damaged or if the center hole is distorted or enlarged the gear pulley must be replaced rather than the old one re installed Flat Blade Screwdrivers from 1 16 inch 1 5 mm to 1 4 inch 6 5 mm Phillips Screwdrivers numbers 0 1 and 2 TORX T8 and TORX T10 drivers Fine Point Offset Fine Point and Needle Nose pliers Small Diagonal Cutters or other cutter for cutting cable ties Hex Keys 1 5 mm and 2 0 mm Hex Driver 5 5 mm this can also be used for securing push nuts Small and Medium Spring Hook Tools Belt Tensioning Tool Zebra P N 900754 003 oe A ee Se S ie a 76 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 9 3 5 5 Printhead Assembly page 79 5 6 Cleaning Roller page 84 NOTE 1 Disconnect all the plugs when replacing the Main PCBA otherwise only disconnect the plugs for the associated replacement assembly NOTE 2 Not present on P110m Removal Sequence This figure shows the recommended removal sequence For each item follow th
50. d printing Front and Back Feature selection for dual sided printing Choices based on r bbon type YMCKOK e YMCKO on Front K on Back e YMCKO on Front YMCKO on Back YMCKO e YMCKO on Front YMCKO on Back e YMCO on Front K on Back Monochrome Conversion Specifies the method of monochrome conversion used in printing Different selections have different effects on the way the image is printed The options are Diffusion Halftone regular and Barcode Black Panel Defines how black panel is applied in a card design 4 selections e Do Not Use K panel not used e Use Always all black pixels will go to K panel e Text Only only black text goes to K panel e Except in Color Picture all black pixels except bitmap goes to K panel Black Bitmap Applies black bitmap option Front Overlay Varnish Feature selection for applying overlay varnish ribbon to front of card Default setting is full edge to edge varnish There are various varnish options A preview pane is shown for each selection e Full overlay varnish Applies an edge to edge overlay e No overlay Does not apply any overlay e Selected Area Applies overlay only in the area selected by user e Selected area blank Applies overlay only outside the area selected by user e Bitmap based overlay Applies a user defined bitmap in the overlay panel e Smartcard ISO Does not apply overlay in the area of the ISO standard Smart Card contacts e Smart Card AFNOR
51. d to send to printer field type the Print Head Resistance R command a space and the resistance of the Printhead From the Test Card shown above the complete command is R 1568 b Click the Execute button c In the Command to send to printer field type the End of Print EC command a space and the end of print value From the Test Card shown above the complete command is EC 10 d Click the Execute button e In the Offset setting section enter the X and Y offsets for the card front in the Front X and Front Y fields respectively From the Test Card shown above Front X 07 and Front Y 32 f In the Offset setting section enter the X and Y offsets for the card back in the Back X and Back Y fields respectively From the Test Card shown above Back X 05 and Back Y 04 g Click the Set Offsets button Step 7 The Firmware Update is complete 94 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 5 12 Left Side Cover Step 1 Step 2 Step 3 980584 001 Rev A Locate the two screws that hold the Left Side Cover in place Screws With a TORX T10 driver loosen the two screws Remove the Left Side Cover Zebra P110 P110m P120 Card Printers Service Manual 95 5 13 Printhead Fan Step 1 Locate the Printhead Fan Printhead Fan Step 2 With a TORX T10 driver remove the two screws that hold the fan in place Mounting Screws Cable Tie Step
52. dSense M single card feed option A card is inserted part way into the Card Entry Exit Slot The card will be drawn into the printer printed encoded or decoded as specified by the application program and then be ejected out through the Card Entry Exit Slot Rear Panel Connectors Controls and Indicators Standard USB Connection The figure below shows the rear of the Printer with the standard USB interface Power Socket USB Port E O Power Switch 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 3 Ethernet Connection The figure below shows the rear of the printer with the Ethernet Option Power m 11 Socket ee iD OCO ZZ it USB Port Power Switch Network Ethernet Ethernet Ethernet Status Adapter Reset Connector Activity Status Button Indicator Indicator Ethernet Adapter Status Indicator 1 During normal operation the LED is solid GREEN for more than 30 seconds This indicates all the hardware is functioning properly and the Ethernet Adapter has detected the presence of the network It does not mean the Ethernet Adapter has an IP address or is attached to a printer queue 2 If the LED is slowly flashing GREEN 1 time sec the Ethernet Adapter is trying to print Network Status Activity Indicator 1 2 If the LED is solid GREEN a 100Base link is established
53. dee oe eee b yeas 119 5 28 ATM Card Feed Sensor 130 5 29 ATM Pressure Roller amp Card Drive Roller Assemblies 131 5 30 Pressure Roller Lift Motor 135 5 31 Ribbon Take Up Motor 138 5 32 Platen Roller ee eee 140 5 33 Mag Encoder Assembly Head and Sensor 141 5 34 Stepper Motor s sac cayactierieeatd bcs soe O deda ad eens eee ds 143 5 35 Main DIVE MONET sa areni sk 5005 ersehen 149 6 Preventive Maintenance 153 6 1 Cleaning System 153 6 1 1 When to Clean 153 6 1 2 HOW 10 Cleat gt prasok tia ko Bod O v da kv 154 6 2 Cleaning the Printhead 155 6 3 Magnetic Encoder Cleaning 156 Appendix A Model Numbers 157 Appendix B Card Sense Single Card Feed Option 159 Appendix C Ethernet Upgrade 165 Appendix D SOMWEATe ss zre rio above lei EA BABA R on kas 169 Appendix E Spares List 175 Appendix F Worldwide Support 201 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual V vi Zebra P110 P110m P120 Card Printers Service Manual 980584 001 R
54. e Roller assembly in place Step 7 Remove the ATM Pressure Roller assembly Step 8 With a flat blade screwdriver free the locking pins that hold the Card Drive Roller assembly in place 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 133 Locking Pin Step9 Remove the Card Drive Roller assembly 134 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 5 30 Pressure Roller Lift Motor Step 1 Locate the Pressure Roller Lift Motor Pressure Roller Lift Motor Step 2 Remove retaining clip from the middle gear 1 ii 1 FAHRER 41 Jea TN Gear 2 Gear 1 Step 3 Remove the associated gear Step 4 Remove retaining clip from the right gear assembly 2 Step 5 Remove the two associated gears 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 135 Step6 Using a TORX T10 driver remove the screw holding the gear 3 in place Step7 Remove the associated gear Step8 Remove the Rocker Assembly If you need detailed instructions for the removal of the Rocker Assembly refer to Section 5 27 Step 2 Step 9 Using a TORX T8 driver remove the four screws holding the motor to the frame Note that the orange arrows point out the four mounting screws Step 10 Remove the Pressure Roller Lift Motor 136 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Replacement Slide the gears on t
55. e diagram upward to see what must be removed for access For example to remove the Feed Cover Sensor you would remove the Top Cover the Main PCBA the Bottom and Rear Covers and the Left Side Cover nee Printhead Fan page 96 980584 001 Rev A Display page 87 Zebra P110 P110m P120i Card Printers Service Manual Start Here Complete P110i P110m P120i 5 23 Lid page 109 5 23 Card Feeder page 109 page 130 5 24 Flipper Module page 113 5 25 Card Sync Sensor page 116 5 26 Pressure Roller page 117 5 12 Left Side Cover page 95 Pressure Roller amp Card Drive Roller page 131 5 18 Right Side Cover page 102 5 13 Linkage 5 16 Ribbon ID Sensor page 101 PRINT ENGINE 5 35 Main Drive Roller page 149 5 21 Front Cover page 106 sko Linkage page 98 5 19 Ribbon Flag Position Sensor page 103 5 20 Encoder Wheel page 105 533 Mag Encoder Assembly page 141 i 5 4 Terminology The following picture in conjunction with the Removal Sequence drawing will help you keep track of which side of the printer is which in the procedures that follow Lid open Printhead Assembly Card Feeder Card Flipper under Card Feeder Left Side of Printer Ribbon Right Side of Printer Front of Printer 78 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev
