Zebra P110i Service Manual

This document contains information proprietary to Zebra Technologies Corporation. This document and the information contained within is Copyrighted by Zebra Technologies Corporation and may not be duplicated in full or in part by any person without written approval from Zebra. While every effort has been made to keep the information contained within current and accurate as of the date of publication, no guarantee is given that the document is error-free or that it is accurate with regard to any specification. Zebra reserves the right to make changes, for the purpose of product improvement, at any time. Trademarks P110i and P120i are trademarks and Zebra is a registered trademark of Zebra Technologies Corporation. Windows and MS-DOS are registered trademarks of Microsoft Corp. All other trademarks or registered trademarks are marks of their respective holders. Product Disposal Product Disposal Information • Do not dispose of this product in unsorted municipal waste. This product is recyclable, and should be recycled according to your local standards. For more information, please see our web site at: http://www.zebra.com/environment

Zebra P110i / P110m / P120i Card Printers Service Manual iii Contents 1 • General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1.2 Features, Controls, and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 1.4 Card Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Declarations of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Icons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 2 • Installation and Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 2.2 Unpacking the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 2.3 Setting up the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 2.4 Connecting Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 2.5 Connecting the Printer to your Computer . . . . . . . . . . . . . . . . . . . . . . . .17 2.6 Installing the Printer Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 2.6.1 Print Driver Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 2.6.2 USB Driver Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 2.6.3 Ethernet Driver Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 2.7 Changing the Printer Driver Options . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 2.7.1 General Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 2.7.2 Sharing Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 2.7.3 Ports Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 2.7.4 Color Management Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 2.7.5 Security Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 2.7.6 Advanced Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 2.7.7 Device Settings Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 2.8 Loading Ribbon Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

980584-001 Rev. A 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 3.2 Card Printing Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 3.3 Card Path Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 3.4 Card Movement During Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 3.5 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 3.6 CPU PCBA Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 4 • Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 4.2 Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 4.2.1 General Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 4.2.2 Print Quality Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 4.3 Troubleshooting the Ethernet Connection and Adapter . . . . . . . . . . . . .71 4.3.1 Ethernet Adapter Status Indicator . . . . . . . . . . . . . . . . . . . . . . .71 4.3.2 Network Status/Activity Indicator . . . . . . . . . . . . . . . . . . . . . . . .73 4.3.3 Resetting to Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . .74 5 • Replacement Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 5.2 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 5.3 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 5.4 Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 5.5 Printhead Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 5.6 Cleaning Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 5.7 Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 5.8 LCD Display PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 5.9 Bottom Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 5.10 Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89 5.11 Main PCBA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 5.12 Left Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 5.13 Printhead Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 5.14 Feed Cover Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 5.15 Linkage (Right Side and Left Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 5.16 Ribbon ID PCBA (P110i and P120i only) . . . . . . . . . . . . . . . . . . . . . . . .99

Zebra P110i / P110m / P120i Card Printers Service Manual v 5.17 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 5.22 Motor and Roller Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 5.23 Card Feeder (and Lid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 5.24 Flipper Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 5.25 Card Sync Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 5.26 Pressure Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 5.27 Exit Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 5.28 ATM Card Feed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 5.29 ATM Pressure Roller & Card Drive Roller Assemblies . . . . . . . . . . . . .131 5.30 Pressure Roller Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 5.31 Ribbon Take-Up Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138 5.32 Platen Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 5.33 Mag Encoder Assembly (Head and Sensor) . . . . . . . . . . . . . . . . . . . . .141 5.34 Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143 5.35 Main Drive Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149 6 • Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 6.1 Cleaning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 6.1.1 When to Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153 6.1.2 How to Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154 6.2 Cleaning the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155 6.3 Magnetic Encoder Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156 Appendix A • Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Appendix B • Card SenseTM Single Card Feed Option . . . . . . . . . . . 159 Appendix C • Ethernet Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Appendix D • Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Appendix E • Spares List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Appendix F • Worldwide Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Zebra P110i / P110m / P120i Card Printers Service Manual 1 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. In this manual, references that are specific to a particular model will be identified as such; references that apply to all three models will use the term “the printer.” The printers provides full color dye sublimation or monochrome thermal transfer printing on standard 2.125 inch by 3.375 inch (54 mm by 86 mm), PVC or PVC Composite plastic cards. The integrated card feeder and flipper (P120i only) minimizes printer size while maximizing performance. Load-N-Go™ ribbon cartridges are used with an integrated card cleaning roller for easy ribbon changing or replacement. A variety of options (some of which can be factory-installed or field-installed as upgrades) are available, making the printers configurable for varied application environments: • Magnetic stripe encoder option • CardSenseTM single-card feed option • USB or USB and Ethernet interface option Its auto-switching 100 ~ 240 Volts AC, 50 ~ 60 Hz external power supply uses interchangeable power cords for maximum flexibility.

980584-001 Rev. A 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. Covered Card Feeder Opening the Card Feeder Cover gives access to the automatic card feeder. The translucent cover allows you to see when the card supply is running low. Lid Release Button Pressing the Lid Release Button allows the printer’s lid to swing open. This gives internal access for changing the Ribbon Cartridge, changing Cleaning Rollers, and cleaning the printer. LCD Display Panel The LCD Display Panel displays printer status information. Messages also alert the user of the need for action, and indicate certain fault conditions. Card Entry / Exit Slot LCD Display Panel Multi-Function Control Button Lid Release Button Card Feeder Cover

Zebra P110i / P110m / P120i Card Printers Service Manual 3 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. CardSenseTM single-card feed option: A card is inserted part-way into the Card Entry / Exit Slot. The card will be drawn into the printer, printed, encoded, or decoded as specified by the application program, and then be ejected out through the Card Entry / Exit Slot. Rear Panel Connectors, Controls, and Indicators Standard USB Connection The figure below shows the rear of the Printer with the standard USB interface. Power Switch USB Port Power Socket

980584-001 Rev. A Ethernet Connection The figure below shows the rear of the printer with the Ethernet Option. Ethernet Adapter Status Indicator 1. During normal operation, the LED is solid GREEN for more than 30 seconds. This indicates all the hardware is functioning properly, and the Ethernet Adapter has detected the presence of the network. It does not mean the Ethernet Adapter has an IP address or is attached to a printer queue. 2. If the LED is slowly flashing GREEN (1 time/sec), the Ethernet Adapter is trying to print. Network Status/Activity Indicator 1. If the LED is solid GREEN, a 100Base link is established. 2. If the LED is flashing GREEN, a 100Base link is established, and network activity has been detected. 3. If the LED is solid ORANGE, a 10Base link is established. 4. If the LED is flashing ORANGE, a 10Base link was established, and network activity has been detected. Power Switch USB Port Power Socket Ethernet Connector Ethernet Reset Button Network Status / Activity Indicator Ethernet Adapter Status Indicator

