Flip station calibration: This routine determines the number of motor steps it takes for the carrier to descend from the “rest position datum” (Edge A in the diagram) to the “real” rest position, that being the carrier’s physical end stop.This stored number is used to drive the carrier down to the rest position before each and every flip station action.

Calibraton is a one-time setup routine, but is also a useful starting point when diagnosing flip station problems.

Power OFF. Lift the cover, then push the carrier down to its physical end stop. Push at the back of the carrier, near the guide shaft. Do NOT force!

Click Flip Station Calibration. This elevates the carrier until Edge A just clears the photo sensor, at which point the motor stops, and the step count is saved in flash memory. The motor then drives the carrier back down to the rest position.

Carrier Motion

Vertical motion of the carrier is detected by a single photo sensor, activated by two tabs at the back of the carrier molding. The carrier is positioned by counting a specific number of motor steps from the instant the sensor’s optical path is opened or closed by edges A, B and C.

Flip station components

The two halves of the sensor (arrow) are

contained in cavities in the molded back wall of the flip station. The sensor tabs are integral with the carrier molding. Edge C is hidden by the card ejector

arm.

Flip Station Parameters in the Driver

Start > Printers (or Printers and Faxes) > Right click Zebra P640i > Properties > Device Settings > Printer Adjustment > Flip Station Adjust

Card Position Adjust (Pixels): Adjusts how far the truck drives into the flip station. Should be set so that the card is centered in the flip arms (if it isn’t centered, the truck may have difficulty removing the card after the flipping action). If the card position is incorrect, the truck can depart, leaving the card in the

flip arms, or it may drag the card an inch or two toward the print station, then jam.

Start >

Printers (or

Printers and Faxes) > Right click Zebra P640i > Properties > Device Settings > Control > Advanced Utilites > Move Truck (to Flip Station)

In 1, the card should drive smoothly to rest almost touching the right hand edge of the flip station base molding. It must not rebound off the edge. To move the card further to the right, increase (make less negative) the Card Adjust parameter, and vice versa.

 

Card

Now click

 

Flip Test 3

 

 

Truck

Platen

with Flip

 

 

enabled.

 

 

The card

 

 

should

land as 2, with a gap of between 0.04" and 0.1" (1 to

2.5mm). The exact gap isn’t critical, but it has to be visibly there.

RestPositionAdjust:

Adjusts how far down the carrier drives. This parameter is the number of motor steps, more or less, relative to the Edge A event at the photo sensor (diagram

980541-001 Rev. A

P640i Card Printer User Guide

53