Datacard® SD Series Card Printers

Transcription

Datacard® SD Series Card Printers
SD260L™, SD360™ and SD460™
Service Manual
SD260L Serial Number D11000 and Later
SC360 Serial Number B17000 and Later
March 2014
Part No. 527269-001, Rev B
Liability Statement
Please do not attempt to operate or repair this equipment without adequate
training. Any use, operation, or repair you perform that is not in accordance with
the information contained in this documentation is at your own risk.
Proprietary Notice
All figures and information herein are the property of DataCard Corporation. All
unauthorized use and reproduction is prohibited.
Trademark Acknowledgments
Datacard is a registered trademark and service mark of DataCard Corporation in
the United States and other countries.
Windows and Internet Explorer are registered trademarks of Microsoft
Corporation.
Firefox is a registered trademark of Mozilla.
Java is a registered trademark of Oracle and/or its affiliates. (www.java.com)
All other product names are the property of their respective owners.
Datacard Group
11111 Bren Road West
Minnetonka, MN 55343-9015
Phone: 952-933-1223
Fax: 952-933-7971
www.datacard.com
© 2014 DataCard Corporation. All rights reserved.
Printed in the United States of America.
ii
Revision Log
Datacard SD Series Card Printers Service Manual
Revision
Date
A
July 2012
B
March 2014
Description of Changes
First release of this manual.
Updated manual to include SD460 information.
Regulatory Compliance
Notice for USA (FCC Notice)
This equipment generates, uses, and can radiate radio frequency energy. If it is
not installed and used in accordance with this instruction manual, it may interfere
with radio communications. This equipment has been tested and found to be
within the limits for Class A computing devices, pursuant to Title 47 CFR Part 15
Subpart B of FCC rules, designed to provide reasonable protection against radio
interference in a commercial environment. Operation of this equipment in a
residential environment may possibly cause interference. In the event of
interference, the users, at their own expense, will be required to take whatever
measures are necessary to correct the problem.
Notice for Canada
This digital apparatus does not exceed the Class A limits for radio noise for
digital apparatus set out in the Radio Interference Regulations of the Canadian
Department of Communications. The term “IC:” before the equipment
certification number only signifies that the Industry Canada technical
specifications were met.
Le présent appareil numérique n'émet pas de bruits radioélectriques dépassant
les limites applicables aux appareils numériques de la classe A prescrites dans le
Règlement sur le brouillage radioélectrique édicté par le ministère des
Communications du Canada.
Safety
All Datacard products are built to strict safety and reliability specifications in
accordance with UL60950-1 and CUL requirements; therefore, safety issues
pertaining to operation and repair of Datacard equipment are primarily
environmental and human interface.
The following basic safety tips are given to ensure safe installation, operation, and
maintenance of Datacard equipment and are not to be considered as
comprehensive on matters of safety. For more safety information refer to
“Precautions” on page 1-3, and “Avoiding Electrostatic Discharge” on page 5-4.
iii
Safe Environment
•
Connect equipment to a grounded facility power source. Do not defeat or
bypass the ground lead.
•
Place the equipment on a stable surface, and ensure that the floors in the work
area are dry and non-slip. Insulated rubber floor mats are preferred.
•
Know the location of equipment branch circuit interrupters or circuit breakers
and how to turn them on and off in case of emergency.
•
Know the location of fire extinguishers and how to use them. Use only ABC
type extinguishers on electrical fires.
•
Know local procedures for first aid and emergency assistance at the customer
facility.
•
Use adequate lighting at the equipment.
•
Maintain the recommended range of temperature and humidity in equipment
area.
•
Do not use this product in an environment containing volatile or flammable
compounds.
Safe Human Interface
•
Use proper lifting techniques when moving or installing the equipment.
•
Use standard electrostatic discharge (ESD) precautions when working on or
near electrical circuits.
•
Do not defeat or disconnect safety interlocks on covers.
Warning: To avoid a possible electric shock, always unplug the system before
servicing.
iv
Table of Contents
Introduction _____________________________________________________
1-1
About This Manual ____________________________________________________ 1-3
Intended Audience _______________________________________________ 1-3
Symbol Conventions_______________________________________________ 1-3
Precautions___________________________________________________________ 1-3
Introduction to Printers ________________________________________________ 1-4
Simplex Printer with Smart Card Option _____________________________ 1-4
Duplex Printer _____________________________________________________ 1-5
SD460 System _____________________________________________________ 1-6
Options Available_____________________________________________________ 1-7
Functional Block Diagrams ____________________________________________ 1-9
Simplex Print Engine _______________________________________________ 1-9
Duplex Print Engine _______________________________________________ 1-10
Basic Integrator Smart Card_______________________________________ 1-11
SCM Dual Smart Card ____________________________________________ 1-12
Duali Single-Wire Smart Card ______________________________________ 1-13
Duplex Module___________________________________________________ 1-14
Printer Components __________________________________________________ 1-15
Sensors __________________________________________________________ 1-15
Motors ___________________________________________________________ 1-16
Circuit Boards ____________________________________________________ 1-17
LCD Panel ___________________________________________________________ 1-18
Status Lights______________________________________________________ 1-19
LCD Menu Options _______________________________________________ 1-20
Printer Manager _____________________________________________________ 1-23
Zero Configuration Networking____________________________________ 1-23
Connecting to Printer Manager ___________________________________ 1-23
Ethernet Connection _________________________________________ 1-24
USB Connection ______________________________________________ 1-25
Logging in to Printer Manager ________________________________________ 1-26
Printer Manager Language Support _______________________________ 1-26
User Access Levels _______________________________________________ 1-26
Printer Manager Passwords _______________________________________ 1-26
Printer Manager Menu Options _______________________________________ 1-27
Status____________________________________________________________ 1-27
Printer Settings ___________________________________________________ 1-28
Troubleshooting __________________________________________________ 1-38
Maintenance ____________________________________________________ 1-41
Log Out__________________________________________________________ 1-41
Firmware Update ____________________________________________________ 1-42
Theory of Operation ______________________________________________
2-1
Sequence of Operation _______________________________________________ 2-3
v
Power-On Initialization _____________________________________________ 2-3
Power Down Sequence ___________________________________________ 2-3
Default Card Production Sequence ________________________________ 2-4
Duplex Sequence _________________________________________________ 2-5
Smart Card Sequence _____________________________________________ 2-6
Single-Wire Smart Card Solution ________________________________ 2-7
Single-Wire Smart Card Solution or Loosely Coupled Solution _____ 2-7
Card Feed____________________________________________________________ 2-8
Card Cleaning ____________________________________________________ 2-8
Acceptable Card Thickness and Types _____________________________ 2-8