Zebra P110i / P110m / P120i Card Printers Service Manual 5 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. Depending on the cause of the error message, restarting the printer or curing the displayed Error may return the printer to operational status, or the printer may require troubleshooting and repair. MESSAGE Operational INITIALIZING SELF TEST READY DOWNLOADING DATA MAG ENCODING PRINTING MONO PRINTING CYAN PRINTING YELLOW PRINTING MAGENTA PRINTING BLACK PRINTING OVERLAY DOWNLOADING FIRMWARE CLEANING REMOVE RIBBON THEN CLOSE LID EMPTY FEEDER THEN CLOSE COVER FEED LONG CLEANING CARD IN EXIT REMOVE LONG CLEANING CARD INSERT FEEDER CLEANING CARD CLOSE FEEDER DOOR REMOVE FEEDER CLEANING CARD SINGLE CARD READY-PRINT OR EJECT INSERT CARD PUSH BUTTON TO CONTINUE

980584-001 Rev. A 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 MESSAGE

Zebra P110i / P110m / P120i Card Printers Service Manual 7 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 (11.8 dots/mm) print resolution Monochrome Printing (P110m) • Monochrome thermal transfer printing • 300 dpi (11.8 dots/mm) print resolution Bar Code • Code 39, Code 128 B & C with & without check digit • 2 of 5 & 2 of 5 Interleaved • UPC-A, EAN 8, & EAN 13 • PDF-417 2D bar code and other symbologies can be printed via Windows drivers Cards • The use of Zebra cards will give the best print quality • Types: PVC, PVC Composite • Card width/length: ISO CR-80-ISO 7810, 2.12" (54mm) x 3.38" (86mm) • Magnetic Stripe-ISO 7811 • Smart Card-ISO 7816 • Card thickness: 30 mil (.76mm) (± 10%) • Card feeder capacity: 100 cards (30 mil) • Card output hopper capacity: 45 cards (30 mil) Ribbon Cartridges • The use of Zebra True Colours® ribbons will give the best print quality • Load-N-GoTM ribbon cartridge with integrated card-cleaning roller • i Series technology featuring contact-chip-based ribbon detection (P110i & P120i) • YMCKO: 200 cards/cartridge (P110i & P120i) • YMCKOK: 165 cards/cartridge (P120i only) • Monochrome: 1000 cards/cartridge in black or blue; 850 cards/cartridge white

980584-001 Rev. A 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 and built-in Ethernet (optional) Dimensions • Width: 7.9 in (201mm) • Depth: 12.9 in (328mm) • Height: 8.5 in (216mm) • Weight: 9.5 lbs (4.3kg) Electrical • 110 ~ 240 Volts AC, 50 ~ 60 Hz (auto switching) • 8 MB image memory standard • FCC Class A, CE, UL, and CUL approved Environmental • Operating Temperature: 60°F to 86°F (15°C to 30°C) • Operating Humidity: 20% to 65% non-condensing • Storage Temperature: 23°F to 158°F (-5°C to 70°C) (see Ribbon Storage Information, above) • Storage Humidity: 20% to 70% non-condensing • Ventilation: Free air Options • Magnetic encoder (30 mil cards only), 3 track HiCo/LoCo • CardSenseTM single card-feed mode • Cleaning Kit (1 cleaning card and 1 cleaning swab)

Zebra P110i / P110m / P120i Card Printers Service Manual 9 1.4 Card Dimensions ISO standard dimensions for plain card ISO standard dimensions for magnetic stripe card 980504-07-01 2.125 ± 0.002in (53.98 ± 0.050mm) Radius 0.125in (3.18mm) 3.375 ± 0.010in (85.72 ± 0.25mm) 0.009 ~ 0.034in (0.23 ~ 0.84mm) 980504-07-02 0.623in (15.82mm) min 0~0.115in (2.92mm) 0~0.115 in (2.92 mm) MAGNETIC STRIPE 0.218in (5.54mm) max

980584-001 Rev. A Declarations of Conformity Declarations of Conformity For a formal certificate, please contact the Compliance Office at Zebra’s Camarillo facility. EUROPE: Norway Only: This product is also designed for IT power system with phase to phase voltage 230V. Earth grounding is via the polarized, 3-wire power cord. FI: “Laite on liitettävä suojamaadoitus koskettimilla varustettuun pistorasiaan” SE: “Apparaten skall anslutas till jordat uttag” NO: “Apparatet må tilkoples jordet stikkontakt” FCC Regulations Models P110i / P110m / P120i have been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and operated in accordance with the User’s Manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. Pursuant to Part 15.21 of the FCC Rules, any changes or modifications to this equipment not expressly approved by Zebra may cause harmful interference and void the FCC authorization to operate this equipment. FCC Radiation Exposure Statement (applicable to 15.247 device only) This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment. This equipment should be installed and operated with minimum 20 cm between the radiator and your body. This transmitter must not be collocated or operating in conjunction with any other antenna or transmitter unless authorized to do so by the FCC. Industry Canada Notice This device complies with Industry Canada ICES-003 class A requirements. Cet équipement est conforme à l 'ICES-003 classe A de la Norme Industrielle Canadienne. 89/336/EEC modified by 92/31/EEC and 93/68/EEC EMC Directive EN 55022 (1998) RF Emissions control EMC Directive EN 301489-3 V1.4.1 RF Emissions and Immunity for radio equipment EMC Directive EN55024 (2001) Immunity to Electro-Magnetic Disturbances 73/23/EEC modified by 93/68/EEC Low voltage Directive EN 60950-1 (2001) Product safety 1999/5/CE R&TTE Directive EN300330-2 V1.1.1 Radio Frequency Interferences

Zebra P110i / P110m / P120i Card Printers Service Manual 11 Icons Throughout this manual, different icons highlight important information, as follows: Note • Indicates information that emphasizes or supplements important points of the main text. Important • Advises you of information that is essential to complete a task, or points out the importance of specific information in the text. Provides an example or scenario to demonstrate or clarify a section of text. Electrostatic Discharge Caution • Warns you of the potential for electrostatic discharge. Electric Shock Caution • Warns you of a potential electric shock situation. Caution • Warns you of a situation where excessive heat could cause a burn. Caution • Advises you that failure to take or avoid a specific action could result in physical harm to you, or could result in physical damage to the hardware.