56. e lifetime of the printer Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Single Feed Dialog box for disabling or enabling single feed support Single Feed Options Current Status Disabled About WA Zebra P120i Card Printer V zebra Version 3 10 02 Copyright Zebra Technologies Corporation 2003 2006 Once the printer driver options have been configured to your satisfaction click the OK button to save your new configuration and close the Properties window 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 39 2 8 Loading Ribbon Cartridge The printer requires approved ribbon cartridges The Resin Thermal Transfer and Dye Sublimation ribbons are specifically designed for your printer e The P110 and P120 Printers require the use of i Series ribbons for full color printing e Each ribbon cartridge includes an integrated adhesive cleaning roller assembly that is used to clean the cards entering the printer Improper cleaning will reduce printer life and degrade print quality e When the ribbon is completely used change the whole cartridge assembly Electrostatic Discharge Caution DO NOT TOUCH the print head or the electronic A components on the print head Discharge of electrostatic charge from the human body or other surfaces can damage the print head or other electronic components Step 1 Open the printer lid by pressing the Cover Release button on the top of y
57. en detected Network activity detected by this LED does not mean the activity is data for the print server The activity is all activity on the network seen on the Ethernet Adapter 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 73 74 4 3 3 Resetting to Factory Defaults To reset the Ethernet Adapter configuration parameters to the factory defaults Step 1 Turn printer power OFF O Step 2 Press the Ethernet Reset Button hold it in while turning the printer power ON gt 07 5317 1 r I Tg lt 5 lt I H Ethernet Reset Button Step 3 Keep the Ethernet Reset Button pressed until the Status Indicator light turns GREEN Step 4 Release the Ethernet Reset Button Printing a Configuration Card To print a configuration card press and hold the Ethernet Reset Button until a card starts to print Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Replacement Procedures 5 1 Introduction The following sections describe removing both major assemblies and where applicable subassemblies and or components that are considered replaceable In general only removal directions are presented unless otherwise noted replacement would be performed by reversing the removal steps Replacement instructions for some items are not presented removal and replacement of these items are considered too obvious to warrant a detailed description Spares Kits a
58. er Solutions website at http www zebracard com 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 169 Entering Software Commands Note The screen shots shown in this section are for the printer using the USB interface If you are using the Ethernet interface the screens will refer to the Network Printer Step 1 From the Printers and Faxes list right click the Card Printer and select Properties from the pop up menu Step 2 The Printer Properties window will open Click on the Device Settings tab amp Zebra P120i USB Card Printer Properties Color Management Security Device Settings Sharing Ports Advanced Location Comment Model Zebra P120i USB Card Printer Features Color Yes Paper available Double sided Yes 86mmx54mm Card Staple No Speed Unknown Maximum resolution 300 dpi Printing Preferences Print Test Page Step 3 Click on the Tools tab and then click on the Properties button amp Zebra P120i USB Card Printer Properties General Sharing Advanced Color Management Security Device Settings 3 Zebra P120i Card Printer Device Settings Printer Model Firmware Version P120iM V1 13 03 w Encoder Settings Tools Fiw Download Device Information Single Feed About 170 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Step 4 This brings up the Tools d
59. ervice Manual 980584 001 Rev A Appendix B Card Sense Single Card Feed Option Printing a Single Card Without Using the Feeder For operating the card printer in single card feed mode the printer requires that the operator install an optional Card Sense Single Card Feed Kit In Single Card Feed Mode ATM Mode the printer will only accept cards through the front slot not from the card feeder 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 159 160 Installing the Card Sense Single Card Feed Kit Step 1 Set the printer to OFF Step 2 Printer Lid Important Make sure the output hopper remains closed Zebra P110 P110m P120i Card Printers Service Manual Ribbon Cartridge 980584 001 Rev A Step3 Place the black roller from the Single Card Feed Kit into the blue tabs at the front of the printer Roller from Single Card Feed Kit Blue Tabs Step4 While holding the black roller down firmly set the printer to ON The printer will initialize raise the blue tabs and snap the roller into place Step 5 Open the lid of the Card Cleaning Cartridge Card Cleaning Cartridge Step 6 Peel protective wrapper from the adhesive cleaning roller by gently pulling on the blue tape and discard the wrapper Step 7 Insert the cleaning roller into the Card Cleaning Cartridge and close the cartridge
60. ev A 1 General Description 1 1 Description This manual contains service information for Zebra P1107 P110m and P1201 Plastic Card Printers manufactured by Zebra Technologies Corporation Camarillo California The only difference between these models is as follows e The P110 supports single sided full color or monochrome printing e The P110m supports single sided monochrome printing only e The P120i supports single or dual sided full color or monochrome printing In this manual references that are specific to a particular model will be identified as such references that apply to all three models will use the term the printer The printers provides full color dye sublimation or monochrome thermal transfer printing on standard 2 125 inch by 3 375 inch 54 mm by 86 mm PVC or PVC Composite plastic cards The integrated card feeder and flipper P1207 only minimizes printer size while maximizing performance Load N Go ribbon cartridges are used with an integrated card cleaning roller for easy ribbon changing or replacement A variety of options some of which can be factory installed or field installed as upgrades are available making the printers configurable for varied application environments e Magnetic stripe encoder option e CardSense single card feed option e USB or USB and Ethernet interface option Its auto switching 100 240 Volts AC 50 60 Hz external power supply uses interchangeable
61. fully pry off the four rubber feet they are held in place with adhesive Note that the feet cover access holes to the screws holding the Bottom Cover in place Step 3 With a TORX T10 driver remove the four bottom cover screws Step 4 Remove the Bottom Cover 88 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 5 10 Rear Cover Step 1 With a TORX T10 driver loosen the two screws from the top of the Rear Cover Step 2 With a TORX T10 driver remove the two screws from the bottom of the Rear Cover Screws Step 3 Remove the Rear Cover 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 89 5 11 Main PCBA Important Before starting this procedure Print a Test Card see Section 2 10 You will need the Head Resistance the X and Y Offsets and the End of Text value to update the firmware on the replacement Main PCBA If for any reason you are unable to print the Test Card contact Zebra Technical Support to obtain the above values Note If replacing a Main PCBA that includes the Ethernet Interface Option see Appendix C for additional information Step 1 With the Bottom Cover removed the Main PCBA is visible and accessible Step 2 With a TORX T10 driver remove the five screws holding the Main PCBA in place Note that the five orange arrows point out the PCBA mounting hardware Tee m a TTT ima i Trh in a TA el 90 Zebra P110 P110m P120
62. fully push the Platen Roller shaft out of its right side mounting hole Step 2 Turn the Print Engine over reach in and remove the Platen Roller 140 Zebra P110 P110m P120 Card Printers Service Manual 980584 001 Rev A 5 33 Mag Encoder Assembly Head and Sensor v Note This procedure is for those printers that include the Magnetic Encoder option Step 1 Locate the Mag Encoder Assembly Head and Sensor Mounting Screws Step 2 With a TORX T10 driver remove the two screws holding the Mag Encoder assembly to the frame Step 3 If not already done disconnect the Mag Encoder Head and Sensor plug from connector J23 on the Main PCBA Step4 Remove the Mag Encoder Assembly Mounting Screw Step 5 With a TORX T8 driver remove the screw holding the Sensor to the Bracket 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 141 Step6 Remove the Head amp Sensor Cable Assembly from the Bracket Note that there are two springs attached to the Head The springs are a snug fit on their mounting pins Also note that the Magnetic Head is not attached to the bracket it floats on the springs Replacement Important The orientation of the Head is critical When installing the Head ensure that the heavy line is facing toward the Sensor Thinner Line Heavy Line Sensor 142 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 5 34 Stepper Motor