Card Transport ________________________________________________________ 2-9
Card Printing ________________________________________________________ 2-10
Color Printing Sequence __________________________________________ 2-10
Monochrome Printing Sequence __________________________________ 2-11
Ribbon Advance_____________________________________________________ 2-13
Magnetic Stripe Encoding ____________________________________________ 2-15
Magnetic Stripe Write Operation __________________________________ 2-16
Magnetic Stripe Read Operation__________________________________ 2-17
Color Management __________________________________________________ 2-18
Overview ________________________________________________________ 2-18
Color Variations __________________________________________________ 2-18
Other Color Variation Factors _____________________________________ 2-20
Differences in Monitor and Printed Images _________________________ 2-20
Monitor Calibration_______________________________________________ 2-21
Magnetic Cards _____________________________________________________ 2-22
Magnetic Data Principles _________________________________________ 2-22
Magnetism ___________________________________________________ 2-22
Magnetic Media _____________________________________________ 2-23
Electrical Current and Magnetism _____________________________ 2-23
Writing Data__________________________________________________ 2-23
Reading Data ________________________________________________ 2-24
Magnetic Data _______________________________________________ 2-25
Encoding Format_________________________________________________ 2-26
Bit Density ____________________________________________________ 2-26
Word Length _________________________________________________ 2-26
Record Length _______________________________________________ 2-27
Parity Check _________________________________________________ 2-27
Data String ___________________________________________________ 2-27
Leading/Trailing Clock Pulses __________________________________ 2-27
Specific Data_________________________________________________ 2-28
Start Sentinel/End Sentinel_____________________________________ 2-28
Longitudinal Redundancy Check (LRC) ________________________ 2-28
Magnetic Stripe Primary Data Standards ______________________________ 2-29
ISO/IEC 7811 (Parts 2 and 6)_______________________________________ 2-29
AAMVA DL/ID-2000 _______________________________________________ 2-29
vi
Saflok, Ving, and Timelox _________________________________________
Multiple Record Format (SDS) _____________________________________
JIS X 6302 (Type I and Type II Cards) _______________________________
Magnetic Media Locations _______________________________________
Data Track Locations _____________________________________________
Summary of Specifications ________________________________________
7-bit Alphanumeric Character Set as Defined by ISO/IEC 7811 __
5-bit Numeric Character Set as Defined by ISO/IEC 7811 ________
Smart Card Technology ______________________________________________
Contact Smart Cards _____________________________________________
Contactless Smart Cards _________________________________________
Communication ______________________________________________
Signal Modulation ____________________________________________
Signal Modulation Summary Diagram __________________________
Reader-to-Card Communication ______________________________
Card-to-Reader Communication ______________________________
Adjustments _____________________________________________________
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3-1
Factory and Power-On Settings ________________________________________ 3-3
Viewing Printer Status _________________________________________________ 3-3
Viewing and Changing Printer Settings _________________________________ 3-4
Communication __________________________________________________ 3-4
Activity Log _______________________________________________________ 3-5
Activity Log Example ______________________________________________ 3-6
Behavior __________________________________________________________ 3-8
Vital Product Data ________________________________________________ 3-9
Front Panel Options _______________________________________________ 3-9
Print Settings _________________________________________________________ 3-11
CableCompMaxStrobe___________________________________________ 3-11
CardRegistration _________________________________________________ 3-12
CardRegistrationCalibration ______________________________________ 3-13
Color Management ______________________________________________ 3-14
FanTempOn _____________________________________________________ 3-15
KPower __________________________________________________________ 3-15
Kpower1200 _____________________________________________________ 3-16
Kpower600_______________________________________________________ 3-16
KpowerCalibration _______________________________________________ 3-16
KpowerCalibration1200 ___________________________________________ 3-17
KpowerCalibration600 ____________________________________________ 3-17
KPowerDuplex ___________________________________________________ 3-17
KWhiteShade ____________________________________________________ 3-18
LeadTrim_________________________________________________________ 3-18
RibbonOffset_____________________________________________________ 3-19
RibbonStripOffset_________________________________________________ 3-20
SettingsGroupPurpose ____________________________________________ 3-20
TPower __________________________________________________________ 3-21
vii
TPowerCalibration________________________________________________ 3-21
TPowerDuplex____________________________________________________ 3-21
TWhiteShade_____________________________________________________ 3-22
TrailTrim __________________________________________________________ 3-22
VerticalOffset ____________________________________________________ 3-23
YMCMinShade ___________________________________________________ 3-24
YMCPower_______________________________________________________ 3-24
YMCPower600 ___________________________________________________ 3-24
YMCPowerCalibration ____________________________________________ 3-25
YMCPowerCalibration600_________________________________________ 3-25
YMCPowerDuplex ________________________________________________ 3-25
YMCWhiteShade _________________________________________________ 3-26
Print Misadjustment __________________________________________________ 3-27
Pick Settings _________________________________________________________ 3-28
Motor PWM ______________________________________________________ 3-28
Pick Auto TimeOut________________________________________________ 3-28
Pick Card Offset__________________________________________________ 3-29
Pick Card Offset (1-6)_____________________________________________ 3-29
Pick Manual Timeout _____________________________________________ 3-30
PickReversePwm _________________________________________________ 3-30
PickReverseTime _________________________________________________ 3-31
Transport Settings ____________________________________________________ 3-32
Boosted Transport Speed _________________________________________ 3-32
TransMedSpeed__________________________________________________ 3-32
TransportSpeed __________________________________________________ 3-32
Magnetic Stripe Settings ______________________________________________ 3-33
Enabling the Proprietary Magnetic Stripe Option ___________________ 3-33
Magnetic Stripe General Settings__________________________________ 3-36
Magnetic Stripe Custom Track Settings ____________________________ 3-39
Magnetic Stripe Track Height Test _________________________________ 3-41
Start Sentinel Position Adjustment__________________________________ 3-43
Update Password ____________________________________________________ 3-44
Set Job Queue State _________________________________________________ 3-46
Flipper Adjustments __________________________________________________ 3-47
Emboss Card Out ________________________________________________ 3-48
Flipper Emboss Angle _____________________________________________ 3-48
Flipper Flipped Angle _____________________________________________ 3-49
Flipper Home Offset ______________________________________________ 3-49
