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Mag Encoder Upgrade Kit Instructions P630i/P640i - Zebra … · 2011. 9. 19. · Zebra® P630i &...

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P1001802 Rev A (Draft 1) Upgrade Kit 105927G-262 Installation Instructions 1 Zebra ® P630i & P640i Mag Encoder Upgrade Instructions Introduction These instructions describe installing Mag Encoder Upgrade Kit 105927G-262 in a Zebra P630i or P640i Card Printer. Caution • This upgrade kit may only be installed by Zebra trained and certified personnel. Any attempt to install it by other than Zebra trained and certified personnel will void the product warranty and may cause damage to the equipment.
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Page 1: Mag Encoder Upgrade Kit Instructions P630i/P640i - Zebra … · 2011. 9. 19. · Zebra® P630i & P640i Mag Encoder Upgrade Instructions Introduction These instructions describe installing

P1001802 Rev A (Draft 1) Upgrade Kit 105927G-262 Installation Instructions 1

Zebra® P630i & P640iMag Encoder Upgrade Instructions

Introduction

These instructions describe installing Mag Encoder Upgrade Kit 105927G-262 in a Zebra P630i or P640i Card Printer.

Caution • This upgrade kit may only be installed by Zebra trained and certified personnel. Any attempt to install it by other than Zebra trained and certified personnel will void the product warranty and may cause damage to the equipment.

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2 Upgrade Kit 105927G-262 Installation Instructions P1001802 Rev A (Draft 1)

Mag Encoder Upgrade InstructionsParts List

Parts List

Recommended Tools

This section lists the tools required for the installation of the Mag Encoder Upgrade Kit; specific tools are called out in each step as appropriate.

1. Hex Wrench: 3/32" and 5/64"2. Nut Driver: 5/16" 3. Phillips Screwdriver: #14. Shim: .030"5. PVC Card: 10 mil 6. Open-End Wrench: 1/4"7. Thread Locking Compound; e.g., Loctite®

8. PC Interface with P630i/P640i Driver installed

Procedure

Kit: 105927G-262

QTY PART NUMBER DESCRIPTION

1 500899G-2 Magnetic Encoder Assembly

2 806369-406 Shoulder Screw

2 738005-06 Nylon Washer

2 734077 Compression Spring

1 806106G-009 Flat Steel Washer

Electric Shock Caution • Before performing any of the procedures in this section, set the printer power to OFF (O) and disconnect the power cord.

Electrostatic Discharge Caution • All replacement procedures must be performed at a static-free work station, an anti-static wrist strap must be worn and properly terminated, or other appropriate protection must be used.

Caution • Before beginning any of the procedures that follow, read completely through this procedure. If you do not have the specified tools, or if any step(s) seem beyond your skill or experience level, do not attempt the procedure. You may cause additional damage to the printer.

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Mag Encoder Upgrade InstructionsProcedure

P1001802 Rev A (Draft 1) Upgrade Kit 105927G-262 Installation Instructions 3

Preliminary Set-up

Step 1. Remove the Rear Cover; see Service Manual.

Step 2. Remove the Main PCBA; see Service Manual.

Step 3. Remove the Cleaning Cartridge.

Step 4. With a Phillips #1 screwdriver, remove the three screws holding the Clean Station Front Mounting Bracket in place; and set the Bracket aside.

Step 5. Install a .030" shim on the Magnetic Encoder Assembly (PN 500899G-2); see figure below.

Step 6. Remove the cap protecting the Read/write head.

Important • Use the .030" shim while installing the shoulder screws (and associated hardware), then remove it once the screws are tightened.

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4 Upgrade Kit 105927G-262 Installation Instructions P1001802 Rev A (Draft 1)

Mag Encoder Upgrade InstructionsProcedure

Installation

Step 1. Set the Magnetic Encoder Assembly (PN 500899G-2) in place; circled below.

Step 2. With a 5/64" hex wrench, install the shoulder screw (PN 806369-406), nylon washer (PN 738005-06), compression spring (PN 734077), and flat steel washer (PN 806106G-009) on the right side of the Magnetic Encoder; circled below.

Step 3. With a 5/64" hex wrench, install the shoulder screw (PN 806369-406), nylon washer (PN 738005-06), and compression spring (PN 734077) on the left side of the Magnetic Encoder; arrow above. Note that there is no flat washer on the left side.

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Mag Encoder Upgrade InstructionsProcedure

P1001802 Rev A (Draft 1) Upgrade Kit 105927G-262 Installation Instructions 5

Step 4. Remove the .030" shim from the Magnetic Encoder Assembly.

Step 5. Carefully pull the ground wire and cable through the opening behind the Hopper; arrow below.

Step 6. With a 5/16" nut driver, install the the ground wire using the screw holding the Plate to the Frame.

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6 Upgrade Kit 105927G-262 Installation Instructions P1001802 Rev A (Draft 1)

Mag Encoder Upgrade InstructionsProcedure

Step 7. Install the Main PCBA.

