DataCard SP75 Plus User manual

Datacard

®

CP80™ and CP80™ Plus

Card Printers

Service Manual

May 2007

Part No. 539490-002, Rev C

ii

Liability Statement

This product has been built to the high standards of Datacard Group. Please do

not attempt to operate or repair this equipment without adequate training. Any

use, operation, or repair in contravention of this document is at your own risk.

By acceptance of this system you hereby assume all liability consequent to your

use or misuse of this equipment. Datacard assumes no liability for incidental,

special, or consequential damage of any kind. Equipment specifications,

applications, and options are subject to change at the sole discretion of Datacard

without notice.

Proprietary Notice

All drawings and information herein are the property of DataCard Corporation.

All unauthorized use and reproduction is prohibited.

Trademark Acknowledgments

Datacard is a registered trademark and service mark of DataCard Corporation in

the United States and other countries. CP80 is a trademark of DataCard

Corporation.

All other product names are the property of their respective owners.

Datacard Group

11111 Bren Road West

Minnetonka, MN 55343-9015

952.933.1223

Fax: 952.933.7971

www.datacard.com

Printed in the United States of America.

iii

Contents

Chapter 1: Introduction __________________________________________________________ 1-1

Intended Audience_________________________________________________________________1-2

Avoiding Electrostatic Discharge ____________________________________________________1-2

Symbol Conventions________________________________________________________________1-3

Chapter 2: Theory of Operation___________________________________________________ 2-1

Print Engine Functional Block Diagram _______________________________________________2-3

Laminator Functional Block Diagram_________________________________________________2-4

Printer Components ________________________________________________________________2-5

Sensors_______________________________________________________________________2-5

Motors _______________________________________________________________________2-6

Miscellaneous ________________________________________________________________2-7

LCD Service Mode Menu Diagram _____________________________________________2-8

Laminator Components_____________________________________________________________2-9

Sensors_______________________________________________________________________2-9

Motors _______________________________________________________________________2-9

Sequence of Operation____________________________________________________________2-10

Power-on Initialization ________________________________________________________2-10

Default Card Printing Sequence ______________________________________________2-10

Lamination Process __________________________________________________________2-12

Graphics Printing __________________________________________________________________2-13

Printhead Settings____________________________________________________________2-14

Magnetic Cards___________________________________________________________________2-16

Magnetic Data Principles_____________________________________________________2-16

Encoding Format ____________________________________________________________2-21

Magnetic Stripe Primary Data Standards ____________________________________________2-24

ISO/IEC 7811 (Parts 2 and 6) __________________________________________________2-24

AAMVA DL/ID-2000 __________________________________________________________2-24

Saflok and Ving______________________________________________________________2-24

Multiple Record Format (SDS)_________________________________________________2-25

JIS X 6302 (Type I and Type II Cards)___________________________________________2-25

Magnetic Media Locations___________________________________________________2-26

Data Track Locations_________________________________________________________2-27

Summary of Specifications____________________________________________________2-28

Character Encoding _________________________________________________________2-29

Smart Card Technology____________________________________________________________2-31

Contact Smart Cards ________________________________________________________2-32

Non-Contact Smart Cards____________________________________________________2-33

Types of Cards _________________________________________________________2-33

Communication _______________________________________________________2-34

Signal Modulation______________________________________________________2-34

Signal Modulation Summary Diagram ___________________________________2-35

Reader to Card Communication________________________________________2-36

Card to Reader Communication________________________________________2-36

iv

Chapter 3: Routine Maintenance _________________________________________________ 3-1

Required Tools and Supplies_________________________________________________________3-2

Print Engine Routine Maintenance Procedure ________________________________________3-3

Clean the Interior of the Printer ________________________________________________3-3

Mechanical Inspection________________________________________________________3-5

Laminator Routine Maintenance Procedures_________________________________________3-8

Clean the Interior of the Laminator_____________________________________________3-8