Zebra P110i / P110m / P120i Card Printers Service Manual 13 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2.5 Connecting the Printer to your Computer . . . . . . . . . . . . . . . . . . . . . . . . 17 2.6 Installing the Printer Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.7 Changing the Printer Driver Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2.8 Loading Ribbon Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 2.9 Loading Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 2.10 Printing a Test Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 2.11 Printer Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 The procedure to be followed for Packing the Printer for Shipment is given at the end of this section.

980584-001 Rev. A 2.2 Unpacking the Printer Your printer ships in a cardboard carton, protected by styrofoam inserts and a protective anti- static bag. Keep all packaging material in case you need to move or re-ship the printer. 1. Before opening and unpacking the printer, inspect the carton to ensure that no damage occurred during shipment. 2. Ensure that you have a clean and nearly dust free environment for proper operation and storage of the printer. 3. Unlatch and remove the handle, open the carton, and remove the box containing the printer accessories from the shipping carton. 4. Remove the styrofoam packing material from the top of the printer. 5. Lift the printer out of the carton by holding it on both sides of the bottom and lifting the printer gently from the carton. 6. Make sure the following accessories are included with your printer: a. Software CD-ROM b. Quick Start Guide c. Cleaning Kit d. 120 VAC and 230 VAC Power Cords e. Power Transformer f. USB Printer Cable If any items are missing, please contact your dealer. To reorder, please refer to Appendix F, Worldwide Support, of this manual.

Zebra P110i / P110m / P120i Card Printers Service Manual 15 2.3 Setting up the Printer Step 1. Place the printer in a location that allows easy access to all sides. The printer should never be operated while resting on its side or upside down. Step 2. Remove the yellow CAUTION label from the back of the printer. . Step 3. Ensure that the printer’s power switch is in the OFF (O) position.

980584-001 Rev. A 2.4 Connecting Power Step 1. Insert the power supply plug into the power socket, attach the power cord (120VAC or 230VAC) to the power supply, then plug the power cord in to a grounded electrical socket of the proper voltage and type. Step 2. Ensure that the printer’s power switch is in the OFF (O) position. 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. The power supply pack can only be replaced by the same product from the manufacturer. Caution • Intermittent or unpredictable operation may occur from unsecured connectors. If damaged, the power cable must be replaced by an exact equivalent. The socket should always be easily accessible to power off the printer. 115 VAC 230 VAC

Zebra P110i / P110m / P120i Card Printers Service Manual 17 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 USB

980584-001 Rev. A 2.6 Installing the Printer Driver To install the Printer on Windows 2000, Windows XP, Windows Server 2003, or Windows Vista operating systems, insert the User Documentation and Drivers CD, included with your printer, into your computer; and the InstallWizard will walk you through the required installation steps. The InstallWizard will: • Automatically install the User Interface when the driver CD is inserted. • Start the installation process when the Install Printer Driver menu item is selected from the Main Menu. • Allow you to install Ethernet drivers, if you plan on networking your card printer. • Check to see which operating system you are using. • Detect previous versions of the driver and clean up any unnecessary Windows registry entries. You must select “Remove” from the install options to remove any previous driver versions. • Install the new driver files. • Reboot your computer. If your User Documentation and Drivers CD does not load automatically: 1. Click on Start, then click on Run. 2. Type d:\index.htm, where d: is your CD drive letter. 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.

Zebra P110i / P110m / P120i Card Printers Service Manual 19 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. A 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.

Zebra P110i / P110m / P120i Card Printers Service Manual 21 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. A 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 23 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. A 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 25 2.7 Changing the Printer Driver Options 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. • General - Displays printer name, tab selection for Printing Preferences and Print Test Page. • Sharing - OS feature where printer can be shared to other clients on a network. • Ports - OS feature displays available communication ports. • Advanced - OS feature to select printer availability and spooling options. • Color Management - Allows user to define color profile(s) with color printers. • Security - OS feature where permissions to printers can be defined. • Device Settings - Allows user to view Printer Model and Firmware Version, Encoder Settings, Tools, Firmware Download, Single Feed, and About (driver version information). 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.”

980584-001 Rev. A 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.

Zebra P110i / P110m / P120i Card Printers Service Manual 27 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. This will change the overall lightness or darkness of the image. Move the slider to the right to increase, and to the left to decrease. • Contrast - decrease or increase the image contrast by moving the RGB (Red, Green, Blue) slider bars left or right. This magnifies or minimizes the difference between the light and dark parts of the image. Move the sliders to the right to increase, and to the left to decrease. Use the Restore Defaults Button to reset the settings to the driver defaults. Ribbon - Displays type of ribbon installed in printer. Printer/Ribbon Details - Displays ribbon type and remaining panel count. Important • Printed colors can appear different from displayed colors; the above controls allow you to optimize the printed results.

980584-001 Rev. A 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. The options are Diffusion, Halftone regular, and Barcode. Black Panel - Defines how black panel is applied in a card design. 4 selections: • Do Not Use - K panel not used • Use Always - all black pixels will go to K panel • Text Only - only black text goes to K panel • Except in Color Picture - all black pixels except bitmap goes to K panel Black Bitmap - Applies black bitmap option. Front Overlay Varnish - Feature selection for applying overlay varnish ribbon to front of card. Default setting is full edge-to-edge varnish. There are various varnish options. A preview pane is shown for each selection. • Full overlay varnish - Applies an edge-to-edge overlay • No overlay - Does not apply any overlay • Selected Area - Applies overlay only in the area selected by user • Selected area blank - Applies overlay only outside the area selected by user • Bitmap based overlay - Applies a user-defined bitmap in the overlay panel • Smartcard ISO - Does not apply overlay in the area of the ISO standard Smart Card contacts • Smart Card AFNOR - Does not apply overlay in the area of the AFNOR standard Smart Card contacts • Magnetic Stripe - Does not apply overlay in the area of the ISO standard Magnetic Stripe