63. g _ Track 1 Track 2 7 Track 3 Command to send to printer Enter a printer command without leading escape character in the top edit box and click on the Execute button to send to the printer directly The Printer Status will show the status of the printer Refer to Appendix D Software for a complete list of the printer commands Test Card Three test cards are available Standard Printer Parameters and Encoder Parameters Clean Click on the Printer Only button to clean the printer Remove all consumables before executing a cleaning cycle Offset Setting Enter the X and Y direction offset and click on the Set Offset button to set the X and Y offsets for printing image Direct Encoding Select the track and enter the data to encode on the magnetic stripe The Encode button feeds a card from the feeder and encodes the data To read magnetic data select the tracks to be read select Read To eject the card from the printer select Eject Card Send File This command will allow a prn or txt file to print e The prn file must be created with a Zebra printer driver using the same ribbon as present in the printer e The txt file must contain firmware commands only with only one command per line The first line must only contain MASTER e The last line must only contain SLAVE Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A F W Download Dialog box for download
64. he printer power off wait 10 seconds then turn the printer back ON If the Ethernet Adapter still fails the POST the Ethernet Adapter has a hardware problem that can be fixed only by replacing or returning the unit Contact Technical Support for repair or replacement information If the LED is alternately flashing RED and GREEN for longer than 2 minutes the Ethernet Adapter is in firmware download mode This means it is waiting for new firmware data to be sent before it continues normal functioning Do the following If the Ethernet Adapter was purposely put into firmware download mode finish the download with the proper update utility Contact the Zebra web site at http www zebracard com and click on the Drivers amp Downloads tab Contact Technical Support for help recovering this unit Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 4 3 2 Network Status Activity Indicator A bi color Status Activity LED indicates network speed established link and network activity Network Status Activity Indicator Step 1 If the LED is off no link was established Step 2 If the LED is solid GREEN a 100Base link is established Step 3 If the LED is flashing GREEN a 100Base link is established and network activity has been detected Step 4 If the LED is solid ORANGE a 10Base link is established Step 5 If the LED is flashing ORANGE a 10Base link was established and network activity has be
65. heir respective shafts in the order indicated below then lock them in place screws for 1 amp 2 and clips for 3 amp 4 in the same order aT V gt Dao TAT m Important When re installing the gears 1 amp 2 ensure that the grooves outlined in orange are aligned as indicated 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 137 5 31 Ribbon Take Up Motor Step 1 Locate the Ribbon Take Up Motor Ribbon Take Up Motor Step 2 Remove the belt a Remove the clip from the lower pulley 1 11 FETT 41 eon T gt Bil I i r Belt Lower Pulley 1 Motor Gear 2 b Slide the pulley off the shaft c Remove the belt 138 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Step 3 With a TORX T8 driver remove the screw holding the motor gear 2 in place Step4 Remove the gear Step 5 With a TORX T10 driver remove the three outside screws holding the motor to the frame Note that the orange arrows point out the three mounting screws Step6 Remove the Ribbon Take Up Motor Replacement Important When re installing the gears ensure that the grooves outlined in orange are aligned as indicated 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 139 5 32 Platen Roller With the Ribbon Take Up Motor removed you can remove the Platen Roller Step 1 With a Phillips screwdriver care
66. i Card Printers Service Manual 980584 001 Rev A Step 3 Carefully lift the Main PCBA out of the frame and disconnect the various wires and connectors that attach to the Main PCBA Be careful to avoid damaging any of them Step 4 The following picture shows the connections to the Main PCBA J2 J6 J23 J3 J12 Flip Ribbon Mag Cam ATM Motor Flag Encoder Motor Card Position Head amp Feed Sensor Sensor Sensor J14 USB Port J8 Feed sever Sona A En Sensor RIM O 8 2 a ao Mi E ae uli MI ME zr JE a u 7 hr O l m a poke MU izbi 1 ui Mej vfs bht g J16 Ribbon Motor J11 Flipper Position U Bi PAR Sensor r i ik s zd E 3 A Bill E dni s li in ie a MO fi i ah ia J21 Auxiliary Fan J10 Card Load Sensor J7 Lid Sensor J13 Feeder Motor sunrpesga bee me J26 Platen Motor J19 DC Power Supply J25 J28 J24 J5 J9 J18 Print Printhead LCD Color Card Ribbon Head Display Ribbon Sync ID PCBA Fan Sensor Sensor Motor Step 5 When the Main PCBA is removed the view from the bottom of the printer looks like the following picture 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 91 92 Step 6 Set the Main PCBA aside Side 1 Ai id i pi dos Ni t eti MITA PF U ii waaay Hanul i mim 4111111 TTT yii zg p T k m si 1 F BE nE EB Ki Zebra P110 P110m
67. ing is via the polarized 3 wire power cord FI Laite on liitett v suojamaadoitus koskettimilla varustettuun pistorasiaan SE Apparaten skall anslutas till jordat uttag NO Apparatet m tilkoples jordet stikkontakt FCC Regulations Models P110 P110m P1207 have been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and operated in accordance with the User s Manual may cause harmful interference to radio communications Operation of this equipment in a residential area 1s likely to cause harmful interference in which case the user will be required to correct the interference at his own expense Pursuant to Part 15 21 of the FCC Rules any changes or modifications to this equipment not expressly approved by Zebra may cause harmful interference and void the FCC authorization to operate this equipment FCC Radiation Exposure Statement applicable to 15 247 device only This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment This equipment should be installed and operated with minimum 20 cm between the radiator and your body This transmitter must not be collocated or operating i
68. ing printer firmware Important Do not turn off the power to the printer until the process is done and the LCD displays READY If the download process is interrupted the printer will not operate Firmware Download Selected Firmware file details Selected Firmware type Check sum Close e Select the appropriate bin file from the host computer that is specified for the printer e Select Start Firmware Download to execute the download process 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual oF 38 Device Information Printer configuration status window Device Information Device Information Yendor Name Model Firmware Version 4 20iM IRENE Serial Number P120PLTO7E Z lt o Head Resistance Magnetic Encoder Smart card Ribbon Type Remaining Count Panels printed Close Model Firmware Version Identifies the printer model number and installed firmware version Serial Number Lists the printer serial number Head Resistance Lists the printhead resistance value Magnetic Encoder Identifies if this option 1s present Smart Card Identifies if a smart card encoder is present and type of encoder Ribbon Type Identifies the ribbon installed in the printer Remaining Count Shows the remaining card count for the ribbon installed For monochrome ribbons this will display Unknown Panels Printed Displays the total number of panels printed for th
69. isplay Type the command here Command ta send to then click the Printer Status Execute button Print Test Card Cleaning Standard w Printer only w Offset setting Front gt Front l e Direct encoding Orso om r III Step 5 Type the desired command in the Command to send to printer field and click the Execute button 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 171 Software Commands Complete information about each command including description syntax and parameters is presented in the EPCL Programmer s Guide Zebra document 980415 001 which can be downloaded from the Zebra Card Printer Solutions website at http www zebracard com The following listing includes the software commands that apply to the P1107 P110m and Zebra P110 P110m P120i Card Printers Service Manual P120i Printers IA Stop Motor A Standard Test Card Al Printer Test Card A2 Magnetic Encoder Test Card ATM Set Card Feeding Mode amp B Load Magnetic Encoder Track Write Buffer BS Set Black Synchro B vB Write Bar Code BLACK Print Black Card KC Set Coercivity C Adjusts Monochrome Intensity C Adjust Color Contrast ICC Get Number of Cards Printed CDER Get Magnetic Encoder Read Settings amp CDER Set Magnetic Encoder Track Read Encode Parameters amp CDEW Set Magnetic Encoder Track Write Encode Parameters CDOTS Image Print Quality Compensation Factor CH Adjust Hologr