Mechanical Inspection________________________________________________________3-9

Run the Cleaning Cards______________________________________________________3-10

Chapter 4: Troubleshooting_______________________________________________________ 4-1

General Notes______________________________________________________________________4-3

General Troubleshooting Procedures ________________________________________________4-4

Non-Clearing Repetitive Messages_____________________________________________4-4

Troubleshooting Sensors _______________________________________________________4-5

Troubleshooting Motors (Printer)________________________________________________4-7

Testing General DC Motors ______________________________________________4-7

Testing the Ribbon and Pick Motors_______________________________________4-8

Testing the Cam Motor __________________________________________________4-8

Testing the Printhead Fan________________________________________________4-9

Testing Transport and Duplex Motors______________________________________4-9

Troubleshooting Motors (Laminator)____________________________________________4-9

Troubleshooting Other Devices ________________________________________________4-9

Testing the Smart Card Solenoid__________________________________________4-9

Testing the Duplex Clutch_______________________________________________4-10

Diagnosing the Duplex Interface Board__________________________________4-11

Diagnosing the Ribbon RFID Antenna____________________________________4-11

Performance Problems_____________________________________________________________4-12

Printer Initialization Errors______________________________________________________4-12

Card Jams at Card Input_____________________________________________________4-13

Card Jams in Printing Area ___________________________________________________4-14

Ribbon Break Errors___________________________________________________________4-15

Card Jams Between Upper and Lower Duplex_________________________________4-15

Laminate Problems __________________________________________________________4-16

Error Codes _______________________________________________________________________4-18

Error Code Prefixes___________________________________________________________4-18

General Notes_______________________________________________________________4-18

Driver API (AP) _______________________________________________________________4-19

Printer Driver Errors (DR)_______________________________________________________4-20

Input Errors (IS) _______________________________________________________________4-22

Duplex Module Errors (DM) ___________________________________________________4-22

System Errors (SY) ____________________________________________________________4-23

Magnetic Stripe Errors (MS) ___________________________________________________4-25

Laminator Errors (OP)_________________________________________________________4-30

Print Errors (PR)_______________________________________________________________4-34

Smart Card Errors (SC)________________________________________________________4-36

Chapter 5: Adjustments __________________________________________________________ 5-1

v

General Notes______________________________________________________________________5-3

Installing Printer Diagnostics _________________________________________________________5-4

Using Printer Diagnostics ____________________________________________________________5-6

Parts of the Diagnostics Window _______________________________________________5-6

Menu Options ________________________________________________________________5-7

Changing Printer Values_______________________________________________________5-9

Viewing and Saving Values _____________________________________________5-10

Working With Scripts ____________________________________________________5-11

Setting Printer Value Parameters ______________________________________________5-12

Printer ID_______________________________________________________________5-12

Card Registration Offset ________________________________________________5-12

Card Strip Offset _______________________________________________________5-13

Ribbon Type ___________________________________________________________5-13

Ribbon Offset __________________________________________________________5-13

Vertical Offset _________________________________________________________5-13

Transport Speed________________________________________________________5-14

YMC, K, T, & F Strobe Duty ______________________________________________5-14

YMC, K, T, and F Power and Base Power _________________________________5-15

Duplex Infeed Offset ___________________________________________________5-15

Duplex Home Offset____________________________________________________5-16

Duplex Print Return Offset_______________________________________________5-16

Duplex Handoff Offset__________________________________________________5-16

Smart Card Registration Offset __________________________________________5-16

Image Clipping Leading and Trailing ____________________________________5-17

Setting Printer Options________________________________________________________5-18

Viewing Printer Status ________________________________________________________5-19

Testing Motors _______________________________________________________________5-20

Testing Motor Functions ______________________________________________________5-21

Setting Up Step Tests for the Printer ____________________________________________5-22

Running a Magnetic Stripe Test Card__________________________________________5-23

Configuring the Magnetic Stripe Module ______________________________________5-24