Flipper Registration Offset _________________________________________ 3-50
Flipper Reject Angle ______________________________________________ 3-50
Flipper Rotation Speed ___________________________________________ 3-50
Flipper Smart Angle_______________________________________________ 3-51
Flipper Trans Ramp Down Reg Speed______________________________ 3-51
Smart in Offset ___________________________________________________ 3-51
Smart Out Offset _________________________________________________ 3-51
viii
Laminator Offsets ____________________________________________________
Laminator________________________________________________________
Laminator Type __________________________________________________
Updating Printer Settings______________________________________________
Troubleshooting __________________________________________________
3-52
3-52
3-59
3-61
4-1
General Troubleshooting Procedures___________________________________ 4-4
Non-Clearing Repetitive Messages ____________________________________ 4-4
Sensors_______________________________________________________________ 4-5
Test the Sensors ___________________________________________________ 4-5
Test the Sensors Using Continuous Update __________________________ 4-5
Determine if the Sensor Has Failed__________________________________ 4-6
Test Card _____________________________________________________________ 4-7
Troubleshooting Motors_______________________________________________ 4-12
Testing the Ribbon and Pick Motors________________________________ 4-13
Testing the Cam and Transport Motors_____________________________ 4-13
Other Troubleshooting Procedures ____________________________________ 4-14
Placing Cam in Uninstall Position __________________________________ 4-14
Testing the Thermal Printhead (TPH) Fan ___________________________ 4-14
Diagnosing the Ribbon RFID Antenna______________________________ 4-14
SSA Test__________________________________________________________ 4-14
Testing Smart Cards __________________________________________________ 4-15
Dual Contact/Contactless ________________________________________ 4-15
HID iClass Reader/Writer __________________________________________ 4-18
Indentive Smart Card_____________________________________________ 4-23
Basic Smart Card Integrator_______________________________________ 4-26
Performance Problems _______________________________________________ 4-27
Printer Initialization Errors __________________________________________ 4-27
Card Jams at Card Input _________________________________________ 4-28
Card Stalls at Output Stacker _____________________________________ 4-28
Card Jams in Printing Area ________________________________________ 4-29
Ribbon Break Errors _______________________________________________ 4-29
Messages and Conditions ____________________________________________ 4-30
Messages on the Printer LCD ______________________________________ 4-30
Respond to Messages ____________________________________________ 4-34
Printer Messages _________________________________________________ 4-34
100: Request not supported ___________________________________ 4-34
101: Job could not complete__________________________________ 4-34
102: Card not in position ______________________________________ 4-34
103: Printer problem __________________________________________ 4-35
104: Critical problem __________________________________________ 4-35
105: Magstripe data error _____________________________________ 4-35
106: Magstripe data not found ________________________________ 4-36
107: Magstripe read data error ________________________________ 4-36
108: Magstripe read no data __________________________________ 4-37
ix
109: Print ribbon problem______________________________________
110: Print ribbon out or missing _________________________________
111: Card not picked _________________________________________
112: Card hopper empty ______________________________________
113: Close cover to continue __________________________________
114: Cover opened during job_________________________________
116: Magstripe not available __________________________________
117: Reader not available _____________________________________
118: Print ribbon type problem_________________________________
119: Print ribbon not supported ________________________________
120: User paused the printer ___________________________________
121: Print ribbon not identified _________________________________
122: Magstripe format problem ________________________________
123: Insert new card side 1 up _________________________________
124: Insert same card side 2 up ________________________________
149: Option not installed ______________________________________
150: Print while unlocked ______________________________________
151: Failed to lock ____________________________________________
172: Insert cleaning card ______________________________________
173: Improper shutdown ______________________________________
Laminator Messages______________________________________________
177: Laminator not available __________________________________
196: Laminator error critical____________________________________
197: Laminator entry card problem ____________________________
198: L1 area card problem ____________________________________
200: Laminator exit card problem______________________________
201: L1 supply problem ________________________________________
202: L1 supply out or missing ___________________________________
203: L1 supply type problem ___________________________________
204: L1 supply not supported __________________________________
205: L1 supply not identified ___________________________________
206: L2 supply problem ________________________________________
211: L1 heater problem _______________________________________
212: L2 heater problem _______________________________________
213: L1 heater sensor problem _________________________________
214: L2 heater sensor problem _________________________________
x
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4-46
4-46
4-46
4-46
4-46
215: L1 heater roller problem __________________________________ 4-46
217: Debow problem _________________________________________ 4-47
218: Impresser problem _______________________________________ 4-47
219: Impresser sensor problem _________________________________ 4-47
220: Impresser heater problem ________________________________ 4-47
221: Bar code scanner problem _______________________________ 4-47
222: Firmware version mismatch _______________________________ 4-47
223: Laminator system mismatch ______________________________ 4-48
Driver-Only Messages_____________________________________________ 4-48
500: The printer is not available ________________________________ 4-48
501: The printer connection was lost ___________________________ 4-48
502: The card data is missing or is not usable ___________________ 4-48
505: USB communication issue _________________________________ 4-49
506: A card is currently processing _____________________________ 4-49
507: The printer is unlocked ____________________________________ 4-49
508: The printer is shutting down _______________________________ 4-49
509: The printer is offline or suspended _________________________ 4-50
Driver SDK Messages______________________________________________ 4-50
511: Cannot lock or unlock the printer. Locks are not installed. __ 4-50
512: Cannot lock or unlock the printer. The password is incorrect or
invalid. _______________________________________________________ 4-50
513: Cannot lock or unlock the printer. The printer is busy. _______ 4-50
514: Cannot lock or unlock the printer. The cover is open._______ 4-50
515: Failed to lock or unlock the printer. The locks did not function. 4-50
516: Timeout expired before bar code could be read. __________ 4-50
517: Wrong printer job ID. _____________________________________ 4-51
Using the DPCL Service Utility _________________________________________ 4-51
Install the Utility on the PC_________________________________________ 4-51
Connect the PC and Printer over a Network _______________________ 4-51
View Printer Message Log_________________________________________ 4-53
Lock and Unlock Card Production ________________________________ 4-53
