Zebra® P110i™/ P110m / P120i™ Card Printers Service Manual 980584-001 Rev.
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.
Contents 1 • General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1.2 Features, Controls, and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 1.4 Card Dimensions . . . . . . . . . . . . . . . . . . . . . . . .
2.9 Loading Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 2.10 Printing a Test Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 2.11 Printer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 2.12 Packing the Printer for Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 3 • Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .
.17 Lid Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 5.18 Right Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 5.19 Ribbon Flag Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 5.20 Encoder Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 5.21 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 General Description 1.1 Description This manual contains service information for Zebra P110i, P110m, and P120i Plastic Card Printers, manufactured by Zebra Technologies Corporation, Camarillo, California. The only difference between these models is as follows: • The P110i supports single-sided, full-color or monochrome printing. • The P110m supports single-sided, monochrome printing only. • The P120i supports single- or dual-sided, full-color or monochrome printing.
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 Cover Lid Release 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.
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 is 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.
Ethernet Connection The figure below shows the rear of the printer with the Ethernet Option. Power Socket USB Port Power Switch Network Status / Activity Indicator Ethernet Adapter Status Indicator Ethernet Reset Button Ethernet Connector 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.
LCD Panel Messages LCD Panel messages fall into three categories: • Operational Operational Messages are displayed during the Printer’s normal operation. • Warnings Warnings alert the operator to action that should be taken; the printer will generally continue operation. • Errors Errors are displayed when a situation causes the printer to stop operating.
MESSAGE 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 6 Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
1.3 Specifications General • Load-N-GoTM drop-in ribbon cartridge • 16-digit LCD display • Driver for Windows 2000, Windows XP, Windows Server 2003, and Windows Vista Color / Monochrome Printing (P110i & P120i) • 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.
Ribbon Storage Information • True Colours® Ribbons will have a longer shelf life and give better quality printing if the following guidelines are followed. • Avoid direct sunlight, high temperature, high humidity. Do not place near solvents or other chemicals. Do not touch printing surface of ribbon. • Storage Temperature Range: 41° to 86° F (+5° to 30° C) • Optimum Storage Temperature: 70° F / +21° C Interfaces • USB 1.1 (cable included) • USB 1.
1.4 Card Dimensions ISO standard dimensions for plain card 2.125 ± 0.002in (53.98 ± 0.050mm) 980504-07-01 Radius 0.125in (3.18mm) 3.375 ± 0.010in (85.72 ± 0.25mm) 0.009 ~ 0.034in (0.23 ~ 0.84mm) ISO standard dimensions for magnetic stripe card 0.623in (15.82mm) min 980504-07-02 0.218in (5.54mm) max MAGNETIC STRIPE 0~0.115in (2.92mm) 980584-001 Rev. A Zebra P110i / P110m / P120i Card Printers Service Manual 0~0.115 in (2.
Declarations of Conformity Declarations of Conformity 89/336/EEC EMC Directive EN 55022 (1998) EMC Directive EN 301489-3 V1.4.1 EMC Directive EN55024 (2001) 73/23/EEC modified by 93/68/EEC Low voltage Directive EN 60950-1 (2001) 1999/5/CE R&TTE Directive EN300330-2 V1.1.
Icons 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.
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2 Installation and Setup 2.1 General Information This section will guide you through the installation and setup of your printer. This consists of the following procedures, which should be performed in the order presented. 2.2 Unpacking the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 2.3 Setting up the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 2.4 Connecting Power . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Unpacking the Printer Your printer ships in a cardboard carton, protected by styrofoam inserts and a protective antistatic 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.
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. 980584-001 Rev. A Ensure that the printer’s power switch is in the OFF (O) position.
2.4 Connecting Power 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 supply and properly protected against electrical surges and grounding faults.
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. 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 980584-001 Rev.
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.
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. Step 2. From the Select Language window, choose the appropriate language for your system. The Main Menu will open in the selected language. Step 3. From the Main Menu, under Install Printer Driver, select the appropriate printer model (P110i / P110m or P120i). 980584-001 Rev.
Step 4. The InstallShield Wizard will launch, and a progress window will be displayed. Step 5. Once the InstallShield Wizard has been installed, the Welcome to InstallShield Wizard window will open. 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 P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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 . Step 3. Most users should select the Complete setup type; then click the Next button. Step 4. Select the appropriate Program Folder, then click the Next button. 980584-001 Rev.