Configuring Custom Track Formats____________________________________________5-26

Running Magnetic Stripe Diagnostics__________________________________________5-27

Testing the Smart Card Option________________________________________________5-28

Setting Laminator Values _____________________________________________________5-30

Laminator Parameter Dependencies____________________________________5-31

Temperature___________________________________________________________5-32

Patch Size _____________________________________________________________5-32

Foil Advance Offset ____________________________________________________5-33

Card Registration Offset ________________________________________________5-34

Debow Enable_________________________________________________________5-34

Roller Down Distance___________________________________________________5-35

Transport Apply Speed _________________________________________________5-35

Foil Control 1(Foil Strip Distance)_________________________________________5-36

Foil Control 2 (Foil Apply Speed Ratio) ___________________________________5-36

Foil Control 3 (Foil Registration Speed) ___________________________________5-37

Duplex Handoff Offset__________________________________________________5-37

Duplex Home Offset____________________________________________________5-37

Duplex Flipped Offset __________________________________________________5-37

Duplex Reject Offset ___________________________________________________5-38

Duplex Debow Offset___________________________________________________5-38

Duplex Horizontal Infeed Offset _________________________________________5-38

vi

Duplex Vertical Infeed Offset ___________________________________________5-38

MFG Card Registration Baseline_________________________________________5-39

MFG Temperature Baseline _____________________________________________5-39

MFG Patch Registration Baseline ________________________________________5-39

Viewing Laminator Sensors and Enabling Heaters ______________________________5-40

Testing Laminator Motors _____________________________________________________5-41

Network Option Adjustments _______________________________________________________5-42

Software Adjustment Procedures ___________________________________________________5-46

Saving and Restoring a Printer Configuration __________________________________5-46

Start Sentinel Position_________________________________________________________5-49

Card Registration Offset Adjustment __________________________________________5-50

Ribbon Offset Adjustment ____________________________________________________5-51

Updating the Printer Firmware ________________________________________________5-52

Upper Duplex Rotational Adjustment__________________________________________5-53

Lower Duplex Rotational Adjustment__________________________________________5-54

Chapter 6: Removal and Replacement ___________________________________________ 6-1

General Notes______________________________________________________________________6-4

Symbols ______________________________________________________________________6-4

Required Tools________________________________________________________________6-4

Screw Torque Specifications ___________________________________________________6-5

Print Engine Front Wire Routing Diagram________________________________________6-6

Print Engine Duplex and Printhead Wire Routing Diagram________________________6-7

Laminator Front Wire Routing Diagram _________________________________________6-8

Laminator Rear Wire Routing Diagram__________________________________________6-9

Power Supply Wire Routing Diagram __________________________________________6-10

Print Engine Cable Connection Diagram ______________________________________6-11

Laminator Cable Connection Diagram________________________________________6-12

Enclosure Components ____________________________________________________________6-13

Swingarm Cover_____________________________________________________________6-13

Main Enclosure ______________________________________________________________6-15

Input Hopper ________________________________________________________________6-17

LCD Display _________________________________________________________________6-19

Output Hopper ______________________________________________________________6-22

Swingarm Assembly________________________________________________________________6-23

Printhead Fan _______________________________________________________________6-24

Printhead Spring _____________________________________________________________6-25

Upper Printer Sensors_______________________________________________________________6-26

Card Input Sensor____________________________________________________________6-26

Swingarm Sensor_____________________________________________________________6-27

Ribbon Motion Sensor ________________________________________________________6-28

Ribbon Index Sensor _________________________________________________________6-29

Cam Sensor _________________________________________________________________6-30

Card Hopper Empty Sensor___________________________________________________6-31

Upper Printer Motors _______________________________________________________________6-32

Transport Motor______________________________________________________________6-32

Pick Motor___________________________________________________________________6-33

vii

Cam Motor__________________________________________________________________6-35

Ribbon Motor and Gear______________________________________________________6-36

Upper Printer Assembly_____________________________________________________________6-38