Back Up and Restore Settings _____________________________________ 4-54
Print Misadjustment _______________________________________________ 4-55
Routine Maintenance ____________________________________________
Required Tools and Supplies ___________________________________________
For Remove and Replace Procedures ______________________________
For Magnetic Stripe Option ________________________________________
For Smart Card Option_____________________________________________
Avoiding Electrostatic Discharge_______________________________________
Screw Torque Specifications ___________________________________________
Preventive Maintenance Procedures ___________________________________
Mechanical Inspection ____________________________________________
xi
5-1
5-2
5-2
5-3
5-3
5-4
5-5
5-6
5-6
Cleaning the Interior of the Printer _________________________________
Lubricating the Grease Points _____________________________________
Lubricating the Magnetic Stripe Assembly _________________________
Cleaning the Rollers ______________________________________________
Maintaining the Smart Card Module ______________________________
Visual Inspection for Card Quality _________________________________
Maintaining the Magnetic Stripe Module __________________________
Operator Maintenance_______________________________________________
Cleaning the Thermal Printhead (TPH) _____________________________
Using the Cleaning Card__________________________________________
Updating Printer Settings______________________________________________
Replacing the Print Engine Drive Board ________________________________
Downloading Settings File for Board _______________________________
Updating Settings ________________________________________________
Enabling the Proprietary Magnetic Stripe Option _______________________
Downloading Settings File for Magnetic Stripe Option ______________
Updating Settings ________________________________________________
Verifying Proprietary Magnetic Stripe Option _______________________
Removal and Replacement_______________________________________
5-12
5-12
5-16
5-17
5-19
5-21
5-21
5-22
5-22
5-23
5-25
5-27
5-27
5-28
5-29
5-29
5-30
5-30
6-1
Introduction to this Chapter____________________________________________ 6-4
General Notes ____________________________________________________ 6-4
Required Tools ____________________________________________________ 6-4
Safety ____________________________________________________________ 6-4
Symbols __________________________________________________________ 6-4
Printer Components _______________________________________________ 6-5
Cable Routing ____________________________________________________ 6-5
Transport Cables_______________________________________________ 6-5
Smart Card and Duplex Cables ________________________________ 6-6
Swingarm Cable Routing_______________________________________ 6-7
Freeing Cables from Clamps _______________________________________ 6-8
Functional Block Diagrams _________________________________________ 6-8
Exterior Components __________________________________________________ 6-9
Ribbon Cartridge__________________________________________________ 6-9
Ribbon Cartridge Lid _____________________________________________ 6-10
Swingarm Lid and Enclosure Flap__________________________________ 6-12
Enclosures _______________________________________________________ 6-13
Card Tray____________________________________________________________ 6-15
100-Card Input Lid and Cover_____________________________________ 6-15
Tray Assembly and Manual Feed __________________________________ 6-16
Front Bezel, LCD Interface Panel, and 25-Card Output _____________ 6-17
LCD Interface Panel Routing ______________________________________ 6-18
Simplex Base _____________________________________________________ 6-19
Tray _________________________________________________________________ 6-20
Pick Gate and Pick Gate Spring___________________________________ 6-20
Pick Roller Assembly ______________________________________________ 6-21
xii
Picker Crankshaft, Pick Block Assembly ____________________________ 6-22
Transport Components _______________________________________________ 6-23
Timing Belt _______________________________________________________ 6-23
Belt Plate ________________________________________________________ 6-24
Platen Roller Assembly ____________________________________________ 6-25
Card Guide/Spring and Registration Drive Assembly________________ 6-26
Drive Pulleys and Idler Pulleys _____________________________________ 6-28
Backup Roller, Registration Backup and Top Cleaning Rollers _______ 6-29
Backup Roller Springs and Brackets, Capstan Roller Sleeve _________ 6-30
Belt Tensioner and Spring, Idler Pulleys _____________________________ 6-31
Cam Slide _______________________________________________________ 6-32
Cam, Cam Shaft, Cam Gear, Cam Idler Gear _____________________ 6-33
Swingarm Components ______________________________________________ 6-34
Ferrite Bead______________________________________________________ 6-34
Thermal Printhead (TPH) __________________________________________ 6-35
Fan ______________________________________________________________ 6-36
Swingarm, Torsion Spring, Damper_________________________________ 6-37
Print Engine Sensors __________________________________________________ 6-40
Head Latch Sensor _______________________________________________ 6-40
Ribbon Index Sensor, Ribbon Bridge _______________________________ 6-41
Card Input Sensor ________________________________________________ 6-42
Card Exit Sensor __________________________________________________ 6-43
Cam Home Sensor _______________________________________________ 6-44
Print Engine Motors ___________________________________________________ 6-45
Pick Motor and Pick Drive Gear ___________________________________ 6-45
Ribbon Motor, Ribbon Drive Gear _________________________________ 6-46
Cam Drive Motor Assembly _______________________________________ 6-47
Transport Motor Assembly_________________________________________ 6-48
Circuit Board Components ___________________________________________ 6-49
Print Engine Drive Board __________________________________________ 6-49
Sensor Encoder Cable Assembly (RFID) ____________________________ 6-51
Ribbon Motion Magnetic Encoder Board __________________________ 6-53
Magnetic Stripe Option ______________________________________________ 6-54
Magnetic Stripe Board ISO (IAT) and JIS (NTT) ______________________ 6-54
Magnetic Stripe Optical Encoder and Mounting ___________________ 6-55
Magnetic Stripe Rocker Assembly and Read/Write _________________ 6-57
Smart Card Options __________________________________________________ 6-58
Smart Card Assembly, Simplex ____________________________________ 6-58
Smart Card Assembly, Duplex _____________________________________ 6-59
Smart Card Circuit Board _________________________________________ 6-60
Smart Card Lid Assembly, Duplex__________________________________ 6-61
Smart Card Contact Board _______________________________________ 6-62
Smart Card Station Spring_________________________________________ 6-63
Smart Card Gate Roller ___________________________________________ 6-64
Smart Card Cable Connector_____________________________________ 6-65
xiii
Card Guide ______________________________________________________
Dual Reader Board (Contact/Contactless) ________________________
i-Class Read/Write or PC Prox Board _______________________________
Duali Single Wire Smartcard _______________________________________
Duplex Components _________________________________________________
Duplex Frame ____________________________________________________
Duplex Home Sensor _____________________________________________
Duplex Transport and Flipper Motors_______________________________
Duplex Circuit Board _____________________________________________
Duplex Backup Idler Roller, Springs ________________________________
Flipper Assembly and Transport Gear ______________________________
Duplex Drive Rollers and Body Gear _______________________________
xiv
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6-71
6-73
6-73
6-74
6-75
6-76
6-77
6-78
6-79
Chapter 1: Introduction
This chapter provides an introduction to card printer components
and the Printer Manager application.