22 Step 5. The Install Wizard will show the progress of the installation. Step 6. Read the appropriate information. Step 7. Driver installation is now complete. Click the Finish button. 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. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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. Step 3. Most users should select the Complete setup type; then click the Next button. Step 4. Specify the IP address, then click the Next button. 980584-001 Rev.
24 Step 5. Select the appropriate Program Folder, then click the Next button. Step 6. The Install Wizard will show the progress of the installation. Step 7. Driver installation is now complete. Click the Finish button. 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. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
2.7 Changing the Printer Driver Options 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.” 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.
2.7.1 General Tab The General tab Shows the printer model and lists the features of the printer. Click on the Printing Preferences button to change the card settings; see Printing Preferences on page 27. 26 Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
Printing Preferences Paper / Output - Specifies layout of card. • Orientation - Landscape or Portrait printing layout. • Rotation - Rotate the image 180° if Front is 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. • Intensity - decrease or increase the image intensity by moving the RGB (Red, Green, Blue) slider bars left or right.
Print on both sides - Selection for single-sided or dual-sided printing. Front and Back - Feature selection for dual sided printing. Choices based on ribbon type: YMCKOK • YMCKO on Front, K on Back • YMCKO on Front, YMCKO on Back YMCKO • YMCKO on Front, YMCKO on Back • 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.
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.
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 ribbon. • Contrast - adjusts the black and overlay contrast from 0 to 10.
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. 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. 980584-001 Rev.
2.7.4 Color Management Tab Use the Color Management tab to add, remove, or change printer color profiles. 2.7.5 Security Tab Use the Security tab to change permissions for the printer. 32 Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
2.7.6 Advanced Tab On the Advanced tab, you can choose various printer properties, install different printer drivers, and change default printer settings. 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. 980584-001 Rev.
Printer Model/Firmware Version Gives the printer model and firmware version. Encoder Settings Dialog box for setting Magnetic Encoder parameters. This feature is not enabled if the printer does not have the magnetic encoder option. 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.
ADVANCED SETTINGS DIALOGUE BOX 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.
Tools Dialog box for testing and communicating with the printer. 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.
F/W Download Dialog box for downloading 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. 980584-001 Rev. A • Select the appropriate .bin file from the host computer that is specified for the printer. • Select Start Firmware Download to execute the download process.
Device Information Printer configuration status window. 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 is present. Smart Card - Identifies if a smart card encoder is present and type of encoder. Ribbon Type - Identifies the ribbon installed in the printer.
Single Feed Dialog box for disabling or enabling single-feed support. About 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.
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. • The P110i and P120i Printers require the use of i Series ribbons for full color printing. • 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.
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. 980584-001 Rev. A 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.
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. 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.
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.
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 Card Feeder 44 Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
Cards with Magnetic Stripe Caution • ONLY USE cards that comply with ISO 7810 & 7811 standards for magnetic stripe cards. The magnetic stripe must be flush to the surface of the card to work properly. 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.
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 46 Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
2.10 Printing a Test Card With ribbon cartridge and cards loaded, your printer is ready to print. To check the operation of the printer, you should 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 P120i Serial Nr: 060376 Firmware: V1.
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.
Printing a Sample Card Once you completed creating your sample card, you are ready to print. Ensure your printer has a True ColoursTM Card Printer Ribbon Cartridge installed and there is card stock in the card feeder. Print your sample card as follows: Step 1. Select File > Print to open the Print dialogue box. Step 2.
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 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.
3 Theory of Operation 3.1 Introduction This section includes five major topics: Card Printing Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Card Path Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Card Movement During Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
Printing Technologies and Ribbons There are two types of printing technology used in the P110i 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.
A YMCKOK ribbon has successive panels as follows: Dye Sublimation Printing Process Yellow (“Y”) Dye Magenta (“M”) Dye Cyan (“C”) Dye Thermal Transfer Printing Process Black (“K”) Resin Overlay (“O”) Varnish Black (“K”) Resin (YMCKOK Pattern Repeats) 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.