Zebra P110i / P110m / P120i Card Printers Service Manual 29 Back Overlay Varnish - Feature selection for applying overlay varnish ribbon to back of card. Default setting is full edge-to-edge varnish. There are various varnish options. A preview pane is shown for each selection. • Full overlay varnish - Applies an edge-to-edge overlay • No overlay - Does not apply any overlay • Selected Area - Applies overlay only in the area selected by user • Selected area blank - Applies overlay only outside the area selected by user • Bitmap based overlay - Applies a user-defined bitmap in the overlay panel • Smartcard ISO - Does not apply overlay in the area of the ISO standard Smart Card contacts • Smart Card AFNOR - Does not apply overlay in the area of the AFNOR standard Smart Card contacts • Magnetic Stripe - Does not apply overlay in the area of the ISO standard Magnetic Stripe Hologram Overlay Varnish - Feature selection for applying hologram overlay varnish ribbon to the front of card. Does not apply to this printer. There are various varnish options. A preview pane is shown for each selection. • Full overlay varnish - Applies an edge-to-edge overlay • No overlay - Does not apply any overlay • Selected Area - Applies overlay only in the area selected by user • Selected area blank - Applies overlay only outside the area selected by user • Bitmap based overlay - Applies a user-defined bitmap in the overlay panel • Smartcard ISO - Does not apply overlay in the area of the ISO standard Smart Card contacts • Smart Card AFNOR - Does not apply overlay in the area of the AFNOR standard Smart Card contacts • Magnetic Stripe - Does not apply overlay in the area of the ISO standard Magnetic Stripe

980584-001 Rev. A 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. • Color Intensity - adjusts the intensity of each color from 0 to 10. • Color Contrast - adjusts the contrast of each color from 0 to 10. • Click on Restore Defaults button to reset the settings to the factory default values. Printing Mode - Feature selection for type of printing required: • Print only • Print and Encode • Encode Only - Use this when magnetic encoding is the only function desired, printing and/or laminating will not occur. Copies - Default number of copies of cards printed.

Zebra P110i / P110m / P120i Card Printers Service Manual 31 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. A 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.

Zebra P110i / P110m / P120i Card Printers Service Manual 33 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. A 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. Note that Start of Data characters must be immediately followed by a one-digit number representing desired track where the data will be written. Use the normal Windows default fonts. End of Data - Ending of the data string for the encoder. Advanced Settings - Click here for more information. (see ADVANCED SETTINGS DIALOGUE BOX on page 35. Restore Defaults - Click here to reset the encoder settings to the default values. HiCo/LoCo - Select the type of coercivity of magnetic stripe cards to be used. Coercivity is a measurement of a material's resistance to being magnetized. Low coercivity material magnetizes easier than high coercivity material. Encoder Position - Select the printer encoder position between Reversed and Normal. Reversed is not supported by this printer. Encoder Type - Select the type of encoder. JIS2 and AAMVA are not supported by this printer.

Zebra P110i / P110m / P120i Card Printers Service Manual 35 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. LRC Parity (For Non-ISO encoding only): Choose the LRC Parity you want to work with, even, odd, or no parity. Click the Restore Defaults button to reset the settings to the original values.

980584-001 Rev. A 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. Clean - Click on the Printer Only button to clean the printer. Remove all consumables before executing a cleaning cycle. Offset Setting - Enter the X and Y direction offset, and click on the Set Offset button to set the X and Y offsets for printing image. Direct Encoding - Select the track, and enter the data to encode on the magnetic stripe. The Encode button feeds a card from the feeder and encodes the data. To read magnetic data, select the tracks to be read, select Read. To eject the card from the printer, select Eject Card. Send File - This command will allow a .prn or .txt file to print. • The .prn file must be created with a Zebra printer driver using the same ribbon as present in the printer. • The .txt file must contain firmware commands only with only one command per line. The first line must only contain “MASTER”. • The last line must only contain “SLAVE”.

Zebra P110i / P110m / P120i Card Printers Service Manual 37 F/W Download Dialog box for downloading printer firmware. • Select the appropriate .bin file from the host computer that is specified for the printer. • Select Start Firmware Download to execute the download process. 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 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. Remaining Count - Shows the remaining card count for the ribbon installed. For monochrome ribbons, this will display Unknown. Panels Printed - Displays the total number of panels printed for the lifetime of the printer.

Zebra P110i / P110m / P120i Card Printers Service Manual 39 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. A 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. • When the ribbon is completely used, change the whole cartridge assembly. Step 1. Open the printer lid by pressing the Cover Release button on the top of your printer. Step 2. Peel protective wrapper from adhesive cleaning roller by gently pulling on the blue tape. Discard the protective wrapper. Electrostatic Discharge Caution • DO NOT TOUCH the print head or the electronic components on the print head. Discharge of electrostatic charge from the human body or other surfaces can damage the print head or other electronic components ✓

Zebra P110i / P110m / P120i Card Printers Service Manual 41 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. Step 4. Close the printer lid, and push down until you hear an audible click. After the lid is closed, the ribbon automatically synchronizes when the printer power is on. Adhesive Cleaning Roller

980584-001 Rev. A 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. Load cards into card feeder as follows: Step 1. Open card feeder cover. Step 2. Slide card guide all the way to the right until it locks in place with an audible click. Caution • DO NOT bend cards or touch print surfaces as this can reduce print quality. Note • The surface of the cards must remain clean and dust free. Always store cards in an enclosed container. Ideally, use cards as soon as possible. If cards stick together, carefully fan or shuffle them. Note • For Cards with magnetic stripe, refer to Section for loading instructions. Card Feed Cover Card Guide

Zebra P110i / P110m / P120i Card Printers Service Manual 43 Step 3. Remove cellophane wrapper from card stack. Step 4. Holding the card deck by the sides, hold it vertically against a flat surface such as a desktop. If the deck is too thick for your hand to hold it comfortably, use about half a deck at a time. Step 5. Push the stack back and forth to an angle of about 45° from vertical, so as to separate all of the cards. Step 6. Restore the card stack to its original squared-off condition, and place the cards in the input hopper. 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.

980584-001 Rev. A 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 Card Feeder Cover Card Stack

Zebra P110i / P110m / P120i Card Printers Service Manual 45 Cards with Magnetic Stripe The magnetic encoder is a factory-installed item with the read/write head positioned below or above the card path. Note that the magnetic encoder is settable via the driver for HiCo or LoCo encoding. When loading cards with magnetic stripes into the card feeder, please ensure that the magnetic stripe is facing the left side of the printer, and closest to the bottom edge of the card feeder, as shown below. 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. Magnetic Stripe Note • Zebra-approved HiCo and LoCo PVC cards are available.

