If you detect that either of the arms catches at one end of the platen, but is free at the other, the carrier needs Azimuth adjustment, see below. Always correct for azimuth error before adjusting the gap between arms and platen.

If there is no azimuth error, but insufficient clearance between arms and platen, see Gap adjustment below.

Azimuth adjustment: The flip station carrier is held in alignment with the platen by a U-shape molding that rides along a fixed rail in the motor housing behind the carrier. Using a fiber tip pen mark the screw for reference, then adjust it in very small increments, such as 1/8 of a turn. A full turn of the screw moves the U-shape molding about 0.08" (2 mm), rotating the carrier almost 3º.

To fine tune the azimuth adjustment, run Flip Test 3 with flip selected. If the gap between the rear flipper arm and the platen is to spec (0.004") at the arm’s mid-point, and if neither end of the arm snags after repeated flip cycles, you can be sure the azimuth adjustment is good.

Flip carrier sensor tabs: This view is from left to right, along the center wall of the printer ockwise rotation of the azimuth adjust screw causes clockwise rotation of the carrier assembly, viewed from above. Example: if the platen tugs down the right hand end of front flipper arm as the carrier elevates, the carrier needs clockwise rotation.

Gap adjustment: The flipper arms must be separated so that they clear the platen, but not so far that they

lose their grip on the card. There is

afine line between too tight (grabbin g the platen) and too loose (failing to hold the card securely)

.

Because it is easily accessible, and doesn’t require removal of the rear cover, try to correct the problem with the front flipper adjustment.

Note • Inserting a CR-80 card into the flipper arms to check for grip is easier if you remove the color ribbon.

Mark the bushing for reference with a fiber tip pen. Using a ¼" open end wrench, adjust in very small increments, such as 1/8 of a turn. A full clockwise turn of the screw moves the bushing in by about 0.03” (¾ mm).

If you are starting from scratch, set the nose of bushing about 0.02" (½ mm) proud of the inner surface of the carrier. You can estimate this by comparison with a CR-80 card, which is 0.03" thick.

After adjusting the gap: Check operation of the flip station by running Flip Test 3 with Flip, both with and without a card in the flipper arms.

The rear flipper arm is different: You need to remove the rear cover for access. Also, it’s not possible to adjust the bushing without first removing the cam.

Flip Station Routines in the Driver

Start > Printers (or Printers and Faxes) > Right click Zebra P640i > Properties > Device Settings > Control

>Advanced Utilites

Flip Test 1: Picks up a card, runs it to the flip station, flips it, raises it to the laminator infeed, then ejects it through the laminator. The sequence repeats until the PRINT button is pressed and released.

Flip Test 2: Picks up a card, runs it to the flip station, flips it, returns it to the platen, then backs it out to the card sensor (by the mag head). The sequence repeats until the PRINT button is pressed and released.

Flip Test 3: See Flip Station Adjustment Procedure, preceding page. Exercises the flip station by raising and lowering the flip station carrier, one cycle per click. The radio buttons select Flip or No Flip cycles.

Eject Card: Picks up a card, runs it to the flip station, raises it to the laminator infeed, then ejects it through the laminator. Like Flip Test 1, but done

once only, and without flipping.

Flip/Pause: Picks up a card, runs it to the flip station, raises it to the laminator infeed, then holds this position (termed the Insertion Height in the flip station dialog) until the user presses the PRINT button (at which point the flip carrier descends, and the truck returns the card to the hopper).

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P640i Card Printer User Guide

980541-001 Rev. A