The following figure shows how the ribbon and card move relative to each other during the printing process. (This obviously does not apply to the P110m Printer.) Printhead at Fixed Position 1. 2. 3. 4. Ribbon Moves Yellow Panel into Position at Printhead Card is Fed to Printing Position Under the Printhead Card and Ribbon Move Together as Yellow Panel is Printed Card and Ribbon Stop at End of Yellow Panel 5. Ribbon is Stationary; Card is Moved Back to Printing Position 6.
Dye Sublimation Printing (P110i and P120i 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 intense color at that pixel). This is repeated for each of the dye panels (i.e., Yellow, Magenta, and Cyan), to result in full-color images.
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 Rollers Platen Roller Feeder Roller Card Flipper Rollers Cleaning Rollers The figure below shows the relative locations of the sensors that track card and ribbon position and movement.
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. Magnetic Stripe Encoder (optional) Card Flipper (under Hopper) Printhead Card Input Hopper Card Output Hopper Lid Multi-Function LCD Panel Cleaning Roller Platen Roller Card Guide 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 4. The card is printed. Dye-Sublimation Printing (P110i and P120i 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.
3.5 Block Diagram 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. 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.
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 basic understanding of how the CPU PCBA connects to the rest of the Printer helps to better understand the Printer.
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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 general, for a given failure symptom one or more possible causes are listed, with suggested corrective action to take.
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 Cause / Solution The LCD Panel displays OUT OF CARDS message. 1. Check for cards in the card feeder. If no cards are present, load cards. 2. Press the Control Button for one second. The printing job will restart. The LCD Panel displays OUT OF RIBBON message. 1.
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.
Example • There are non-printing horizontal lines (white) on the card surfaces. • Possible Cause: Ribbon cartridge is 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. • Possible Cause: Printhead is dirty. Solution: Clean the printhead. • Possible Cause: Printhead elements are damaged (e.g., scratched or burnt). Solutions: Replace the printhead.
Example • Printing shows very pale or inconsistent results. • Possible Cause: Ribbon cartridge has been stored improperly or is damaged. Solution: Change the ribbon cartridge and print again. • Possible Cause: Cards may not meet specifications. Solution: Use a different supply of cards. • Possible Cause: Contrast and/or intensity may be set to values which are too high. Solution: Adjust contrast and/or intensity values in software.
Example • Printing shows blurry printed image. • 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. • Possible Cause: Ribbon may not be synchronized on the correct color panel position. Solution: Open lid, then close lid to synchronize ribbon. • Possible Cause: Cards may not meet specifications.
Example • No printing on the card. • Possible Cause: Ribbon cartridge may not be installed in the printer. Solution: Check for ribbon 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 elements may be scratched or burnt. Solution: Call Service for printhead repair or replacement information. 980584-001 Rev.
Example • Irregular white lines in the print, like the ribbon is wrinkling -- Ribbon Wrinkle. • Possible Cause: Ribbon cartridge may not be correctly positioned. Solution: Check to make sure that the ribbon is loaded correctly. • Possible Cause: Cards may not meet specifications. Solution: Use a different supply of cards. • Possible Cause: Dirty printhead and/or print path. Solution: Clean the printhead. Clean the print path. • Possible Cause: Worn or uneven platen roller surface.
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.
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: • 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. Step 4.
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.
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 ( | ). 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.
5 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.
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.
5.3 Removal Sequence This figure shows the recommended removal sequence. For each item, follow the 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. Start Here Complete P110i / P110m / P120i 5.5 Printhead Assembly 5.7 Top Cover 5.9 Bottom Cover 5.10 Rear Cover page 79 page 85 page 88 page 89 5.6 Cleaning Roller 5.8 LCD Display page 84 5.
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 P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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.
80 Step 4. Push the Printhead Assembly in and upward. Step 5. Lift the Printhead Assembly out of the frame. Step 6. Disconnect the green ground wire. Step 7. With a small flat-blade screwdriver, loosen and remove the printhead data and power cable. Step 8. 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. Step 9. Remove the Printhead Assembly.
Printhead Replacement Printhead Installation Step 1. Record the resistance of the new Printhead Assembly. Printhead Resistance Step 2. 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.