About This Manual ___________________________________________________ 1-3
Intended Audience _______________________________________________ 1-3
Symbol Conventions _______________________________________________ 1-3
Precautions __________________________________________________________ 1-3
Introduction to Printers________________________________________________ 1-4
Simplex Printer with Smart Card Option _____________________________ 1-4
Duplex Printer _____________________________________________________ 1-5
SD460 System _____________________________________________________ 1-6
Options Available ____________________________________________________ 1-7
Functional Block Diagrams ___________________________________________ 1-9
Simplex Print Engine _______________________________________________ 1-9
Duplex Print Engine _______________________________________________ 1-10
Basic Integrator Smart Card _______________________________________ 1-11
SCM Dual Smart Card ____________________________________________ 1-12
Duplex Module ___________________________________________________ 1-14
Printer Components _________________________________________________ 1-15
Sensors___________________________________________________________ 1-15
Motors ___________________________________________________________ 1-16
Circuit Boards ____________________________________________________ 1-17
LCD Panel __________________________________________________________ 1-18
Status Lights ______________________________________________________ 1-19
LCD Menu Options _______________________________________________ 1-20
Printer Manager _____________________________________________________ 1-23
Zero Configuration Networking ____________________________________ 1-23
Connecting to Printer Manager ___________________________________ 1-23
Ethernet Connection __________________________________________ 1-24
USB Connection ______________________________________________ 1-25
Logging in to Printer Manager ________________________________________ 1-26
Printer Manager Language Support _______________________________ 1-26
User Access Levels ________________________________________________ 1-26
Printer Manager Passwords________________________________________ 1-26
Printer Manager Menu Options _______________________________________ 1-27
Status ____________________________________________________________ 1-27
SD Series Card Printers Service Manual
1-1
Printer Settings ___________________________________________________
Troubleshooting __________________________________________________
Maintenance ____________________________________________________
Log Out__________________________________________________________
Firmware Update ____________________________________________________
1-2
1-28
1-38
1-41
1-41
1-42
Introduction
About This Manual
This chapter give general information about the printer.
Intended Audience
This manual is for authorized representatives who are responsible for the
maintenance, service, and repair of the card printer. Service representatives must
complete an authorized service training course and be certified prior to servicing
the printer.
Symbol Conventions
The following symbols are used in this manual.
ESD!
Designates a procedure that involves electrostatic discharge sensitive
components. ESD procedures should be used.
Caution: Indicates a strong cautionary message to avoid serious
damage to the printer.
Warning: Indicates a strong warning message to prevent personal
injury to the technician.
Indicates a reminder message or other additional information for the
customer engineer.
Warns the technician to wear safety glasses during the procedure.
Precautions
While working with the printer, observe the following precautions:
•
Remove power and unplug the system when performing maintenance
•
Remove watches, jewelry, and rings before servicing equipment
•
Avoid wearing loose clothing when working around moving parts
•
Be aware of your surroundings when servicing the equipment
•
Ensure that you are properly grounded at all times
•
Wear protective eyewear when replacing parts on the system
For more safety information refer to the “Safety” section in the Revision Log and
“Avoiding Electrostatic Discharge” on page 5-4.
1-3
Introduction to Printers
Simplex Printer with Smart Card Option
The figure below show the main parts of the SD260L card printer with the Smart
Card option. The main features and options available for the printer are:
• Single side color and monochrome
printing
• 100-card output tray option
• 100-card input tray or manual feed option
• Kensington lock
• Output tray with 25-card capacity
• Magnetic stripe options (ISO and JIS)
• Smart card reader/writer
1-4
Introduction
Duplex Printer
The figure below shows the main parts of the SD360 and SD460 duplex card
printer. The main features and options available for the printer are:
• Double side color and monochrome
printing
• 200-card input tray with card detection
option
• 100-card input tray
• 100-card output tray option
• Output tray with 25-card capacity and
reject tray
• Kensington lock
• Smart Card reader/writer
• Magnetic stripe options (ISO and JIS)
1-5
SD460 System
The figure below shows the main parts of the SD460 system, including a printer
and laminator components:
• Duplex printer
• Optional impresser component
• L1 and optional L2 lamination modules
1-6
Introduction
Options Available
The SD series printers have the following components as standard (S), optional (OP) or not available (NA).