70. l for a given failure symptom one or more possible causes are listed with suggested corrective action to take These causes should be checked and corrective actions taken in the order given they are listed in order of likelihood and complexity When the suggestions presented fail to lead to a repair a CPU Board replacement if not prescribed should nevertheless be tried A check for broken or disconnected cables and any loss of power should also take place along with checks for obvious mechanical damage Zebra Card Printer solutions offers Technical Support and factory repair as options 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 63 4 2 Troubleshooting Procedures 4 2 1 General Issues The table below offers causes and solutions to symptoms related to improper operation Check the table when experiencing any loss of operation or print quality Problem Description The LCD Panel displays OUT OF CARDS message The LCD Panel displays OUT OF RIBBON message The LCD Panel displays MECHANICAL ERROR message The LCD Panel displays ENCODING ERROR message The LCD Panel displays INSERT CARD message with cards in the Card Feeder The LCD Panel displays CLEAN PRINTER message Zebra P110 P110m P120i Card Printers Service Manual Cause Solution 1 Check for cards in the card feeder If no cards are present load cards Press the Control Button for one second The printing job wil
71. l restart Check the ribbon Replace if defective or entirely used Ribbon will automatically synchronize and printing will restart with a new card Check that you are using the correct card type see Technical Specifications If two cards are fed into the printer at the same time Open the Lid and remove the Ribbon Cartridge empty the Card Feeder and pull out the jammed cards Replace the Ribbon Cartridge Remove cards from Card Feeder separate them as shown in Loading Cards in section 2 and replace Check that ribbon is loaded correctly Check that you are using the correct magnetic card type for low or high coercivity encoding Verify command syntax Contact Zebra technical support Printer may be in the Single Feed mode Change mode Printer cleaning required see Section 6 980584 001 Rev A 4 2 2 Print Quality Issues Important The use of Zebra cards and True Colours ribbons will give the best print quality This section will help you resolve print quality problems The print quality is dependent on several factors The two most important factors that will increase your print quality are cleanliness and card stock To diagnose and fix print quality problems follow the troubleshooting procedures below Example Small spots appear on the printed card with a non printed area or a different color e Possible Cause Contamination on the card surface So
72. lan Wil Larajicle Step 8 After installing the Driver restart your computer When you apply power to the printer the Windows New Hardware Found wizard will find the printer 24 Zebra P110 P110m P120 Card Printers Service Manual 980584 001 Rev A 2 7 Changing the Printer Driver Options gt Note The screen shots shown in this section are for the printer using the USB interface If y 7 you are using the Ethernet interface the screens will refer to the Network Printer You can change the default settings for the printer driver Change the options as follows Step 1 From the Printers and Faxes list right click the Card Printer and select Properties from the pop up menu Step 2 The Printer Properties window will open Zebra P120i USB Card Printer Properties Color Management Security Device Settings General i Sharing Parts Advanced ma ca Zebra P1201 USE Card Printer Model Zebra P1201 USE Card Printer Features Color es Paper available Double sided Yes Sbmm Ssrmen Card Staple No Speed Unknown Maximum resolution 300 dpi Printing Preferences Print Test Page e General Displays printer name tab selection for Printing Preferences and Print Test Page e Sharing OS feature where printer can be shared to other clients on a network e Ports OS feature displays available communication ports e Advanced OS feature to select printer availability and spooling options e Color Ma
73. lti Panel Ribbons have an smart chip built into the supply spool the smart chip identifies the ribbon type and panel count Note that the lack of a smart chip will be interpreted by the Printer as being a Monochrome Ribbon Printing with a Multi Panel Ribbon requires multiple passes of the card under the Printhead once per panel Ribbon ID M A Smart Chip Contacts A v Contact Pad For dual sided printing a typical situation would be to print a full color graphic such as a person s picture along with black text and or bar coding on the front and black text and or bar coding on the rear In this case a YMCKOK Multi Panel Ribbon would typically be used 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 53 A YMCKOK ribbon has successive panels as follows Dye Sublimation Printing Process Thermal Transfer Printing Process ei N KOK P Yellow Magenta Cyan Black Overlay Black R Kanin Y M C K O K Dye Dye Dye Resin Varnish Resin P M Ribbon Movement From Supply Spool Other ribbons are available for the Printer see the Supplies List on the Driver and Documentation CD that came with your printer or go to the Zebra Card Printer Solutions website at http www zebracard com Additionally the driver software allows the user to specify which ribbon panels are printed on either side of the card The ribbon synchronizes to its st
74. lution Check that cards are stored in a dust free environment Use a different supply of cards e Possible Cause Cleaning roller not installed Dust inside the printer and or dirty cleaning roller Solution Perform a cleaning of the printer Check that the protective cover was removed from the ribbon cartridge cleaning roller If printing one card at a time replace the cleaning roller located at the front of the printer 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 65 Example There are non printing horizontal lines white on the card surfaces V m U e Possible Cause Ribbon cartridge 1s not correctly positioned Solution Ensure that the ribbon is properly rolled onto the ribbon cores of the cartridge and that there are no wrinkles in the ribbon Replace ribbon cassette e Possible Cause Printhead is dirty Solution Clean the printhead e Possible Cause Printhead elements are damaged e g scratched or burnt Solutions Replace the printhead 66 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Example Printing shows very pale or inconsistent results e Possible Cause Ribbon cartridge has been stored improperly or is damaged Solution Change the ribbon cartridge and print again e Possible Cause Cards may not meet specifications Solution Use a different supply of cards e Possible Cause Contrast and or inte
75. mber of copies of cards printed Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 2 7 2 Sharing Tab On the Sharing tab you can choose to share the printer over the network and install additional drivers to accommodate different operating systems Zebra P120i USB Card Printer Properties Color Management Security Device Settings General sharing Ports Advanced k pi You can share this printer with other users on your network To Ka enable sharing for this printer click Share this printer O Share this printer Drivers IF this printer iz shared with users running different versions of Windows you may want to install additional drivers sa that the users do not have to find the print driver when they connect to the shared printer Additional Drivers 2 7 3 Ports Tab Use the Ports tab to add delete and configure the printer ports as well as choose which port the printer is assigned Zebra P120i USB Card Printer Properties PR Color Management i Device Settings General Sharing i Advanced Zebra P1201 USB Card Printer Print ta the following portis Documents will print to the first free checked port Port Description Printer LI COM Serial Port LI COM3 Serial Port LI COM4 Serial Port LI FILE Print to File LI ATL Zebra USE Printer USB Virtual printer port fo Zebra P1201 USB Card Printer LI USE Virtual printer port fo
76. move the components of the Single Card Feed Kit in order to operate in normal mode 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 163 Printing a Single Card Step 1 Place the printer power switch in the ON position Insert a single card into the slot at the front of the printer directly above the card Step 1 output hopper Do not feed more than one card at a time Printer will take the card Note If single card feeding will be the normal mode of operation you may select that mode through the driver software In single card feed mode the card will not be printed until the print job has been sent to the printer and the card to be printed has been inserted into the single card feed slot 164 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A APPENDIX C Ethernet Upgrade Introduction This Appendix describes installing the Ethernet Upgrade on P110i P120i or P110m Printers Important Your printer s Main PCBA must be part number 404600 009P Other Main PCBAs do not support this upgrade Important Before beginning this procedure see Section 5 11 for information concerning removal and replacement of the Main PCBA 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 165 Procedure Step 1 Remove the printer s Bottom Cover and Rear Cover see Section 5 9 and Section 5 10 respectively Step 2 Remove the old