Firmware Update Step 1. Go to start > Printers and Faxes. 82 Step 2. From the Printers and Faxes list, right click the Card Printer; and select Properties from the pop-up menu. Step 3. The Printer Properties window will open. Click on the Device Settings tab. Step 4. Click on Tools > Properties. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
Step 5. This brings up the Tools display. Type the command here ... ... then click the Execute button. Note • The Print Head Resistance command is !R. See Appendix D for the complete list 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). Step 7. Click the Execute button. Step 8. The firmware update is complete. 980584-001 Rev.
5.6 Cleaning Roller Step 1. Locate the Cleaning Roller. Cleaning Roller Step 2. 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 P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
5.7 Top Cover Step 1. Press the access button in, and raise the Lid. Access Button Step 2. 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.
86 Step 4. 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. Step 5. Remove the Top Cover. Step 6. Set the Top Cover aside. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
5.8 LCD Display PCBA Step 1. 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 Step 3. With a TORX T10 driver, remove the two screws that hold the LCD Display PCBA to the frame. Step 4. Remove the LCD Display PCBA. 980584-001 Rev.
5.9 88 Bottom Cover Step 1. Turn the printer over, bottom side up. Step 2. With a flat-blade screwdriver, carefully 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. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
5.10 Rear Cover Step 1. With a TORX T10 driver, loosen the two screws from the top of the Rear Cover. Screws Step 2. With a TORX T10 driver, remove the two screws from the bottom of the Rear Cover. Screws Step 3. 980584-001 Rev. A Remove the Rear Cover.
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. 90 Step 1.
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.
Step 6. Set the Main PCBA aside. Side 1 Side 2 92 Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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 Offsets, and the End of Text value to update the firmware on the replacement Main PCBA. If for any reason you were unable to print the Test Card, contact Zebra Technical Support to obtain the above values. Step 1. Go to start > Printers and Faxes. Step 2.
Step 6. From the information on the Test Card, update the printer’s firmware. P120i Serial N°: P120i-060376 Firmware: V1.10.16 USB Head resistance: 1568 Offset X:07/05 Y:32/04 EC: 10 Print counter: 00002716 a. In the “Command 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.
5.12 Left Side Cover Step 1. Locate the two screws that hold the Left Side Cover in place. Screws Step 2. With a TORX T10 driver, loosen the two screws. Step 3. Remove the Left Side Cover. 980584-001 Rev.
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 96 Step 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. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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.
5.15 Linkage (Right Side and Left Side) Step 1. Locate the Linkage (right side). Linkage (3 pieces) Spring 98 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). Step 5. Repeat Step 1 through Step 4 for the left side. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
5.16 Ribbon ID PCBA (P110i and P120i 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 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 standoffs. 980584-001 Rev.
100 Step 5. Remove the cover. Step 6. Slide the two springs off their respective standoffs. Step 7. 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. Step 9. Remove the Ribbon ID PCBA. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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.
5.18 Right Side Cover Step 1. Locate the two screws that hold the Right Side Cover in place. Screws 102 Step 2. With a TORX T10 driver, loosen the two screws. Step 3. Remove the Right Side Cover. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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 screws holding the sensor cover to the frame. Screws Step 3. 980584-001 Rev. A Remove the cover.
Step 4. With a TORX T8 driver, remove the screw holding the sensor in place. Ribbon Flag Position Sensor Mounting Screw 104 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 P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
5.20 Encoder Wheel Step 1. Locate the Encoder Wheel. Encoder Wheel Step 2. 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. Step 3. Slip the gear wheel, felt washer, Encoder Wheel, and second felt washer off the clutch shaft. 980584-001 Rev.
5.21 Front Cover Step 1. Locate the Front Cover. Mounting Screws Front Cover (three pieces) 106 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 left-side piece of the Front Cover to the frame. Step 4. Remove the Front Cover (three pieces). Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
5.22 Motor and Roller Locations Cleaning Roller Platen Roller Main Drive Rollers Exit Pressure Roller 980584-001 Rev.
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 P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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.
110 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. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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 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.
Step 9. 112 Remove the Card Feeder. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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. Clip Pulley Belt Mounting Screw 980584-001 Rev.
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 114 Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
Step 6. Cut the 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.
5.25 Card Sync Sensor Step 1. Locate the Card Sync Sensor. Card Sync Sensor 116 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. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
5.26 Pressure Roller Step 1. Locate the Pressure Roller. Pressure Roller Step 2. Turn the Print Engine over. Pressure Roller 980584-001 Rev.