Transport Assembly___________________________________________________________6-40

Main Control Board __________________________________________________________6-43

Transport Timing Belt _________________________________________________________6-47

Belt Tensioner Pulley and Tension Spring _______________________________________6-48

Drive and Idler Pulleys________________________________________________________6-49

Cleaning Rocker Assembly ___________________________________________________6-50

Front Rocker Assembly _______________________________________________________6-51

Rear Rocker Assembly________________________________________________________6-52

Ribbon Guide _______________________________________________________________6-53

Pick Roller ___________________________________________________________________6-55

Cleaning Drive Roller_________________________________________________________6-57

Front Drive Roller_____________________________________________________________6-59

Rear Drive Roller _____________________________________________________________6-61

Platen Roller_________________________________________________________________6-64

Printhead Cam ______________________________________________________________6-65

Printhead Lifter ______________________________________________________________6-66

Front Card Guide ____________________________________________________________6-67

Rear Card Guide ____________________________________________________________6-68

RFID Antenna________________________________________________________________6-70

Upper Duplex Module _____________________________________________________________6-71

Duplex Entry Sensor __________________________________________________________6-73

Duplex Home Sensor _________________________________________________________6-75

Duplex Interface Board_______________________________________________________6-76

Duplex Entry Rocker__________________________________________________________6-77

Duplex Motor________________________________________________________________6-78

Magnetic Clutch/Spring Clutch/Duplex Rollers_________________________________6-80

Magnetic Stripe Option ____________________________________________________________6-84

Magnetic Stripe Circuit Board_________________________________________________6-84

Magnetic Stripe Registration Sensor ___________________________________________6-85

Magnetic Stripe Head________________________________________________________6-86

Magnetic Stripe Rocker Assembly_____________________________________________6-88

Smart Card Option ________________________________________________________________6-89

Smart Card Interface Board __________________________________________________6-89

Solenoid Assembly/Solenoid Link______________________________________________6-90

Smart Card Contact _________________________________________________________6-92

Contactless Smart Card Coupler______________________________________________6-95

Laminator Transport Assembly ______________________________________________________6-97

Power Supplies ______________________________________________________________6-98

Upper Laminator Transport Rollers_____________________________________________6-99

Lower Laminator Transport Rollers ____________________________________________6-101

Intermediate Transport Rollers and Card Guide _______________________________6-103

Upper Platen Roller__________________________________________________________6-105

Lower Platen Roller__________________________________________________________6-106

Rear Cooling Fan ___________________________________________________________6-107

viii

Hand Guard________________________________________________________________6-108

Laminator RFID Antennas____________________________________________________6-111

Laminator Sensors ________________________________________________________________6-112

Duplex Exit Sensor___________________________________________________________6-112

Card Exit Sensor_____________________________________________________________6-113

Card Registration Sensor ____________________________________________________6-114

Upper Foil Index Sensor______________________________________________________6-115

Lower Foil Index Sensor______________________________________________________6-116

Foil Motion Sensors __________________________________________________________6-117

Heater Home Sensor ________________________________________________________6-118

Laminator Motors_________________________________________________________________6-120

Card Transport Motor _______________________________________________________6-120

Foil Advance Motors ________________________________________________________6-122

Heater Lift Motors ___________________________________________________________6-123

Major Subassemblies______________________________________________________________6-124

Upper Heater Assembly _____________________________________________________6-124

Lower Heater Assembly _____________________________________________________6-125

Upper Foil Drive Assembly ___________________________________________________6-126

Lower Foil Drive Assembly____________________________________________________6-128

Heating Element/Heated Roller/Thermocouple _______________________________6-129

ix

Revision Log

Datacard CP80 and CP80 Plus Card Printers Service Manual

Revision Date Description of Changes

A March 2006 First release of this document.

B June 2006 Updated for RoHS compliance.