DP= Desktop Printer
FII- Financal Instance Issuance
S= Standard
OP= Option
NA= Not Available
Y= Yes
N= No
FK= Field Kit
SD260L
DP
SD360
DP
SD460
DP
S
S
NA
Simplex
S
NA
S
Duplex
NA
S
S
Printing
S
S
OP
Magnetic Stripe
OP
OP
OP
JIS Magnetic Stripe
FK
FK
OP
JIS ISO (Dual) Magnetic Stripe - Japan
NA
NA
NA
S
S
S
S
S
S
NA
NA
NA
Reject Tray
S
S
S
Manual Feed
S
S
S
Input Hopper (100)
S
S
S
Input Hopper (200)
FK
FK
FK
MultiHopper (600)
NA
NA
NA
Sales Channel
Standalone Printer
Data Encryption - D3 board only for SD/CD
View
LCD Screen
Touch Screen*
Trays and Hoppers
Output (25)
S
S
NA
Output (100)
FK
FK
S
Output Cover (secure)
NA
NA
NA
1-7
SD260L
SD360
SD460
Locks and Alarms
Tilt Alarm
NA
NA
NA
Lock Cable
OP
OP
OP
Locks Mechanical - Printer
NA
NA
NA
Locks Mechanical - Input Hopper
NA
NA
NA
Locks - Reject Tray
NA
NA
NA
USB*
S
S
S
Ethernet
S
S
S
DPCL2 - only D3 boards
S
S
S
NA
NA
NA
Y
Y
Y
Software and Drivers
Activation
XPS Driver
SDK
Y
Y
Y
CardWizard
N
N
N
OpenCard
N
Y
N
CPX
N
N
N
OP
OP
OP
SCM (contact/contactless)
OP
OP
OP
Duali (contact/contactless)
NA
NA
NA
3rd party contactless only
OP
OP
OP
3rd party contact only
OP
OP
OP
HID pcProx
OP
OP
OP
HID reader only
OP
OP
OP
HID reader/writer
OP
OP
OP
Embosser
NA
NA
NA
Embosser - 2nd wheel
NA
NA
NA
Indent
NA
NA
NA
Rear Indent
NA
NA
NA
Laminator
NA
NA
S (SLM)
L2
NA
NA
OP
Serial Laminate
NA
NA
NA
Bar Code Reader/Serial Laminate Scanner
NA
NA
NA
OCR Reader
NA
NA
NA
Impresser/Tactile
NA
NA
OP
Electro/mechanical Locks
NA
NA
NA
Smart Card - Single Wire
Duali (contact/contactless) - only D3 boards
Smart Card - Loosely coupled
Embosser
Laminator
1-8
Introduction
Functional Block Diagrams
Simplex Print Engine
1-9
Duplex Print Engine
1-10
Introduction
Basic Integrator Smart Card
1-11
SCM Dual Smart Card
1-12
Introduction
Duali Single-Wire Smart Card
1-13
Duplex Module
1-14
Introduction
Printer Components
This section describes the sensors, motors, and circuit boards in the printers.
Sensors
The sensors that may be in a card printer are listed in the following table. See
“Functional Block Diagrams” on page 1-9 for connection information.
Name
Function
Card Present
(Manual Feed)
This optional sensor on manual input printers detects when a card is
present and ready to be picked.
Card Present
(Hopper Empty)
This sensor in the input hopper frame detects when the card input tray is
empty.
Card Input
This wide-slot photocell detects the presence of a card entering the print
engine from the input hopper.
Ribbon Motion
The sensor body is a chip that monitors the magnetic field of the magnet
on the ribbon cartridge to track the movement of the ribbon. Also see,
“Ribbon Motion Encoder Board” on page 1-17.
Ribbon Index
This sensor is used to determine the position of the print ribbon panels. The
sensor bounces a beam off the reflective sticker on the printhead. When
the index mark, or K-panel, on the ribbon passes between the sensor and
the reflector, the beam is broken (not reflected). The Y, M, C, & T panels
do not interrupt the beam.
Head Latch
This sensor detects when the swingarm is open.
Cam Home
As the printhead cam rotates, a flag on the cam interrupts the beam of
the cam sensor. This sensor allows the printer to detect the position of the
printhead lifters, which move the printhead away from the platen roller
when no printing is occurring.
Card Exit
Located just after the rear rollers on the right side of the printer, this sensor
detects the presence of a card exiting the exit rollers.
MS Encoder
This encoder monitors the rotation of the idler roller in the magnetic stripe
module. It provides positional feedback to the module to ensure proper
magnetic encoding.
Flipper Home
This sensor determines the rotational position of the duplex flipper using
three flags that pass through the sensor.
1-15
Name
Function
Smart Card
Registration/
Position
This sensor determines whether a card is present in the smart card
module.
Smart Card
Contact
This switch detects a contact smart card is in position.
Motors
A printer has two 24-volt DC motors used for ribbon movement and card
picking; their speed is controlled by pulse width modulation. All other motors
are stepper motors. See “Functional Block Diagrams” on page 1-9 for connection
information.
Name
Function
Pick Motor
This DC motor drives the card picking mechanism.
Transport Motor
This stepper motor drives the print engine.
Cam Motor
This stepper motor drives the mechanism that lifts the cam rollers and
printhead.
Ribbon Motor
This DC motor drives the print ribbon take-up roll.
Duplex Transport
Motor
This 2-phase (4-wire), 24-volt stepper motor turns the duplex drive rollers.
Duplex Flipper
Motor
This 2-phase (4-wire), 24-volt stepper motor rotates the entire flipper
assembly.
TPH Fan
The fan cools the thermal printhead (TPH). The airflow direction is toward
the heat sink.
1-16
Introduction
Circuit Boards
The printer has several boards that are connected to the print engine drive board.
See “Functional Block Diagrams” on page 1-9 for connection information.
Name
Function
RFID Antenna Board
The RFID antenna circuit board is a simple loop antenna that
communicates with the RFID chip in the ribbon supply spool.
Magnetic Stripe
Daughter Board
The circuit board controls the magnetic stripe head and provides an
interface for the encoder.
Ribbon Motion
Encoder Board
When the ribbon cartridge is installed in the printer the diametric
magnet is located next to the Ribbon Encoder board. The diametric
magnet is a specially built magnet that has its poles on opposites
halves of the round surface. As the magnet rotates, the sections of the
magnet where the two poles meet pass the chip on the encoder
board and generate pulses. An 8-bit chip monitors the magnitude of
the magnetic field to determine true position. It measures 256
interrupts per revolution.
Smart Card Daughter
Board
This circuit board provides a communication interface between the
application computer and the smart card module. Most of the
communication aspects and the data transfer are controlled by an
external software application that is transparent to the printer.