77. move the screw and washer holding the rocker assembly to the frame k ti r Mounting Screw Main Drive Roller d Remove the retainer clip on the Main Drive Roller e Remove the Main Drive Roller pulley f Lift and jiggle the left arm to free the rocker assembly 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 121 g Remove the rocker assembly Step 3 Remove the retainer clip on the Exit Roller then remove the Exit Roller pulley Exit Roller Pulley Tensioner Pulley Step 4 Note that a tensioner pulley is accessible with the Platen Roller pulley removed Remove the retainer clip then remove the tensioner pulley 122 Zebra P110 P110m P120 Card Printers Service Manual 980584 001 Rev A Step 5 With a TORX T10 driver remove the screw holding the plastic retaining plate to the frame The retaining plate holds the Platen Roller and Exit Roller in place Mounting Screw Step 6 In addition to the mounting screw removed in the previous step two clips hold the plastic retaining plate to the frame Use a flat blade screwdriver to loosen the clips inside the printer shown in the next two figures then remove the retaining plate Clip 1 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 123 Clip 2 Step 7 Remove the retaining plate 124 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Step8 With a Philli
78. n click on Run 2 Type d index htm where d is your CD drive letter 18 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 2 6 1 Print Driver Installation Install the Printer driver as follows Step 1 Insert the User Documentation and Drivers CD into the CD drive of the host computer The Select Language window will open 0024 Card Printer Please Select Language AWLI Solutions Step 2 From the Select Language window choose the appropriate language for your system The Main Menu will open in the selected language 6 Value Line N zebra P110 P110m P120 Printer Driver Documentation Support View README gt gt View CD README gt gt Register Your Product gt gt P110i P110m gt gt Warranty Media List gt gt P120i gt gt Ethernet FAQ gt gt P110i gt gt P110m gt gt P120i Install Printer Driver User s Manual gt gt P110i P110m gt gt P110i P110m gt gt P120i gt gt P120i gt gt Web Site gt gt Install Adobe Acrobat gt gt Install ZebraNet Utilities Requires Acrobat Requires active internet connection 2006 ZIH Corp Step 3 From the Main Menu under Install Printer Driver select the appropriate printer model P1107 P110m or P1207 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 19 Step4 The InstallShield Wizard will launch and a progress window will be displayed Card Printer Solutions
79. n conjunction with any other antenna or transmitter unless authorized to do so by the FCC Industry Canada Notice This device complies with Industry Canada ICES 003 class A requirements Cet quipement est conforme a 1 ICES 003 classe A de la Norme Industrielle Canadienne 10 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Icons ima Icons Throughout this manual different icons highlight important information as follows Note Indicates information that emphasizes or supplements important points of the main text Important Advises you of information that is essential to complete a task or points out the importance of specific information in the text Provides an example or scenario to demonstrate or clarify a section of text Electrostatic Discharge Caution Warns you of the potential for electrostatic discharge Electric Shock Caution Warns you of a potential electric shock situation Caution Warns you of a situation where excessive heat could cause a burn Caution Advises you that failure to take or avoid a specific action could result in physical harm to you or could result in physical damage to the hardware 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 11 12 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 2 Installation and Setup 2 1 General Information This section will guide you
80. nagement Allows user to define color profile s with color printers e Security OS feature where permissions to printers can be defined e Device Settings Allows user to view Printer Model and Firmware Version Encoder Settings Tools Firmware Download Single Feed and About driver version information 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 25 26 2 7 1 General Tab The General tab Shows the printer model and lists the features of the printer amp Zebra P120i USB Card Printer Properties gt lt Color Management r Security _ Device Settings sharing Ports Advanced 71 ca Zebra P1201 USB Card Printer Model Zebra P1201 USE Card Printer Features Color es Paper available Double sided Yes S6romso4rim Card Staple No Speed Unknown Maximum resolution 300 dpi Printing Preferences Print Test Page Click on the Printing Preferences button to change the card settings see Printing Preferences on page 27 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Printing Preferences amp Zebra P120i USB Card Printer Printing Preferences PR Options I rebra P170 Card Printer Settings ER Paper Output Orientation Landscape 150 Rotation None Color Adjustment Ribbon MKO Print on both sides Yes Front and Back Front MiCo Back K Monochrome Conversion Diffusion Black Panel Black Bitmap Front Overlay Varni
81. ncoder Settings Dialog box for setting Magnetic Encoder parameters This feature is not enabled if the printer does not have the magnetic encoder option Encoder settings The start of data characters must be immediately followed by a one digit number representing the track where data will be written Use the normal Windows default fonts l Sample 12222 lt start_of_data gt 122 2 lt end_of_data gt HiCo LoCo Encoder position Encoder type O High Coercivity O Reversed ISOAIS Law Coercivity Normal Ouls2 No Change OBAMA Restore Defaults Apply Enable macro processing This option will allow the user to choose the encoding preamble Start of Data Beginning of the data string for the encoder Note that Start of Data characters must be immediately followed by a one digit number representing desired track where the data will be written Use the normal Windows default fonts End of Data Ending of the data string for the encoder Advanced Settings Click here for more information see ADVANCED SETTINGS DIALOGUE BOX on page 35 Restore Defaults Click here to reset the encoder settings to the default values HiCo LoCo Select the type of coercivity of magnetic stripe cards to be used Coercivity is a Measurement of a material s resistance to being magnetized Low coercivity material magnetizes easier than high coercivity material Encoder Position Select the printer encoder position between Re
82. nsity may be set to values which are too high Solution Adjust contrast and or intensity values in software e Possible Cause Dust or embedded contamination on elements of the printhead Solution Clean the printhead 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 67 Example Printing shows blurry printed image e Possible Cause Ribbon cartridge may not be correctly positioned Solution Check that the ribbon is properly rolled onto the ribbon cores of the cartridge with no wrinkles Replace ribbon cartridge making sure it locks in place and print again e Possible Cause Ribbon may not be synchronized on the correct color panel position Solution Open lid then close lid to synchronize ribbon e Possible Cause Cards may not meet specifications Solution Use a different supply of cards e Possible Cause Dust or embedded contamination inside the printer and or dirty cleaning roller Solution Clean the printhead Replace the cleaning roller 68 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Example No printing on the card 980584 001 Rev A Possible Cause Ribbon cartridge may not be installed in the printer Solution Check for r bbon cartridge in the printer Possible Cause Cards may not meet specifications Solution Use a different supply of cards Possible Cause Cable on printhead may be disconnected Printhead element
83. ntense color at that pixel This 1s repeated for each of the dye panels 1 e Yellow Magenta and Cyan to result in full color images Printhead Ribbon Carrier M Layer Ribbon Dye Layer Card Gaseous Dye is Absorbed by Card Platen Roller Thermal Transfer Printing P110 P110m and P120 In Thermal Transfer voltage is either applied or not applied to each Printhead printing element If voltage is applied the ink at that location is transferred to the surface of the card Each pixel is either printed 1 e the ink transferred to the card or not there are no intermediate levels Thermal Transfer printing with a resin ribbon is used for printing bar codes since contrast between the light and dark areas is the highest and the edges are the sharpest Printhead Ribbon Carrier Layer Ribbon 4 Ink Layer Card Ink Transferred to Surface of Card Platen Roller Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 3 3 Card Path Elements The figure below shows the rollers that transport cards as they make their way through the Printer The rollers keep the card on a horizontal path reducing the chance of a card edge catching on anything Exit Rollers Main Drive Feeder Roller Card Flipper Rollers Rollers Platen Roller Cleaning Rollers The figure below shows the relative locations of the sensors that track card and r bbon position and movement Lid Sens