Step 8. Connect the Magnetic Encoder to J14 on the Main PCBA; circled below.

Step 9. Install the Rear Cover.

Step 10. Install the Clean Station Front Mounting Bracket.

Step 11. Install the Cleaning Cartridge.

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Mag Encoder Upgrade InstructionsTest and Adjustment

P1001802 Rev A (Draft 1) Upgrade Kit 105927G-262 Installation Instructions 7

Test and Adjustment

Mechanical Adjustment (Positioning Mag Encoder Head in Bracket):

Step 1. Place 10-mil PVC Card on truck and position truck so the card is under the magnetic encoder head.

Step 2. Back off the adjustment screw (circled below) in the magnetic encoder bracket so that the screw is not touching the bezel.

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8 Upgrade Kit 105927G-262 Installation Instructions P1001802 Rev A (Draft 1)

Mag Encoder Upgrade InstructionsTest and Adjustment

Step 3. Loosen the 1/4” nuts on backside of magnetic encoder bracket (circled below).

Step 4. Loosen magnetic encoder clamping screws (circled below).

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Mag Encoder Upgrade InstructionsTest and Adjustment

P1001802 Rev A (Draft 1) Upgrade Kit 105927G-262 Installation Instructions 9

Step 5. Push down magnetic encoder head until it contacts the 10-mil card on the truck.

Step 6. While holding the magnetic encoder head down and parallel to the magnetic encoder head bracket, carefully tighten the clamping screws (circled above). Do not over tighten; the bracket can distort.

Step 7. Carefully tighten the 1/4” nuts on the backside of magnetic encoder bracket (arrows above). Do not over tighten; the bracket can distort.

Step 8. With a 3/32” Hex Driver, tighten the adjustment screw (circled below) in the magnetic encoder bracket so that the screw is just touching the bezel.

Step 9. Remove 10-mil PVC Card.

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10 Upgrade Kit 105927G-262 Installation Instructions P1001802 Rev A (Draft 1)

Mag Encoder Upgrade InstructionsTest and Adjustment

Electro-Mechanical Adjustment:

Step 1. After installing the Magnetic Encoder, go into the Printer Driver; and perform the Magnetic Encoder Position Adjustment.

a. Select Start > Printers and Faxes, right click the Zebra Card Printer, and select Properties from the pop-up menu.

b. From the Card Printer Properties screen, select Device Settings > Control > Advanced Utilities.

c. Load a few magnetic stripe cards.

d. Click the Mag Position Adjust button; circled below.

e. Observe the printer: 1) pick a card from the Hopper, 2) mag encode it, 3) back up, 4) run the card under the read/write head again to determine the position at which the mag encoding begins, and 5) eject the card through the laminator.

Note that this is a one-time setup when the starting position is stored in the firmware. It is not necessary to repeat this step unless the Magnetic Encoder is mechanically adjusted.

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Mag Encoder Upgrade InstructionsTest and Adjustment

P1001802 Rev A (Draft 1) Upgrade Kit 105927G-262 Installation Instructions 11

Step 2. Perform the Magnetic Encoder Amplitude Adjustment.

a. Click on the Mag Amplitude Adjust button; circled below.

b. Observe the printer load a card and run the card back and forth under the Magnetic Encoder.

c. View the data that comes up in the Mag Data Monitor screen, and make a mental note of this data. Your goal is to set the height adjustment so that the amplitudes for all of the tracks are:

Track 1: Greater than 120

Track 2: Greater than 120

Track 3: Greater than 120

To achieve this result, you will be adjusting the magnetic encoder head until you see the settings go out of specification, and then return half of the distance back. This will put the magnetic encoder head in the middle or “sweet spot” of operation.

d. During the pause in movement of the truck, tighten the adjustment screw in the magnetic encoder bracket 1/4 of a turn and then remove the driver.

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12 Upgrade Kit 105927G-262 Installation Instructions P1001802 Rev A (Draft 1)

Mag Encoder Upgrade InstructionsTest and Adjustment

e. View the Mag Data Monitor screen, and verify that the amplitudes are still within specification.

f. Repeat Step a, keeping track of the amount you have turned the adjustment screw, until the data goes out of specification.

g. Divide the total distance that you have tightened the adjustment screw by 2 and loosen the adjustment screw by that amount (for example, if you have tightened the screw by 1½ turns, loosen the screw ¾ of a turn).

h. Verify that the amplitude data is within specification. Press the Print button on the front panel, and close the Mag Data Monitor dialogue box.

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Mag Encoder Upgrade InstructionsTest and Adjustment

P1001802 Rev A (Draft 1) Upgrade Kit 105927G-262 Installation Instructions 13

Step 3. Go back to the Advanced Utilities menu, and choose Mag Position Adjust.

Step 4. After the Mag Position Adjust test has completed, put a drop of thread locking compound on the adjustment screw.

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14 Upgrade Kit 105927G-262 Installation Instructions P1001802 Rev A (Draft 1)


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