C May 2007 Updated for release of CP80 Plus.

Regulatory Compliance

Notice for USA (FCC Notice)

This equipment generates, uses, and can radiate radio frequency energy. If it is

not installed and used in accordance with this instruction manual, it may

interfere with radio communications. This equipment has been tested and found

to be within the limits for Class A computing devices, pursuant to Title 47 CFR

Part 15 Subpart B of FCC rules, designed to provide reasonable protection

against radio interference in a commercial environment. Operation of this

equipment in a residential environment may possibly cause interference. In the

event of interference, the users, at their own expense, will be required to take

whatever measures are necessary to correct the problem.

Notice for Canada

This digital apparatus does not exceed the Class A limits for radio noise for

digital apparatus set out in the Radio Interference Regulations of the Canadian

Department of Communications.

Le présent appareil numérique n'émet pas de bruits radioélectriques dépassant

les limites applicables aux appareils numériques de la classe A prescrites dans le

Règlement sur le brouillage radioélectrique édicté par le ministère des

Communications du Canada.

x

Safety Issues

All Datacard products are built to strict safety and reliability specifications in

accordance with UL60950-1 and CUL requirements; therefore, safety issues

pertaining to operation and repair of Datacard equipment are primarily

environmental and human interface.

The following basic safety tips are given to ensure safe installation, operation,

and maintenance of Datacard equipment and are not to be considered as

comprehensive on all matters of safety.

Safe Environment

•

Connect equipment to a grounded facility power source. Do not defeat or

bypass the ground lead.

• Place the equipment on a stable surface (table), and ensure floors in work

area are dry and non-slip. Insulated rubber floor mats are preferred.

• Know the location of equipment branch circuit interrupters or circuit

breakers and how to turn them on and off in case of emergency.

• Know the location of fire extinguishers and how to use them. Use only ABC

type extinguishers on electrical fires.

• Know local procedures for first aid and emergency assistance at the customer

facility.

• Use adequate lighting at the equipment.

• Maintain the recommended range of temperature and humidity in

equipment area.

• Do not use this product in an environment containing volatile or flammable

compounds.

Safe Human Interface

• Use proper lifting techniques when moving or installing the equipment.

• Use standard electrostatic discharge (ESD) precautions when working on or

near electrical circuits.

• Do not defeat or disconnect safety interlocks.

• Observe standard safety precautions when servicing the system.

WARNING: To avoid a possible electric shock, always unplug the system

before servicing.

CP80 and CP80 Plus Service Manual 1-1

Chapter 1: Introduction

This chapter provides an introduction to the Datacard® CP80 and

CP80 Plus card printers and how they function.

Intended Audience______________________________________________________________ 1-2

Avoiding Electrostatic Discharge _________________________________________________ 1-2

Symbol Conventions_____________________________________________________________ 1-3

1-2 Introduction

Intended Audience

This manual is intended for use by authorized representatives of Datacard who

are responsible for the maintenance, service, and repair of the CP80 and CP80

Plus card printers.

The service representatives must complete an authorized Datacard training

course prior to servicing the printers.

Avoiding Electrostatic Discharge

While working around control boards and other sensitive components, use

proper equipment and procedures to reduce the possibility of damaging the

components. This section describes the procedure for protecting against damage

due to electrostatic discharge.

CAUTION: Static electricity can destroy components on a circuit board. Use

the following precautions when handling the board, its components, or tools

in contact with the board or its components.

Tools Required:

Static-grounding kit (Part Number: TUL006-006) containing:

• Static-grounding mat

• Mat-grounding cable

• Static-grounding wrist strap

• Wrist strap grounding cable

• Grounding plug

Procedure:

1. Wear appropriate clothing. Avoid wool and synthetic fabrics.

2. Remove movable carpet and rugs.

3. Apply the grounding strap to a wrist. Ensure that there is no clothing

between the strap and skin and that the strap is snug enough to maintain

contact with the skin.