84. nter accessories from the shipping carton 4 Remove the styrofoam packing material from the top of the printer 5 Lift the printer out of the carton by holding it on both sides of the bottom and lifting the printer gently from the carton 6 Make sure the following accessories are included with your printer Software CD ROM Quick Start Guide Cleaning Kit 120 VAC and 230 VAC Power Cords Power Transformer USB Printer Cable 9 29 5 p If any items are missing please contact your dealer To reorder please refer to Appendix F Worldwide Support of this manual 14 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 2 3 Setting up the Printer Step 1 Place the printer in a location that allows easy access to all sides The printer should never be operated while resting on its side or upside down Step 2 Remove the yellow CAUTION label from the back of the printer Step 3 Ensure that the printer s power switch is in the OFF O position 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 15 2 4 Connecting Power A 16 Caution Limit electrical power supplied to the printer to 24 VDC Limit excess current draw to 16 amps or less using an associated circuit breaker or other such device Never operate the printer in a location where operator computer or printer can get wet Personal injury could result The printer must be connected to an earthed electrical power
85. nual 980584 001 Rev A Enclosures amp Covers Kit Description Model s 105940G 103 KIT HOPPER left photo P120i 105940G 228 KIT HOPPER right photo P110i P110m 105940G 110 KIT BUTTON DOOR P110i P110m P1201 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 179 Kit Description Models 105940G 101 KIT PANEL SIDE RIGHT P 1101 P110m P120i 105940G 102 KIT PANEL SIDE LEFT P110i P110m P120i 180 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Kit Description Models 105940G 106 KIT COVER TOP P120i blue P120i 105940G 229 KIT COVER TOP P110i gray P110i P110m 105940G 225 KIT BADGE P110i P110i 105940G 249 KIT BADGE P110m P110m 105940G 108 KIT BADGE P120i P120i 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 181 Feeder Kit Description Models 105940G 247 KIT FEEDER ASSY P110i P110m P120i 182 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Flipper Kit Description Model s 105940G TBD KIT FLIPPER P110i P110i P110m 105940G 018 KIT FLIPPER P120i P120i 105940G 226 KIT SPRING TORSION FLIPPER P110i P110m P120i 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 183 Kit Description Models PZL PR lt a gt en ee 105940G 078 KIT GEAR 120T FLIPPER P120i 105940G 071 KIT BOTTOM CARRIER CARD FLIPPR P110i
86. of a network cable To solve the problem e Verify that the network cable is appropriate and has an RJ 45 connector e Turn the printer power OFF O Remove the network cable from the Ethernet Adapter Plug the network cable back in until you hear a positive click Check the other end of the cable in the same manner Turn the printer power on if the Ethernet Adapter still does not detect a cable continue e Connect the Ethernet Adapter to a known good network If the Adapter is still unable to detect the network cable contact Technical Support for assistance Important Cables with a rating higher than CAT 6 have not been tested 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 71 PE Step 3 If the LED is slowly flashing GREEN 1 time sec the Ethernet Adapter is trying to print a job If the job does not print check the following Step 4 Step 5 Verify that the printer has media and ribbon If the printer is showing any errors it is unlikely that the Ethernet Adapter can send data to the printer The LED continues to blink until the printer malfunction is resolved or until the printer is turned OFF O A flashing RED indicates the Power On Self Test POST is in progress If the LED is solid RED for more than 30 seconds the Ethernet Adapter has failed the POST A failed POST can be caused by any of the following The printer attached to the Ethernet Adapter device is malfunctioning Turn t
87. or J7 Ribbon Flag Position Feed Cover on left side Sensor J6 Sensor J8 on Lid ATM Card Feed Sensor J12 Color Ribbon Sensor J5 on Printhead Mag Encoder Card Sync Flipper Position Sensor J11 Card Load Sensor J10 Sensor J23 Sensor J9 on Flipper on Flipper 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 57 3 4 Card Movement During Printing Step 1 The card is fed from the Card Input Hopper and loaded into the Card Flipper where it is rotated into the print position Card Flipper Printhead under Hopper Magnetic Stripe Lid Encoder optional Card Input Hopper Card Output Hopper Multi Function LCD Panel Cleaning Roller Card Platen Guide Roller Ribbon Cartridge Step 2 The card is moved into the Print Engine passing the Cleaning Roller this cleans dust or dirt particles from the upper card surface Step 3 If the Printer includes an optional Magnetic Stripe Encoder the card is moved to the Magnetic Stripe Encoder and the stripe is encoded After the card is encoded it is checked to verify that the magnetic stripe was properly encoded If encoding fails the card is ejected into the Card Output Hopper This is done to avoid wasting time and ribbon panels on a defective card If the encoding is successful the card is moved into the pre print position just before the Printhead 58 Zebra P110 P110m P120i Card Printers Service M
88. ould print a test card Step 1 Place the printer power switch in the OFF O position Step 2 While holding down the Multi Function Control Button place the printer power switch in the ON position The LCD status window will glow blue Multi Function Control Button Power Switch PLASTIC CARD PRINTER i PRINTER P120 Head resistance 1568 Step 3 Keep pressing the Multi Function Control Button until the SELF TEST message appears in the window Step 4 Release the Multi Function Control Button and a test card will print after a few seconds 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 47 2 11 Printer Operation Printing with the printer requires the Windows printer driver your card design issuing software or printer command level programming through the printer interface The printer can be used with any Windows 2000 or Windows XP software application program using the drivers provided on CD with the printer Creating a Sample Card Before you begin a new printing session print a sample card to ensure that the cards will be printed correctly Follow the steps below to print your first card using the True Colours Card Printer Ribbon Cartridge and the Windows printer driver Note To simplify creating a sample card you can use one of the sample files that were installed during the driver installation process These samples Word files can be found in Step 1 Ste
89. our printer Step 2 Peel protective wrapper from adhesive cleaning roller by gently pulling on the blue tape Discard the protective wrapper ZA Bei LEQ TO L e TEN ka ie TET 40 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Step 3 Insert the ribbon cartridge with the cleaning roller facing down so the gears on the ends of the rollers fit into the appropriate slots Adhesive Cleaning Roller Step 4 Close the printer lid and push down until you hear an audible click After the lid is closed the ribbon automatically synchronizes when the printer power is on 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 41 2 9 Loading Cards To help you load print and collect cards the printer has a Card Feeder and a Card Output Hopper Card Feeder The card feeder is used for loading cards it can hold up to 100 cards of 30 mils thickness The card feeder is located under the card feeder cover of the printer A Caution DO NOT bend cards or touch print surfaces as this can reduce print quality Note The surface of the cards must remain clean and dust free Always store cards in an enclosed container Ideally use cards as soon as possible If cards stick together carefully fan or shuffle them Note For Cards with magnetic stripe refer to Section for loading instructions Load cards into card feeder as follows