Duplex Board
This circuit board contains two stepper motor drivers for the duplex
transport and duplex flipper motors. The sensor signal is passed
through directly from the main control board.
1-17
LCD Panel
The LCD panel, beneath card input hopper in the printer shows printer and
laminator status information. It has menu options to run a cleaning card, view
printer information, and configure the printer.
Pressing the down or up arrow while at the ready screen to access the quick
menu. This allows quick access to vital system information, including the items
below.
•
Printer model
•
Printer serial number
•
IP address
•
Laminator firmware revision
•
Laminator serial number
The power button is a switch that you press to power on the printer and the other
components of the SD/CD series system. The four flat buttons on the panel
require that you just pass your finger near the buttons to activate them. They do
not respond to being pushed or touched with an object.
•
Power button - Press to power on; press and hold (1 second) to power off.
•
User button - Touch lightly to pause and resume printing or respond to, and
clear, error conditions. The user button is also an indicator light.
The following sections list the status indicator light conditions and the LCD menu
information. For adjustment information see Front Panel Options in the printer
service manual.
1-18
Introduction
Status Lights
The following table lists the status light conditions on the LCD panel and
indicates what the lights mean.
Light
Light Condition
Indication
Ribbon
Status Light
Off
Print ribbon and embosser supply is okay.
Flashing green
Laminator supply is low if flashing slowly (every 2 seconds) or
out if flashing quickly (every 1/2 second).
Flashing amber
Print ribbon is low if flashing slowly (every 2 seconds) or out if
flashing quickly (every 1/2 second).
Off
Cards are OK.
Flashing green
There is a problem with the cards related to the laminator
component. The light flashes quickly (every 1/2 second).
Flashing amber
There is a problem with the cards related to the printer
component. The light flashes quickly (every 1/2 second).
Off
System is powered off or suspended.
Green
System is ready.
Flashing green
If the light flashes slowly (every 2 seconds), the system is busy. If
the light flashes quickly (every 1/2 second), the printer has a
hardware error concerning the laminator.
Amber
The system is not ready, or the power button was pressed to
power off the printer.
Flashing amber
If the light flashes at a medium rate (every 1 second), the
system has a problem with an error code displayed on the
LCD. If the light flashes quickly (every 1/2 second), the printer
has a hardware error concerning the printer.
Cycles through
colors quickly
Indicates doors are not closed and/or locked.
Card Status
Light
User Button
and Light
1-19
LCD Menu Options
The following is an overview of the LCD panel menu for the card printers. The
table below describes the items and options from the Main menu.
Main Menu Option
Submenu Item
Option
Maintenance
Cleaning Card
Runs the cleaning card. The following options are
available:
Printer
Laminator (SD460 only)
Test Card
Runs the test card.
Exit
Returns from the Maintenance to the Main menu.
1-20
Introduction
Main Menu Option
Submenu Item
Option
Status
Serial Number
Displays the serial number of the card printer.
Versions
The following options are available:
Firmware
FPGA
Embosser
Smartcard
Opencard
Laminator
Exit
Network Status
Address Mode
IP Address
Subnet Mask
Gateway Address
MAC Address
Exit
USB IP Address
Displays the USB IP address, if any
Card Counters
The following counters are available:
Card Count
Cycle Count
Completed Card
Rejected Cards
Lost Cards
Exit
Magstripe
Coercivity
Exit
Supply Type
Displays the type of ribbon or overlay being used in the
printer or laminator, if any. The menu will also display a
percentage of supply remaining.
Exit
Returns from the Maintenance to the Main menu.
1-21
Main Menu Option
Submenu Item
Option
Configuration
Network
DHCP/Static IP
IP Address
Subnet Mask
Gateway Address
Apply/Restart
Exit
LCD Backlight
Sets the LCD backlight intensity.
Range: 0 to 100%
Default: 100%
Activate
1-22
K Power
-100 to 100
Mag Stripe
Coercivity (High, Low, NTT1, NTT2, NTT3, Apply, Exit)
Exit
Speaker
Enable or disable
Opencard
Enable or disable (if option is available)
Menu
Style: Modern
Exit
Language
Select, reset, and apply a language
Enable
Disable
Enable the printer after receiving it or disable it for
shipping (financial printers only).
Exit
Exit to Main menu.
Introduction
Printer Manager
Printer Manager is the printer interface that contains the card printer settings,
options, and diagnostics. The menus are used to find printer status, make
adjustments, use tests to troubleshoot, perform exercises for preventive
maintenance, and upload printer settings files.
There are three access level logins for Printer Manager: user, administrator, and
service. Menu options are appropriate for each access level.
The card printer connects to a PC or network using either a USB or an Ethernet
cable. Printer Manager is accessed via a Web browser. Supported Web browsers
include Internet Explorer v7, 8 and 9 and Firefox v3.6.
Zero Configuration Networking
When a USB connection is used, the printer uses a USBNET port and zero
configuration networking. Essentially, this enables the printer to use Ethernet
over the USB connection.
After the USB driver has been installed, the printer will have a USB IP (Internet
Protocol) address. Additionally, because zero configuration networking enables
automatic discovery of computers, devices, and services on IP networks, a thirdparty application discovery program may be used.
Bonjour is Apple’s trade name for its free implementation of discovery protocol
that can be used with Printer Manager. Bonjour can be downloaded from the
Apple Website (www.apple.com). Bonjour support and manuals are also
available from Apple.
Bonjour is only used with USB-connected printers, not Ethernet.
Advantages of using this approach:
•
All IP protocols are also available over USB.
•
The printer can operate as a Web Server over Ethernet and USB.
•
Both Ethernet and USB use the same Internet security levels.
•
The USB operates as a class 2.0 device and is faster than Ethernet.
Connecting to Printer Manager
Connect to Printer Manager using either an Ethernet connection and the IP
address of the printer, or by using the USB IP address of the printer. When the
connection is established, Printer Manager operates in the same way over either
connection.
1-23
If you are installing both the USB driver and the Ethernet driver, install the USB
driver first because the Ethernet connection takes precedence over the USB
connection.