980584-001 Rev. A Card Output Hopper Step 1. Raise the printer lid and pull the output hopper down to place it in its functional position. Step 2. When not using the printer, place the card output hopper back in its closed position to protect the printer from dust. Card Output Hopper

Zebra P110i / P110m / P120i Card Printers Service Manual 47 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. Step 3. Keep pressing the Multi-Function Control Button until the SELF TEST message appears in the window. Step 4. Release the Multi-Function Control Button, and a test card will print after a few seconds. P120i Serial Nr: 060376 Firmware: V1.50 Head resistance: 1568 Offset: X002 - Y015 EC: 0014 Printing Counter: 00002716 Multi-Function Control Button Power Switch

980584-001 Rev. A 2.11 Printer Operation Printing with the printer requires the Windows printer driver, your card design/issuing software, or printer command-level programming through the printer interface. The printer can be used with any Windows 2000 or Windows XP software application program, using the drivers provided on CD with the printer. Creating a Sample Card Before you begin a new printing session, print a sample card to ensure that the cards will be printed correctly. Follow the steps below to print your first card using the True ColoursTM Card Printer Ribbon Cartridge and the Windows printer driver. Step 1. Go to the Microsoft Word software. Step 2. Go to File > Print. Step 3. Choose the Zebra Card Printer from the printer names list. Step 4. Press Close to exit the Print dialogue box. Step 5. Go to File > Page Setup. Step 6. Select the Paper tab; and under Paper Size, choose Card. Step 7. Select the Margins tab; and set all the margins to 0 (zero). Under Orientation, select Landscape or Portrait. Step 8. Press OK to exit the Page Setup window. Step 9. The card appears on the window. Step 10. Design a card with both black and colored text and with colored pictures similar to the sample card shown below. (The P110m Printer uses monochrome ribbons only.) Note • To simplify creating a sample card, you can use one of the sample files that were installed during the driver installation process. These samples (Word files) can be found in Start > All Programs > Zebra Card Printers. http://www.zebracard.com

Zebra P110i / P110m / P120i Card Printers Service Manual 49 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. Ensure the following settings in the Print dialogue box: • Printer Name: Zebra < model > Card Printer • Print to File: Unchecked • Page Range: All • Number of Copies: 1 • Collate: Unchecked • Print What?: Document • Print: All pages in range • Pages per sheet: 1 page • Scale to paper size: No Scaling Step 3. Click the OK button. Step 4. The printer will feed in a card and start printing. The data download time will vary depending on complexity of the card design and the computer’s processing speed. Step 5. Once the printing is completed, the card will be ejected from the printer into the printed card hopper. Step 6. Remove the sample card from the card output hopper, and check for any discrepancies. If the sample card is correct, your printer is ready to produce more cards.

980584-001 Rev. A 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. If the original material is lost or damaged, a replacement Shipping Kit can be ordered from Zebra. Refer to the Media List on the Windows Drivers and User Documentation CD supplied with this printer. Worldwide Support locations are listed in Appendix F. Important • Do not ship the printer with either the ribbon or the cards in the printer.

Zebra P110i / P110m / P120i Card Printers Service Manual 51 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 CPU PCBA Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

980584-001 Rev. A 3.2 Card Printing Basics This section provides an overview description of how images are printed on plastic cards. Printhead The Printhead Assembly mounts in the Printhead Bracket, which holds the Printhead at a right angle to the card’s long surface. The Printhead is a thin-film device that consists of a row of individually addressable heating elements. Each heating element is approximately 0.0033 inch (0.08 mm) wide, giving a print resolution of 300 dots per inch. There are a total of 672 heating elements. Since the width of the plastic card is 2.125 inches (54 mm), 638 elements provide full-width coverage. The “extra” 34 elements (17 on either side of the card’s nominal width) are present to support programmable image centering and full bleed imaging even if a card is slightly oversize.

Zebra P110i / P110m / P120i Card Printers Service Manual 53 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.) Multi-Panel Ribbons have a repeating sequence of panels of different dye. i Series True ColoursTM Multi-Panel Ribbons have an smart chip built into the supply spool; the smart chip identifies the ribbon type and panel count. (Note that the lack of a smart chip will be interpreted by the Printer as being a Monochrome Ribbon.) Printing with a Multi-Panel Ribbon requires multiple passes of the card under the Printhead, once per panel. For dual-sided printing, a typical situation would be to print a full-color graphic (such as a person’s picture) along with black text and/or bar-coding on the front, and black text and/or bar-coding on the rear. In this case, a “YMCKOK” Multi-Panel Ribbon would typically be used. Ribbon ID Contacts Smart Chip Contact Pad

980584-001 Rev. A A YMCKOK ribbon has successive panels as follows: Other ribbons are available for the Printer; see the Supplies List on the Driver and Documentation CD that came with your printer, or go to the Zebra Card Printer Solutions website at http://www.zebracard.com. Additionally, the driver software allows the user to specify which ribbon panels are printed on either side of the card. The ribbon synchronizes to its “starting” position whenever the Lid is opened and then closed. For a YMCKOK ribbon, the starting position is with the leading edge of a Yellow Panel at the Printhead location. Ribbon Movement From Supply Spool (YMCKOK Pattern Repeats) Yellow (“Y”) Dye Cyan (“C”) Dye Magenta (“M”) Dye Black (“K”) Resin Overlay (“O”) Varnish Dye Sublimation Printing Process Thermal Transfer Printing Process Black (“K”) Resin

Zebra P110i / P110m / P120i Card Printers Service Manual 55 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.) Note that before printing the “second” K Resin black panel, the card would be moved back to the card flipper, flipped over, and then advanced to the Printhead. Printhead at Fixed Position 1. Ribbon Moves Yellow Panel into Position at Printhead 2. Card is Fed to Printing Position Under the Printhead 3. Card and Ribbon Move Together as Yellow Panel is Printed 4. Card and Ribbon Stop at End of Yellow Panel 5. Ribbon is Stationary; Card is Moved Back to Printing Position 6. Card and Ribbon Move Together as Magenta Panel is Printed