118 Step 3. Carefully apply pressure to the roller to “pop” it loose. Step 4. Remove the Pressure Roller. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
5.27 Exit Roller Step 1. Remove the belts. a. Locate the two belts. Retainer Clip Belt 1 Belt 2 b. Remove the retainer clip 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.
Step 2. Remove the rocker assembly. a. Locate the two springs. Note that the orange arrows point out the two springs. b. Release (and remove) the two springs. 120 Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
c. With a TORX T10 driver, remove the screw (and washer) holding the rocker assembly to the frame. 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.
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. 122 Note that a tensioner pulley is accessible with the Platen Roller pulley removed. Remove the retainer clip, then remove the tensioner pulley. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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.
Clip 2 Step 7. 124 Remove the retaining plate. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
Step 8. With a Phillips screwdriver, carefully push the Exit Roller shaft out of its right-side mounting hole. Step 9. Turn the Print Engine over, reach in, and remove the Exit Roller. 980584-001 Rev.
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 Step 2. 126 With a TORX T10 driver, loosen the three screws indicated in the figure below. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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.
128 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. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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. 980584-001 Rev.
5.28 ATM Card Feed Sensor Step 1. Locate the ATM Card Feed Sensor. ATM Card Feed Sensor 130 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. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
5.29 ATM Pressure Roller & 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. 980584-001 Rev. A Turn the Print Engine over (for access from bottom).
Step 4. With a TORX T10 driver, remove the two screws; and disconnect the ground wires. Two Ground Wires One Ground Wire Step 5. 132 Turn the Print Engine over (for access from top). Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
Step 6. With a flat-blade screwdriver, free the locking pins that hold the ATM Pressure 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.
Locking Pin Step 9. 134 Remove the Card Drive Roller assembly. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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). Gear (#3) 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.
Step 6. Using a TORX T10 driver, remove the screw holding the gear (#3) in place. Step 7. Remove the associated gear. Step 8. 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.
Replacement Slide the gears on their respective shafts in the order indicated below, then lock them in place (screws for #1 & #2 and clips for #3 & #4) in the same order. #1 #3 #2 #4 Important • When re-installing the gears #1 & #2, ensure that the grooves (outlined in orange) are aligned as indicated. 980584-001 Rev.
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). Belt Lower Pulley (#1) Motor Gear (#2) b. Slide the pulley off the shaft. c. Remove the belt. 138 Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
Step 3. With a TORX T8 driver, remove the screw holding the motor gear (#2) in place. Step 4. 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. Step 6. 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.
5.32 Platen Roller With the Ribbon Take-Up Motor removed, you can remove the Platen Roller. 140 Step 1. With a Phillips screwdriver, carefully push the Platen Roller shaft out of its rightside mounting hole. Step 2. Turn the Print Engine over, reach in, and remove the Platen Roller. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
5.33 Mag Encoder Assembly (Head and Sensor) 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. Step 4. Remove the Mag Encoder Assembly. Mounting Screw Step 5. 980584-001 Rev.
Step 6. Remove the Head & 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. Spring Spring Replacement Important • The orientation of the Head is critical. When installing the Head, ensure that the heavy line is facing toward the Sensor.
5.34 Stepper Motor 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. 980584-001 Rev. A With a TORX T10 driver, remove the two screws (and washers) holding the motor bracket to the frame; then remove the bracket.
144 Step 4. With a 5.5 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. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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 Step 2. 980584-001 Rev. A With a TORX T10 driver, loosen the three screws indicated in the figure below.
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 P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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. 980584-001 Rev.
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 P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
5.35 Main Drive Roller Step 1. Locate the Main Drive Roller. Main Drive Roller Step 2. 980584-001 Rev. A With a TORX T10 driver, remove the two screws holding the Main Drive Roller support collar to the frame.
150 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. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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.
152 Step 7. Lift the assembly up and out of the Print Engine. Step 8. Slide the bearing and the support collar off the roller. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
6 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, allow only Zebra authorized technicians to service the Printer. N 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.
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. Step 2. When the cleaning cycle is initiated, the LCD message REMOVE RIBBON THEN CLOSE LID will display. Multi-Function LCD Panel Feeder Cleaning Card Card Feeder Cover Multi-Function Control Button Path Cleaning Card Step 3. After the ribbon is removed and the lid is closed, the message EMPTY FEEDER THEN CLOSE COVER will display. Step 4.