4. Connect one end of the grounding cable to the wrist strap.

5. Using the grounding plug, connect the other end of the grounding cable to

the earth ground of a facility AC outlet.

6. Clear a work area, lay the static-grounding mat on the work area, and

connect the movable end of the long grounding cable to the mat.

7. Always set unshielded static-sensitive materials on the grounded anti-static

mat. Whenever possible, place components into static-shielded bags.

8. When bringing two objects into contact (tool to circuit board or board to mat),

first simultaneously touch both objects with fingers.

CP80 and CP80 Plus Service Manual 1-3

Symbol Conventions

The appearance and purpose of the symbols used in this manual are presented

below.

This symbol is used to designate a procedure that

involves electrostatic discharge sensitive components.

ESD procedures should be used.

CAUTION: This symbol indicates a strong cautionary

message to avoid serious damage to the printer.

WARNING: This symbol indicates a strong warning

message to prevent personal injury to the technician.

This symbol indicates a spring hazard. Safety glasses

should be worn when completing the procedure.



This symbol indicates a reminder message or other

additional information for the technician.

Graphic callouts with a colored background provide

incidental information about the graphic itself.

Graphic leaders with a colored background indicate a

direction of movement or similar information.

1-4 Introduction



CP80 and CP80 Plus Service Manual 2-1

Chapter 2: Theory of

Operation

This chapter provides the theory of operation for the CP80 and CP80

Plus card printers.

Print Engine Functional Block Diagram ____________________________________________ 2-3

Laminator Functional Block Diagram______________________________________________ 2-4

Printer Components______________________________________________________________ 2-5

Sensors_______________________________________________________________________________2-5

Motors _______________________________________________________________________________2-6

Miscellaneous ________________________________________________________________________2-7

LCD Service Mode Menu Diagram_____________________________________________________2-8

Laminator Components __________________________________________________________ 2-9

Sensors_______________________________________________________________________________2-9

Motors _______________________________________________________________________________2-9

Sequence of Operation_________________________________________________________ 2-10

Power-on Initialization________________________________________________________________2-10

Default Card Printing Sequence ______________________________________________________2-10

Lamination Process __________________________________________________________________2-12

Graphics Printing _______________________________________________________________ 2-13

Printhead Settings ___________________________________________________________________2-14

Magnetic Cards ________________________________________________________________ 2-16

Magnetic Data Principles ____________________________________________________________2-16

Encoding Format ____________________________________________________________________2-21

Magnetic Stripe Primary Data Standards _________________________________________ 2-24

ISO/IEC 7811 (Parts 2 and 6) __________________________________________________________2-24

AAMVA DL/ID-2000 __________________________________________________________________2-24

Saflok and Ving______________________________________________________________________2-24

Multiple Record Format (SDS)_________________________________________________________2-25

JIS X 6302 (Type I and Type II Cards)___________________________________________________2-25

Magnetic Media Locations___________________________________________________________2-26

Data Track Locations ________________________________________________________________2-27

2-2 Theory of Operation

Summary of Specifications ___________________________________________________________2-28

Character Encoding _________________________________________________________________2-29

Smart Card Technology_________________________________________________________ 2-31

Contact Smart Cards ________________________________________________________________2-32

Non-Contact Smart Cards____________________________________________________________2-33

Types of Cards ___________________________________________________________________2-33

Communication _________________________________________________________________2-34

Signal Modulation________________________________________________________________2-34

Signal Modulation Summary Diagram _____________________________________________2-35

Reader to Card Communication__________________________________________________2-36

Card to Reader Communication__________________________________________________2-36

CP80 and CP80 Plus Service Manual 2-3

Print Engine Functional Block Diagram

2-4 Theory of Operation

Laminator Functional Block Diagram

CP80 and CP80 Plus Service Manual 2-5

Printer Components

Sensors

All of the optical sensors in the CP80 and CP80 Plus printers are of the open

collector type, and are configured to be active-low with a pull-up resistor on the

output. When the sensor is not active (or not connected at all) the control board

sees a high voltage (5V) at the Signal input. When the sensor is active, it shorts

Signal to Ground. The diagram below is a simplified representation of an

interruption sensor.