980584-001 Rev. A 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. Thermal Transfer Printing (P110i, P110m, and P120i) In Thermal Transfer, voltage is either applied or not applied to each Printhead printing element. If voltage is applied, the ink at that location is transferred to the surface of the card. Each pixel is either printed (i.e., the ink transferred to the card) or not; there are no intermediate levels. Thermal Transfer printing with a resin ribbon is used for printing bar codes, since contrast between the light and dark areas is the highest and the edges are the sharpest. Printhead Platen Roller Ribbon Carrier Layer Ribbon Dye Layer Card Gaseous Dye is Absorbed by Card Printhead Platen Roller Ribbon Carrier Layer Ribbon Ink Layer Card Ink Transferred to Surface of Card

Zebra P110i / P110m / P120i Card Printers Service Manual 57 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. The figure below shows the relative locations of the sensors that track card and ribbon position and movement. Card Flipper Rollers Cleaning Rollers Platen Roller Exit Rollers Main Drive Rollers Feeder Roller ATM Card Feed Sensor J12 Feed Cover Sensor J8 (on Lid) Ribbon Flag Position Sensor J6 Card Sync Sensor J9 Color Ribbon Sensor J5 (on Printhead) Flipper Position Sensor J11 (on Flipper) Mag Encoder Sensor J23 Lid Sensor J7 (on left side) Card Load Sensor J10 (on Flipper)

980584-001 Rev. A 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. Step 2. The card is moved into the Print Engine, passing the Cleaning Roller; this cleans dust or dirt particles from the upper card surface. Step 3. If the Printer includes an optional Magnetic Stripe Encoder, the card is moved to the Magnetic Stripe Encoder, and the stripe is encoded. After the card is encoded, it is checked to verify that the magnetic stripe was properly encoded. If encoding fails, the card is ejected into the Card Output Hopper. This is done to avoid wasting time and ribbon panels on a defective card. If the encoding is successful, the card is moved into the pre-print position, just before the Printhead. Printhead Card Input Hopper Card Guide Ribbon Cartridge Card Output Hopper Card Flipper (under Hopper) Cleaning Roller Magnetic Stripe Encoder (optional) Platen Roller Lid Multi-Function LCD Panel

Zebra P110i / P110m / P120i Card Printers Service Manual 59 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. As the card and ribbon move along, each element of the Printhead receives a pulse of variable width; a wider pulse results in a hotter element which melts a larger amount of yellow dye onto that particular spot on the card. After this yellow pass is completed, the Printhead is raised, the card is moved back, and printing continues with the Magenta ribbon panel, then the Cyan panel, then the Black panel if present, then an Overlay panel. Thermal-Transfer Printing (P110i, P110m, and P120i) If using a monochrome ribbon (used when printing a bar code on a card), the card makes a single pass under the Printhead. The Printhead elements are energized to either on or off. The on level actually transfers the spot of resin under the Printhead element to the card. This results in the sharpest possible images; for bar codes you want the sharpest edges and highest contrast between dark and un-printed areas. Step 5. For dual-sided printing, the card is now moved back to the Card Flipper where the card is turned over (rotated into the 180 position). The card is moved into the Print Engine, passing the Cleaning Roller; this cleans dust or dirt particles from the “back” of the card. The card is printed (same as Step 4). Step 6. When printing is completed, the card is moved to the Card Exit, where it falls into the Output Hopper.

980584-001 Rev. A 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. (Mag Encoder Option Components) Power Control AC Voltage Power Supply 24 VDC Magnetic Encoder LCD Display Panel Printhead Printhead Circuitry Sensor Calibration Circuitry Ribbon and Card Transport Motors Motor Drivers A/D Circuitry for Optical Sensors Optical Sensors USB Circuitry USB Port Ethernet Connection Circuitry Ethernet Extension Board Ethernet Printserver Board Ethernet Port Memory for CPU Clock CPU (Ethernet Option Components) Magnetic Encoder Circuitry Ribbon RFID Circuitry RFID Transponder RFID Tag in Ribbon Core LCD Display and Panel Button Circuitry Panel Button CPU PCBA (Not present on P110m)

Zebra P110i / P110m / P120i Card Printers Service Manual 61 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. J14 (USB Port) J8 (Feed Cover Sensor) J11 (Flipper Position Sensor) J10 (Card Load Sensor) J13 (Feeder Motor) J19 (DC Power Supply) J18 (Ribbon ID PCBA) J5 (Color Ribbon Sensor) J9 (Card Sync Sensor) J28 (Printhead) J2 (Flip Motor) J24 (LCD Display) J16 (Ribbon Motor) J21 (Auxiliary Fan) J7 (Lid Sensor) J26 (Platen Motor) J25 (Print Head Fan Motor) J6 (Ribbon Flag Position Sensor) J23 (Mag Encoder Head & Sensor) J3 (Cam Motor) J12 (ATM Card Feed Sensor)

Zebra P110i / P110m / P120i Card Printers Service Manual 63 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. These causes should be checked and corrective actions taken in the order given; they are listed in order of likelihood and complexity. When the suggestions presented fail to lead to a repair, a CPU Board replacement, if not prescribed, should nevertheless be tried. A check for broken or disconnected cables and any loss of power should also take place along with checks for obvious mechanical damage. Zebra Card Printer solutions offers Technical Support and factory repair as options.

980584-001 Rev. A 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. Check the ribbon. Replace if defective or entirely used. 2. Ribbon will automatically synchronize and printing will restart with a new card. The LCD Panel displays MECHANICAL ERROR message. 1. Check that you are using the correct card type (see Technical Specifications). 2. If two cards are fed into the printer at the same time: Open the Lid and remove the Ribbon Cartridge, empty the Card Feeder, and pull out the jammed cards. Replace the Ribbon Cartridge. Remove cards from Card Feeder, separate them as shown in Loading Cards in Section 2, and replace. 3. Check that ribbon is loaded correctly. The LCD Panel displays ENCODING ERROR message. 1. Check that you are using the correct magnetic card type (for low or high coercivity encoding). 2. Verify command syntax. 3. Contact Zebra technical support. The LCD Panel displays INSERT CARD message with cards in the Card Feeder. 1. Printer may be in the Single Feed mode. Change mode. The LCD Panel displays CLEAN PRINTER message. 1. Printer cleaning required (see Section 6).