90. output hopper capacity 45 cards 30 mil Ribbon Cartridges 980584 001 Rev A The use of Zebra True Colours ribbons will give the best print quality Load N Go ribbon cartridge with integrated card cleaning roller i Series technology featuring contact chip based ribbon detection P1107 amp P1207 YMCKO 200 cards cartridge P1107 amp P1201 YMCKOK 165 cards cartridge P1207 only Monochrome 1000 cards cartridge in black or blue 850 cards cartridge white Zebra P110 P110m P120i Card Printers Service Manual Ribbon Storage Information e True Colours Ribbons will have a longer shelf life and give better quality printing if the following guidelines are followed e Avoid direct sunlight high temperature high humidity Do not place near solvents or other chemicals Do not touch printing surface of ribbon e Storage Temperature Range 41 to 86 F 5 to 30 C e Optimum Storage Temperature 70 F 21 C Interfaces e USB 1 1 cable included e USB 1 1 and built in Ethernet optional Dimensions e Width 7 9 in 201mm e Depth 12 9 in 328mm e Height 8 5 in 216mm e Weight 9 5 lbs 4 3kg Electrical e 110 240 Volts AC 50 60 Hz auto switching e 8 MB image memory standard e FCC Class A CE UL and CUL approved Environmental e Operating Temperature 60 F to 86 F 15 C to 30 C e Operating Humidity 20 to 65 non condensing e Storage Temperature 23 F to 158 F 5 C to 70 C see Rib
91. p 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 48 Start gt All Programs gt Zebra Card Printers Go to the Microsoft Word software Go to File gt Print Choose the Zebra Card Printer from the printer names list Press Close to exit the Print dialogue box Go to File gt Page Setup Select the Paper tab and under Paper Size choose Card Select the Margins tab and set all the margins to 0 zero Under Orientation select Landscape or Portrait Press OK to exit the Page Setup window The card appears on the window Design a card with both black and colored text and with colored pictures s milar to the sample card shown below The P110m Printer uses monochrome ribbons only BARA SAMPLE CARD M CHRIS JONES SALES DIRECTOR 3 http www zebracard com Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Printing a Sample Card Once you completed creating your sample card you are ready to print Ensure your printer has a True Colours Card Printer Ribbon Cartridge installed and there is card stock in the card feeder Print your sample card as follows Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 980584 001 Rev A Select File gt Print to open the Print dialogue box Ensure the following settings in the Print dialogue box e Printer Name Zebra lt model gt Card Printer e Print to File Unchecked e Page Range All e Number
92. ps screwdriver carefully push the Exit Roller shaft out of its right side mounting hole Step9 Turn the Print Engine over reach in and remove the Exit Roller a JE F a da A gt lt a 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 125 Replacement Step 1 Check the Belt Tensioning Tool presets Scale 1 075 and Scale 2 050 Adjust the presets as required Scale 1 Scale 2 Step2 With a TORX T10 driver loosen the three screws indicated in the figure below 126 Zebra P110 P110m P120 Card Printers Service Manual 980584 001 Rev A Step 3 Install the belts and associated gears and pulleys The following two figures show the belt path for the two belts removed in this section a Install Belt 1 Belt 1 b Install the Platen Roller Pulley c Install Belt 2 Platen Roller Pulley Belt 2 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 127 Step 4 Set the Belt Tensioning Tool in place Note that the arrows indicate the alignment guide posts Step 5 With a TORX T10 driver tighten the two motor mount screws Step 6 Rotate the Belt Tensioning Tool 180 degrees 128 Zebra P110 P110m P120 Card Printers Service Manual 980584 001 Rev A Step 7 Set the Belt Tensioning Tool in place Note that the arrows indicate the alignment guide posts Step 8 With a TORX T10 driver tighten the single screw
93. re listed in Appendix E Electric Shock Caution Before performing any of the procedures in this section set the printer power to OFF O and disconnect the power cord Electrostatic Discharge Caution All replacement procedures must be performed at a static free work station an anti static wrist strap must be worn and properly terminated or other appropriate protection must be used Caution Before beginning any of the procedures that follow read completely through the procedure If you do not have the specified tools or if any step s seem beyond your skill or experience level do not attempt the procedure You may cause additional damage to the printer gt BB Note Some of the photographs in this section may show additional parts removed in addition to removals for the process being described 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 75 Important If you are going to replace the Main PCBA Print a Test Card refer to Section 2 10 You will need the Head Resistance the X and Y Offsets and the End of Text value to update the firmware on the replacement Main PCBA If for any reason you are unable to print the Test Card contact Zebra Technical Support to obtain the above values 5 2 Required Tools This section lists the tools required for the replacement procedures described in this section Naturally not all tools are required for a particular procedure specific tools are calle
94. rton Kit Description Model 105940G 001 KIT PACKAGING P 1201 P110i P110m P120i 200 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Appendix F Worldwide Support For Technical Support or Repair Services contact the appropriate facility listed below North America Technical Support Zebra Technologies Card Printer Solutions 1001 Flynn Road Camarillo CA 93012 8706 USA Phone 1 800 511 9909 email techsupport zebra com North America Repair Services Before returning any equipment to Zebra Technologies Corporation for in warranty or out of warranty repair contact Repair Services for a Return Materials Authorization RMA number Repack the equipment in the original packing material and mark the RMA number clearly on the outside Ship the equipment freight prepaid to the address listed below Zebra Technologies Card Printer Solutions 1001 Flynn Road Camarillo CA 93012 8706 USA Phone 800 452 4034 or 1 805 578 1201 email repair ca zebra com 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 201 Europe Middle East and Africa Technical Support Zebra Technologies Card Printer Solutions The Valley Centre Gordon Road High Wycombe Buckinghamshire HP13 6EQ United Kingdom Phone 44 0 870 241 1527 e mail cardts zebra com Europe Middle East and Africa Repair Services Before returning any equipment to Zebra Technologies Corpora
95. s may be scratched or burnt Solution Call Service for printhead repair or replacement information Zebra P110 P110m P120i Card Printers Service Manual 69 Example Irregular white lines in the print like the ribbon is wrinkling Ribbon Wrinkle e Possible Cause Ribbon cartridge may not be correctly positioned Solution Check to make sure that the ribbon is loaded correctly e Possible Cause Cards may not meet specifications Solution Use a different supply of cards e Possible Cause Dirty printhead and or print path Solution Clean the printhead Clean the print path e Possible Cause Worn or uneven platen roller surface Solution Replace the platen roller 70 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 4 3 Troubleshooting the Ethernet Connection and Adapter 4 3 1 Ethernet Adapter Status Indicator A bi color Status Indicator displays the operational status of the Ethernet Adapter Ethernet Adapter Status Indicator The following conditions might occur Step 1 During normal operation the LED is solid GREEN for more than 30 seconds This indicates all the hardware is functioning properly and the Ethernet Adapter has detected the presence of the network It does not mean the Ethernet Adapter has an IP address or is attached to a printer queue Step 2 If the LED is rapidly flashing GREEN 9 times sec the Ethernet Adapter has not detected the presence
96. sh Back Overlay Varnish Hologram Varnish Head Settings Printing Mode Print Copies 1 Paper Output Specifies layout of card e Orientation Landscape or Portrait printing layout e Rotation Rotate the image 180 if Front s selected Color Adjustment To adjust color output Intensity and Contrast Allows you to adjust the image colors these adjustments apply to the entire card not just photographic images e Intensity decrease or increase the image intensity by moving the RGB Red Green Blue slider bars left or right This will change the overall lightness or darkness of the image Move the slider to the right to increase and to the left to decrease e Contrast decrease or increase the image contrast by moving the RGB Red Green Blue slider bars left or right This magnifies or minimizes the difference between the light and dark parts of the image Move the sliders to the right to increase and to the left to decrease Important Printed colors can appear different from displayed colors the above controls allow you to optimize the printed results Use the Restore Defaults Button to reset the settings to the driver defaults Ribbon Displays type of ribbon installed in printer Printer Ribbon Details Displays ribbon type and remaining panel count 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 27 Print on both sides Selection for single sided or dual side