Name Function

Card Input

The card input sensor is an interruption sensor that detects the presence of

a card at the entrance of the printer and registers the trailing edge of the

card for printing.

Printhead Cam

As the printhead cam rotates, a flag on the cam interrupts the beam of the

cam sensor. This allows the printer to know the position of the printhead

lifters.

Swingarm

Open

The swingarm open sensor detects when the swingarm is open. The sensor

itself detects when the swingarm is closed, but the signal is inverted

elsewhere in the system.

Ribbon Index

The ribbon index sensor is used to determine the position of the print ribbon

panels. The sensor bounces a beam off the reflective sticker on the

printhead. When the index mark or K-panel on the ribbon passes between

the sensor and the reflector, the beam is broken (not reflected). The Y, M,

C, and T panels do not interrupt the beam.

Ribbon Motion

The ribbon motion sensor is a two-channel optical interruption sensor that

detects slots on the ribbon encoder wheel. The encoder wheel is located

on the ribbon cartridge. Internally the sensor body contains a pair of

standard interruption sensors.

Magnetic

Stripe

Registration

This is a reflective sensor that locates the leading edge of the card for

magnetic stripe encoding. When no card is present, the sensor beam

reflects off a plate on the magnetic stripe rocker. When a card passes

between the sensor and the reflector, the beam is broken (not reflected).

The sensor itself is active when no card is present, but the signal is inverted

elsewhere in the system.

2-6 Theory of Operation

Name Function

Card Input

The card input sensor is an interruption sensor that detects the presence of

a card at the entrance of the printer and registers the trailing edge of the

card for printing.

Magnetic

Stripe Optical

Encoder

This encoder monitors the rotation of the idler roller in the magnetic stripe

module. It provides positional feedback to the module to ensure proper

magnetic encoding.

Duplex Entry

The duplex entry sensor is an optical interruption sensor that detects the

presence of a card as it enters and leaves the duplex module.

Duplex Home

The duplex home sensor determines the rotational position of the duplex

flipper. The flipper has three flags that pass through the sensor.

Input Hopper

Empty Sensor

Option

This reflective sensor detects when the card hopper has no cards left. It

functions only when special software is created to use it.

Motors

The printer engine has up to five motors depending on the configuration. The

three DC motors are all similar, with an integral reduction geartrain and 24-volt

operation. The speed of the motors is controlled by pulse width modulation.

While the motors are reversible, some are wired to operate in one direction only.

The duplex step motor operates at 24 volts, but the transport step motor operates

at 40 volts.

Name Function

Pick Motor

The pick motor drives the pick roller to bring a card into the

system. The motor is wired for unidirectional operation and cannot

be reversed by the control board. One wire is connected to

ground and the other wire is the control. This motor is driven by a

single channel in the motor driver.

Transport Motor

The transport motor drives the platen roller through a gear, which

also drives the main transport belt. This is a 2-phase (4-wire), 40-volt

stepper motor.

Cam Motor

The cam motor rotates the printhead cam, which operates the

printhead lifters. The lifters raise and lower the printhead into

position for printing or permitting a card to pass beneath.

Ribbon Motor

The ribbon motor drives the gear train of the ribbon cartridge to

advance the ribbon during printing. The motor is wired for

unidirectional operation and cannot be reversed by the control

board. One wire is connected to ground and the other wire is the

control. This motor is driven by a single channel in the motor driver.

Duplex Motor

The duplex motor drives a gear on the duplex clutch. The clutch

permits a single motor to operate the rollers, or to rotate the entire

flipper assembly (this is discussed in more detail on page

2-7). This

is a 2-phase (4-wire), 24-volt stepper motor.

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