Zebra P110i / P110m / P120i Card Printers Service Manual 65 4.2.2 Print Quality Issues This section will help you resolve print quality problems The print quality is dependent on several factors. The two most important factors that will increase your print quality are cleanliness and card stock. To diagnose and fix print quality problems, follow the troubleshooting procedures below: Example • Small spots appear on the printed card with a non-printed area or a different color. • Possible Cause: Contamination on the card surface. Solution: Check that cards are stored in a dust free environment. Use a different supply of cards. • Possible Cause: Cleaning roller not installed. Dust inside the printer and/or dirty cleaning roller. Solution: Perform a cleaning of the printer. Check that the protective cover was removed from the ribbon cartridge cleaning roller. If printing one card at a time, replace the cleaning roller located at the front of the printer. Important • The use of Zebra cards and True Colours® ribbons will give the best print quality.

980584-001 Rev. A 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.

Zebra P110i / P110m / P120i Card Printers Service Manual 67 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. • Possible Cause: Dust or embedded contamination on elements of the printhead. Solution: Clean the printhead.

980584-001 Rev. A 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. Solution: Use a different supply of cards. • Possible Cause: Dust or embedded contamination inside the printer and/or dirty cleaning roller. Solution: Clean the printhead. Replace the cleaning roller.

Zebra P110i / P110m / P120i Card Printers Service Manual 69 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. A 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. Solution: Replace the platen roller.

Zebra P110i / P110m / P120i Card Printers Service Manual 71 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. The following conditions might occur: Step 1. During normal operation, the LED is solid GREEN for more than 30 seconds. This indicates all the hardware is functioning properly and the Ethernet Adapter has detected the presence of the network. It does not mean the Ethernet Adapter has an IP address or is attached to a printer queue. Step 2. If the LED is rapidly flashing GREEN (9 times/sec), the Ethernet Adapter has not detected the presence of a network cable. To solve the problem: • Verify that the network cable is appropriate and has an RJ-45 connector. • Turn the printer power OFF (O). Remove the network cable from the Ethernet Adapter. Plug the network cable back in until you hear a positive click. Check the other end of the cable in the same manner. Turn the printer power on; if the Ethernet Adapter still does not detect a cable, continue. • Connect the Ethernet Adapter to a known good network. If the Adapter is still unable to detect the network cable, contact Technical Support for assistance. Ethernet Adapter Status Indicator Important • Cables with a rating higher than CAT-6 have not been tested.

980584-001 Rev. A 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. If the LED is solid RED for more than 30 seconds, the Ethernet Adapter has failed the POST. A failed POST can be caused by any of the following: • The printer attached to the Ethernet Adapter device is malfunctioning. Turn the printer power off, wait 10 seconds, then turn the printer back ON ( | ). • If the Ethernet Adapter still fails the POST, the Ethernet Adapter has a hardware problem that can be fixed only by replacing or returning the unit. Contact Technical Support for repair or replacement information. Step 5. If the LED is alternately flashing RED and GREEN for longer than 2 minutes, the Ethernet Adapter is in firmware-download mode. This means it is waiting for new firmware data to be sent before it continues normal functioning. Do the following: • If the Ethernet Adapter was purposely put into firmware-download mode, finish the download with the proper update utility. • Contact the Zebra web site at http://www.zebracard.com, and click on the Drivers & Downloads tab. • Contact Technical Support for help recovering this unit.

Zebra P110i / P110m / P120i Card Printers Service Manual 73 4.3.2 Network Status/Activity Indicator A bi-color Status/Activity LED indicates network speed, established link, and network activity. Step 1. If the LED is off, no link was established. Step 2. If the LED is solid GREEN, a 100Base link is established. Step 3. If the LED is flashing GREEN, a 100Base link is established and network activity has been detected. Step 4. If the LED is solid ORANGE, a 10Base link is established. Step 5. If the LED is flashing ORANGE, a 10Base link was established and network activity has been detected. Network activity detected by this LED does not mean the activity is data for the print server. The activity is all activity on the network seen on the Ethernet Adapter. Network Status / Activity Indicator

980584-001 Rev. A 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 ( | ). Step 3. Keep the Ethernet Reset Button pressed until the Status Indicator light turns GREEN. Step 4. Release the Ethernet Reset Button. Printing a Configuration Card To print a configuration card, press and hold the Ethernet Reset Button until a card starts to print. Ethernet Reset Button

Zebra P110i / P110m / P120i Card Printers Service Manual 75 5 Replacement Procedures still 5.1 Introduction The following sections describe removing both major assemblies and, where applicable, subassemblies and/or components that are considered replaceable. In general, only removal directions are presented; unless otherwise noted, replacement would be performed by reversing the removal steps. Replacement instructions for some items are not presented; removal and replacement of these items are considered too obvious to warrant a detailed description. Spares Kits are listed in Appendix E. Electric Shock Caution • Before performing any of the procedures in this section, set the printer power to OFF (O) and disconnect the power cord. Electrostatic Discharge Caution • All replacement procedures must be performed at a static-free work station, an anti-static wrist strap must be worn and properly terminated, or other appropriate protection must be used. Caution • Before beginning any of the procedures that follow, read completely through the procedure. If you do not have the specified tools, or if any step(s) seem beyond your skill or experience level, do not attempt the procedure. You may cause additional damage to the printer. Note • Some of the photographs in this section may show additional parts removed in addition to removals for the process being described.

980584-001 Rev. A 5.2 Required Tools This section lists the tools required for the replacement procedures described in this section. Naturally, not all tools are required for a particular procedure; specific tools are called out in each step as appropriate. 1. Flat-Blade Screwdrivers, from 1/16 inch (1.5 mm) to 1/4 inch (6.5 mm) 2. Phillips Screwdrivers, numbers 0, 1, and 2 3. TORX T8 and TORX T10 drivers 4. Fine-Point, Offset Fine-Point, and Needle-Nose pliers 5. Small Diagonal Cutters or other cutter for cutting cable ties 6. Hex Keys, 1.5 mm and 2.0 mm 7. Hex Driver, 5.5 mm (this can also be used for securing push nuts) 8. Small and Medium Spring Hook Tools 9. Belt Tensioning Tool, Zebra P/N 900754-003 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. Important • When removing any of the nylon or plastic pulleys or gears, the use of a gear puller is strongly recommended. If a gear puller is not available, use pliers and/or a flat-blade screwdriver to pry the gear or pulley off its shaft. In either case, remove any Loctite residue from the shaft and the gear/pulley. Inspect the old gear/pulley very carefully. If any teeth have burrs, are missing, or are damaged, or if the center hole is distorted or enlarged, the gear/pulley must be replaced rather than the old one re-installed.

