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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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.
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.
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.
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.
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.
Mag Encoder Upgrade InstructionsTest and Adjustment
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.
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.
Mag Encoder Upgrade InstructionsTest and Adjustment