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.
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 P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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.
Model numbers include identifiers that specify options using lettering conventions as follows: PART NUMBER DESCRIPTION P 1 1 0 i - _ _ _ _ _ - _ _ _ P 1 1 0 m - _ _ _ _ _ - _ _ _ P 1 2 0 i - _ _ _ _ _ - _ _ _ Base Printer P110i Single-Sided Color Card Printer P110m Single-Sided Monochrome Card Printer P120i Dual-Sided Color Card Printer _ _ _ _ _ - 0 _ _ _ _ - _ _ _ Smart Card Options None _ _ _ _ _ - _ 0 _ _ _ - _ _ _ _ _ _ _ _ - _ M _ _ _ - _ _ _ Magnetic Encoder None Yes (select defaults below) _
Appendix B Card SenseTM 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 SenseTM 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.
Installing the Card SenseTM Single Card Feed Kit Step 1. Set the printer to OFF. Step 2. Open the lid and remove the Ribbon Cartridge. Ribbon Cartridge Printer Lid Important • Make sure the output hopper remains closed. 160 Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
Step 3. 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 Step 4. 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. Blue Tape Card Cleaning Cartridge Step 6.
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.
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. 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.
Printing a Single Card Step 1. Place the printer power switch in the ON ( | ) position. Step 1. Insert a single card into the slot at the front of the printer, directly above the card output hopper. Do not feed more than one card at a time. Printer will take the card. INSERT CARD Note • If single-card feeding will be the normal mode of operation, you may select that mode through the driver software.
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.
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” 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. Ethernet PCBA Step 5. 166 Nylon Standoffs Use two 2-56 Panhead Screws to attach the two Nylon Standoffs to the Main PCBA. Zebra P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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.
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 P110i / P110m / P120i Card Printers Service Manual 980584-001 Rev.
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 Printer Solutions website at http://www.zebracard.com. 980584-001 Rev.
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. Step 3. Click on the Tools tab, and then click on the Properties button.
Step 4. This brings up the Tools display. Type the command here ... ... then click the Execute button. Step 5. Type the desired command in the “Command to send to printer” field, and click the Execute button. 980584-001 Rev.
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.
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174 MR Check for Card Presence &N Select Magnetic Encoding Standard !NL Get Printer Impression and Error Counters +O Print Offset X-Axis O/vO Load Single Line Bit-map (Monochrome) +OY Print Offset Y-axis !P Move Card Forward 8 cm PS Download Color Image Buffer P/vP Draw Single Dot (Monochrome/Overlay) R Reset !R Print Head Resistance &R Reset Magnetic Encoder !RIBBON Get ribbon type installed !RIBLEN Get number of remaining panels on ribbon !RIBPN Get ribbon part number +RO X
APPENDIX E Spares List Introduction The following tables list the Spare Parts Kits available for the P110i, P110m, and P120i Card Printers. Before ordering, be sure to check the Partner Zone on www.zebracard.com for the latest spare parts kits listing. The Spares List is arranged in the following categories: Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Enclosures & Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assemblies 176 Kit # Description 105940G-231 KIT,P/H REPL,G4,P110I/P120I 105940G-230 KIT,PCBA,NO ENET,w/MAG,P110I P110i, P110m 105940G-139 KIT,PCBA,NO ENET,w/MAG,P120I P120i 105940G-248 KIT,PCBA,ENET,P1XX Zebra P110i / P110m / P120i Card Printers Service Manual Model(s) P110i, P110m, P120i P110i, P110m, P120i 980584-001 Rev.
980584-001 Rev.
178 Kit # Description 105940G-007 KIT,TRANSPORT,ENGINE,P120I P110i, P110m, P120i 105925G-002 KIT,POWER SUPPLY,P2XX P110i, P110m, P120i Zebra P110i / P110m / P120i Card Printers Service Manual Model(s) 980584-001 Rev.
Enclosures & Covers 980584-001 Rev.
180 Kit # Description 105940G-101 KIT,PANEL,SIDE,RIGHT P110i, P110m, P120i 105940G-102 KIT,PANEL,SIDE,LEFT P110i, P110m, P120i Zebra P110i / P110m / P120i Card Printers Service Manual Model(s) 980584-001 Rev.