Zebra P110i / P110m / P120i Card Printers Service Manual 77 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. NOTE 1: Disconnect all the plugs when replacing the Main PCBA; otherwise, only disconnect the plugs for the associated replacement assembly. NOTE 2: Not present on P110m. PRINT ENGINE 5.21 Front Cover page 106 5.7 Top Cover page 85 5.9 Bottom Cover page 88 5.10 Rear Cover page 89 5.12 Left Side Cover page 95 5.18 Right Side Cover page 102 5.8 LCD Display page 87 5.11 Main PCBA (NOTE 1) page 90 5.15 Linkage page 98 5.15 Linkage page 98 5.16 Ribbon ID PCBA (NOTE 2) page 99 5.20 Encoder Wheel page 105 5.17 Lid Sensor page 101 5.19 Ribbon Flag Position Sensor page 103 5.13 Printhead Fan page 96 5.14 Feed Cover Sensor page 97 5.27 Exit Roller page 119 5.30 Pressure Roller Lift Motor page 135 5.29 ATM Pressure Roller & Card Drive Roller page 131 5.31 Ribbon Take-Up Motor page 138 5.32 Platen Roller page 140 5.34 Stepper Motor page 143 5.35 Main Drive Roller page 149 Start Here Complete P110i / P110m / P120i 5.25 Card Sync Sensor page 116 5.26 Pressure Roller page 117 5.5 Printhead Assembly page 79 5.6 Cleaning Roller page 84 5.23 Lid page 109 5.23 Card Feeder page 109 5.24 Flipper Module page 113 5.28 ATM Card Feed Sensor page 130 5.33 Mag Encoder Assembly page 141

980584-001 Rev. A 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. “Left Side” of Printer “Right Side” of Printer “Front” of Printer Lid (open) Card Feeder Ribbon Card Flipper (under Card Feeder) Printhead Assembly

Zebra P110i / P110m / P120i Card Printers Service Manual 79 5.5 Printhead Assembly Printhead Removal Step 1. Turn the printer off, and disconnect the power cord. Step 2. Press the access button in, and raise the Lid. Step 3. Locate the Printhead Assembly. Electrostatic Discharge Caution • The Printhead is extremely susceptible to Electrostatic Discharge (ESD) damage. Do not touch the bottom surface of the Printhead. The replacement must be performed at a static-free work station, an anti-static wrist strap must be worn and properly terminated, or other appropriate protection must be used. Important • This procedure describes replacing the Printhead Assembly. The Printhead Assembly is supplied with components in correct alignment with each other. These alignments are critical to proper operation of the printer. Do not deviate from the procedure given here, do not loosen or tighten any screws except those specifically noted in this procedure, and do not attempt to adjust any part of the Printhead Assembly. Note • The Printhead Assembly can be replaced without removing any other parts of the printer. Printhead Assembly

980584-001 Rev. A 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.

Zebra P110i / P110m / P120i Card Printers Service Manual 81 Printhead Replacement Printhead Installation Step 1. Record the resistance of the new Printhead Assembly. 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. Step 6. Press in and downward, lowering the Printhead Assembly into place. Step 7. The Printhead installation is complete. Printhead Resistance Alignment Pin Alignment Hole

980584-001 Rev. A Firmware Update Step 1. Go to start > Printers and Faxes. 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 83 Step 5. This brings up the Tools display. 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. 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

980584-001 Rev. A 5.6 Cleaning Roller Step 1. Locate the 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 Cleaning Roller

Zebra P110i / P110m / P120i Card Printers Service Manual 85 5.7 Top Cover Step 1. Press the access button in, and raise the Lid. 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. Access Button

980584-001 Rev. A 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 87 5.8 LCD Display PCBA Step 1. Locate the LCD Display PCBA. Step 2. Carefully remove the 10-wire plug from the connector on the LCD Display PCBA. 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. LCD Display PCBA 10-Wire Plug Mounting Screws

980584-001 Rev. A 5.9 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 89 5.10 Rear Cover Step 1. With a TORX T10 driver, loosen the two screws from the top of the Rear Cover. Step 2. With a TORX T10 driver, remove the two screws from the bottom of the Rear Cover. Step 3. Remove the Rear Cover. Screws Screws

980584-001 Rev. A 5.11 Main PCBA Step 1. With the Bottom Cover removed, the Main PCBA is visible and accessible. Step 2. With a TORX T10 driver, remove the five screws holding the Main PCBA in place. Note that the five orange arrows point out the PCBA mounting hardware. 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.

Zebra P110i / P110m / P120i Card Printers Service Manual 91 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 5. When the Main PCBA is removed, the view from the bottom of the printer looks like the following picture. J14 (USB Port) J8 (Feed Cover Sensor) J11 (Flipper Position Sensor) J10 (Card Load Sensor) J13 (Feeder Motor) J19 (DC Power Supply) J5 (Color Ribbon Sensor) J9 (Card Sync Sensor) J28 (Printhead) J2 (Flip Motor) J24 (LCD Display) J16 (Ribbon Motor) J21 (Auxiliary Fan) J7 (Lid Sensor) J26 (Platen Motor) J25 (Print Head Fan Motor) J6 (Ribbon Flag Position Sensor) J23 (Mag Encoder Head & Sensor) J3 (Cam Motor) J12 (ATM Card Feed Sensor) J18 (Ribbon ID PCBA)

980584-001 Rev. A Step 6. Set the Main PCBA aside. Side 1 Side 2

Zebra P110i / P110m / P120i Card Printers Service Manual 93 Firmware Update Step 1. Go to start > Printers and Faxes. 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. Step 5. This brings up the Tools display. 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. Type the command here ... ... then click the Execute button. Note • See Appendix D for the complete list of commands

980584-001 Rev. A Step 6. From the information on the Test Card, update the printer’s firmware. 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. In the “Command to send to printer” field, type the End of Print (+EC) command, a space, and the end-of-print value. From the Test Card shown above, the complete command is +EC 10. d. Click the Execute button. e. In the Offset setting section, enter the X and Y offsets for the card front in the Front X and Front Y fields respectively. From the Test Card shown above, Front X = 07 and Front Y = 32. f. In the Offset setting section, enter the X and Y offsets for the card back in the Back X and Back Y fields respectively. From the Test Card shown above, Back X = 05 and Back Y = 04. g. Click the Set Offsets button. Step 7. The Firmware Update is complete. 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