97. supply and properly protected against electrical surges and grounding faults The power supply pack can only be replaced by the same product from the manufacturer Caution Intermittent or unpredictable operation may occur from unsecured connectors If damaged the power cable must be replaced by an exact equivalent The socket should always be easily accessible to power off the printer Step 1 Insert the power supply plug into the power socket attach the power cord 120VAC or 230VAC to the power supply then plug the power cord in to a grounded electrical socket of the proper voltage and type Step 2 Ensure that the printer s power switch is in the OFF O position Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 2 5 Connecting the Printer to your Computer Step 1 If your printer has only the USB interface attach the included USB cable to your computer and the printer ER ee BR G Gajo in oa SER OO00 Step 2 If your printer has the optional Ethernet interface as well as the USB interface connect either the USB cable to printer and computer or the Ethernet cable to the printer and the Ethernet network Important Do not connect both the USB and the Ethernet interfaces at the same time Ethernet
98. t side piece of the Front Cover to the frame Step 4 Remove the Front Cover three pieces 106 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 5 22 Motor and Roller Locations Cleaning Roller Platen Roller Main Drive Rollers Exit Pressure Roller 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 107 Main Drive Roller Platen Roller Ribbon Take Up Gear Exit Roller Ribbon Take up Motor Linkage Gears Pressure Roller Lift Motor Flipper Feed Gear Main Drive Roller Exit Roller Platen Roller Stepper Motor Tension Idler 108 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 5 23 Card Feeder and Lid Step 1 Locate the Card Feeder Card Feeder Step 2 Remove the E clips from each end of the shaft on both sides of the printer E Clip both sides 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 109 Step 3 Push the shaft through the mounting holes thereby freeing the Lid and Card Feeder Note that the cable and ground wires are attached Step 4 Set the Lid to the side 110 Zebra P110 P110m P120 Card Printers Service Manual 980584 001 Rev A Step 5 Unwrap the spiral cable tie Spiral Cable Tie Step 6 Free the ground wire by cutting the cable tie and then pull the ground wire through the access hole Access Hole Cable Tie Step 7 If not
99. through the installation and setup of your printer This consists of the following procedures which should be performed in the order presented 22 Uapackine ihe Eines veva aka did 14 23 SCHE Up ine Pillen id kn bo b Ena kd 15 24 COnneECHNS POW T sa s kaa oo dada o p sk k s sas nb nako 16 2 5 Connecting the Printer to your Computer 17 20 In talline the Printer Diver paz d ose k n ee 18 2 7 Changing the Printer Driver Options 2 8 Loading Ribbon CaritidS su Hu aan nen are 40 20 8 07 18 111122 Cade yo k ithe ee eee eed ee Ge kitov n ME HA 42 210 Paine a NCS i Cats aon eo hed pd wae bo ee gee hee kes 47 211 Pier OperdtOlic zan aa ko a sk do no ok d n da nb nako 48 The procedure to be followed for Packing the Printer for Shipment is given at the end of this section 980584 001 Rev A Zebra P110 P110m P120i Card Printers Service Manual 13 2 2 Unpacking the Printer Your printer ships in a cardboard carton protected by styrofoam inserts and a protective anti static bag Keep all packaging material in case you need to move or re ship the printer 1 Before opening and unpacking the printer inspect the carton to ensure that no damage occurred during shipment 2 Ensure that you have a clean and nearly dust free environment for proper operation and storage of the printer 3 Unlatch and remove the handle open the carton and remove the box containing the pri
100. tion for in warranty or out of watranty repair contact Repair Services for a Return Materials Authorization RMA number Repack the equipment in the original packing material and mark the RMA number clearly on the outside Ship the equipment freight prepaid to the address listed below Zebra Technologies Corporation Zebra Card Printer Solutions Pittman Way Fulwood Preston PR2 9ZD Lancashire U K Phone 44 0 1772 693 069 FAX 44 0 1772 693 046 email repairupdate zebra com Latin America Technical Support Zebra Technologies Card Printer Solutions Latin America 9800 NW 41st Street Suite 220 Doral FL 33178 USA Phone 1 305 558 3100 extension 2821 e mail techsupport zebra com Latin America Repair Services Please contact North America Repair Services 202 Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A Asia Pacific Technical Support and Repair Services Before returning any equipment to Zebra Technologies Corporation for in warranty or out of warranty repair contact Repair Services for a Return Materials Authorization RMA number Repack the equipment in the original packing material and mark the RMA number clearly on the outside Ship the equipment freight prepaid to the address listed below Zebra Technologies Asia Pacific LLC 16 New Industrial Road 05 03 Hudson TechnoCentre Singapore 536204 Phone 65 6885 0833 e mail esoh zebra com Website www zebra
101. tput Hopper Zebra P110 P110m P120 Card Printers Service Manual 173 MR amp N INL O O vO OY PS P vP R IR amp R IRIBBON IRIBLEN IRIBPN RO ROY ISA ISAN ISAP SERIE amp SVM amp T I vT V VK 115 IV V V IW amp W IZ ZNZ Zebra P110 P110m P120i Card Printers Service Manual Check for Card Presence Select Magnetic Encoding Standard Get Printer Impression and Error Counters Print Offset X Axis Load Single Line Bit map Monochrome Print Offset Y axis Move Card Forward 8 cm Download Color Image Buffer Draw Single Dot Monochrome Overlay Reset Print Head Resistance Reset Magnetic Encoder Get r bbon type installed Get number of remaining panels on ribbon Get ribbon part number X Axis Offset Relative Y Axis Offet Relative Self Adjust Perform pre calibration baseline testing Self Adjust Get Printer Serial Number Disable Enable Magnetic Encoding Verifications Magnetic Encoder Card Eject Draw Text Monochrome Overlay Check Printer Type Version Sensor Status Return Operational Parameters Return Color Operational Parameters Black Print Speed Move Card Backward 8 cm Change Encoding Direction Re Synchronize Card Load Bit map Monochrome Clear Error Status Lines 980584 001 Rev A APPENDIX E Spares List Introduction The following tables list the Spare Parts Kits available for the P1107 P110m and P1207 Card Printers Before ordering be sure to check
102. versed and Normal Reversed is not supported by this printer Encoder Type Select the type of encoder JIS2 and AAMVA are not supported by this printer Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A ADVANCED SETTINGS DIALOGUE BOX Advanced settings Track Track 2 O Track 3 Track Settings Start Stop Character Encoding start position a Character parity LAC parity Restore Defaults Apply Track Select the track you want to configure Track Settings Select the mode and density for the tracks Start Stop Character For Non ISO encoding only Enter an ASCII value for the Start and Stop characters Encoding Start Position For Non ISO encoding only Enter the encoding start position in millimeters mm Character Parity For Non ISO encoding only Choose the Character Parity you want to work with even odd or no parity LRC Parity For Non ISO encoding only Choose the LRC Parity you want to work with even odd or no parity Click the Restore Defaults button to reset the settings to the original values 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 35 Tools Dialog box for testing and communicating with the printer Command to send to printer Printer Status Print Test Card u Cleaning zum Standard v Print Printer only v Offset setting Front x Front r Set Offsets Back X Back Y Direct encodin
103. ws holding the sensor cover to the frame Screws Step 3 Remove the cover 980584 001 Rev A Zebra P110 P110m P120 Card Printers Service Manual 103 104 Step 4 With a TORX T8 driver remove the screw holding the sensor in place Ribbon Flag Position Sensor Mounting Screw Step 5 If not already done disconnect the Ribbon Flag Position Sensor plug from connector J6 on the Main PCBA Step 6 Remove the Ribbon Flag Position Sensor Zebra P110 P110m P120i Card Printers Service Manual 980584 001 Rev A 5 20 Encoder Wheel 980584 001 Rev A Step 1 Locate the Encoder Wheel Step 2 Step 3 Encoder Wheel n S ip ade SS iho 1 m Se Compress the clutch spring by pressing the washer inward then use fine point pliers a small flat blade screwdriver or a pair of fine point retaining ring pliers to remove the retainer clip then slip the washer and the clutch spring off the clutch shaft Slip the gear wheel felt washer Encoder Wheel and second felt washer off the clutch shaft 0 e Zebra P110 P110m P120i Card Printers Service Manual 105 5 21 Front Cover Step 1 Locate the Front Cover Mounting Screws Front Cover te a three pieces 3 Step 2 With a TORX T10 driver remove the two screws holding the right side piece of the Front Cover to the frame Step 3 With a TORX T10 driver remove the two screws holding the lef

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