980584-001 Rev.
Feeder 182 Kit # Description 105940G-247 KIT, FEEDER ASSY Zebra P110i / P110m / P120i Card Printers Service Manual Model(s) P110i, P110m, P120i 980584-001 Rev.
Flipper Kit # 980584-001 Rev.
184 Kit # Description 105910G-108 KIT,MOTOR 105940G-078 KIT,GEAR,120T,FLIPPER 105940G-071 KIT,BOTTOM,CARRIER,CARD,FLIPPR Zebra P110i / P110m / P120i Card Printers Service Manual Model(s) P110i, P110m, P120i P120i P110i, P110m, P120i 980584-001 Rev.
980584-001 Rev.
186 Kit # Description 105940G-129 KIT,C/A,FLIPPER SENSORS P110i, P110m, P120i 105940G-079 KIT,GEAR,50T,48P P110i, P110m, P120i 105940G-075 KIT,GEAR,DRIVE,FLIPPER P110i, P110m, P120i Zebra P110i / P110m / P120i Card Printers Service Manual Model(s) 980584-001 Rev.
980584-001 Rev.
Print Engine Transport 188 Kit # Description 105912G-201 KIT,REFLECTIVE TAPE,10/KIT P110i, P110m, P120i 105940G-125 KIT, CLEANING ROLLER P110i, P110m, P120i Zebra P110i / P110m / P120i Card Printers Service Manual Model(s) 980584-001 Rev.
980584-001 Rev.
Print Engine Right Side 190 Kit # Description 105940G-066 KIT,PULLEY,MOTOR,RIBBON P110i, P110m, P120i 105940G-068 KIT,O-RING,.94 X 2.290 P110i, P110m, P120i 105940G-116 KIT,PLUNGER,RIBBON CONT P110i, P110m, P120i 105940G-058 KIT,GEAR,54T,48P,CAM P110i, P110m, P120i Zebra P110i / P110m / P120i Card Printers Service Manual Model(s) 980584-001 Rev.
980584-001 Rev.
192 Kit # Description 105940G-010 KIT,DISC,ENCODER P110i, P110m, P120i 105940G-009 KIT,RIBBON/MOTOR P110i, P110m, P120i 105940G-121 KIT,ESD STRIP,1.69IN LONG P110i, P110m, P120i Zebra P110i / P110m / P120i Card Printers Service Manual Model(s) 980584-001 Rev.
980584-001 Rev.
Print Engine Bottom 194 Kit # Description 105940G-002 KIT,NMB,STEP MTR/21G MLX P110i, P110m, P120i 105940G-003 KIT,MOTOR,CAM,P120I P110i, P110m, P120i Zebra P110i / P110m / P120i Card Printers Service Manual Model(s) 980584-001 Rev.
980584-001 Rev.
196 Kit # Description 105940G-038 KIT,CAP,SENSOR,ATM P110i, P110m, P120i 105940G-049 KIT,SHAFT,CAM P110i, P110m, P120i Zebra P110i / P110m / P120i Card Printers Service Manual Model(s) 980584-001 Rev.
Print Engine Left Side 980584-001 Rev.
198 Kit # Description 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 P110i / P110m / P120i Card Printers Service Manual Model(s) 980584-001 Rev.
980584-001 Rev. A Kit # Description 105940G-093 KIT,PULLEY,GROOVED,PPD .
Shipping Carton 200 Kit # Description 105940G-001 KIT,PACKAGING,P120I Zebra P110i / P110m / P120i Card Printers Service Manual Model(s) P110i, P110m, P120i 980584-001 Rev.
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: email: 1-800-511-9909 techsupport@zebra.com North America - Repair Services Before returning any equipment to Zebra Technologies Corporation for in-warranty or out-ofwarranty repair, contact Repair Services for a Return Materials Authorization (RMA) number.
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: e-mail: + 44 (0) 870 241 1527 cardts@zebra.com Europe, Middle East, and Africa - Repair Services Before returning any equipment to Zebra Technologies Corporation for in-warranty or out-ofwarranty repair, contact Repair Services for a Return Materials Authorization (RMA) number.
Asia Pacific - Technical Support and Repair Services Before returning any equipment to Zebra Technologies Corporation for in-warranty or out-ofwarranty 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.
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