If you install Ethernet first, you must disconnect the Ethernet cable and reboot the
printer before you can install the USB driver correctly. The USB connection will
not work when the Ethernet cable is connected.
Ethernet Connection
Follow the steps below to connect to Printer Manager using a browser and
Ethernet connection.
Make sure the printer is configured for DHCP (Dynamic Host Configuration
Protocol) as described in “LCD Menu Options” on page 1-20.
1. Connect the card printer to the network using an Ethernet cable and turn the
printer on.
2. Use the LCD panel to determine the IP address of the printer.
A. At the Ready status touch the User button once.
B. At the Suspended Menu Available status touch Enter once.
C. Touch the Down Arrow once to change the selection from Maintenance to
Status. Touch Enter once.
D. Use the Down Arrow to scroll to Network Status and touch the Enter
button.
E. Use the Down Arrow button to scroll to IP Address and touch Enter.
F. Write down the IP address.
G. Exit the Status Menu by touching the User button until Ready again
displays.
3. Using Internet Explorer or Firefox, open a browser window and enter the IP
address of the printer into the address bar (example: “https://xxx.xx.xxx.xx”)
Use https only when using a secure network connection. Use http when using
a non secure network connection.
The Printer Manager login will appear.
1-24
Introduction
USB Connection
Follow the steps below to connect to Printer Manager using a browser and a USB
connection.
1. Connect the card printer to the USB port and turn the printer on.
2. If you wish, use the LCD panel to confirm the Serial Number.
A. At the Ready status touch the User button once.
B. At the Suspended Menu Available status touch Enter once.
C. Touch the Down Arrow once to change the selection from Maintenance to
Status and then touch Enter to select it.
D. Use the Down Arrow to scroll to Serial Number and then touch Enter to
select it.
The Serial Number will be displayed.
3. Open a browser window and enter the Serial Number of the printer into the
address bar (example: “https://xxxxxx.local”
The Printer Manager login will appear.
Use
1-25
Logging in to Printer Manager
The initial Printer Manager screen allows the user to select a language and to log
in with a user name and password that determine access levels. Passwords may
either be blank (0 characters) or contain 4 to 32 characters. The characters allowed
are a-z, A-Z, 0-9, +, and /.
Printer Manager Language Support
When you start Printer Manager, first select the language to use from a list
offered in the login window (see sample list in previous figure).
User Access Levels
The access level determines which menu items, options, and adjustments are
available.
WebUser —Allows printing of test cards and minor adjustments.
WebAdmin —Allows an administrator to set up a test card, make minor
adjustments to the printer, configure options, and use diagnostics tools for
troubleshooting. The Administrator level has permission to install feature
upgrades on the printers.
WebService —Permits service access to all of the WebAdmin adjustments with
additional access to offset adjustments.
Printer Manager Passwords
For full service access open Printer Manager, select a language, select WebService
as your access level, and enter the service password (926918).
WebService access can change the passwords for WebService, WebAdmin, and
WebUser. WebAdmin can change only the passwords for WebAdmin and WebUser.
Changing the password from the default value is not recommended. Guard
the password from unauthorized users.
1-26
Introduction
Printer Manager Menu Options
The following sections list and describe the options on the Printer Manager
menus accessible to the Service level login. The Printer Manager has a hover-text
feature in the interface that shows the settings definition information when the
cursor hovers over the description column.
The following tables list menu options and their parameters and describe the
purpose of the options. See “Viewing Printer Status” on page 3-3 and
“Troubleshooting” on page 4-1 for more information on Printer Manager settings.
Status
The options on the Status menu display information about the SD/CD series
system; they cannot be changed here.
Menu Option
Purpose
VPD
Display vital product data (VPD) including the manufacturer, model, options,
and software/firmware version information. This information may be needed
for service providers.
Printer Status
Display printer status information including the current state, time in seconds
system has been on, and any current conditions.
Supplies
Display detailed ribbon information including:
• Ribbon Part Number/Lot Code/Remaining/Max Length/Module/
Supported/ Action Sequence
• Ribbon Supply Code/Special Code/Region Code/Product Code
Audit Data
Display detailed card printer usage data such as how many cleaning cards
have been run, how many good cards were produced, and how many cards
have been lost.
About Printer
Manager
Display information about the Printer Manager firmware version and copyright.
1-27
Printer Settings
The options on the Printer Setting menu display printer settings and laminator
offsets for adjustments.
Menu Option
Description
Purpose
Communication
1. EthAddressMethod
2. EthDnsAddress1
3. EthDnsAddress2
4. EthDnsSearchSuffix
5. EthGatewayAddress
6. EthIPAddress
7. EthMacAddress
8. EthSubnetMask
9. UsbAddressMethod
10. UsbDeviceMacAddres
11. UsbHostMacAddress
12. UsbIpAddress
13. UsbSubnetMask
Display the default and current values of
the communication method (DHCP or
static) and address information.
Changes the current information or
restores the default values.
Activity Log
1.
2.
3.
4.
5.
6.
7.
8.
Allow you to enable or disable both
internal and external logs and designate
the external log server IP address. You
can set activity log filters to notify at
different levels or turn them off. Change
the current values or restore default
values. (Soap is Simple Object Access
Protocol.) The list of filter actions
includes: Emergency, Alert, Critical,
Errors, Warning, Notice, Information,
Debug, and Disabled.
1-28
ExternalLog
ExternalLogServer
FilterCardActions
FilterConfigChanges
FilterJobStates
FilterSoapMsgs
FilterSystem
InternalLog
Introduction
Menu Option
Description
Purpose
Behavior
1. ActivityLogExternal
2. ActivityLogInternal
3. CPX
4. DPCL
5. DPCL2
6. DPCL2Secure
7. DPCLSecure
8. NetworkAccessControl
9. Plugin
10. RejectHopper
11. Remake
12. RemakeMethod
13. RetrieveDataTimeout
14. RibbonInitialize
15. SNMP
16. UnlockTimeout
17. WebServerSecure
Display the default and current status of
printer operation and encoding
methods. Change the current
information or restore the default values.
All default to Disabled except Ribbon
Initialize.
Never change the Web Server and Web
Server Secure options; the printer would
be unable to receive communications.
VitalProduct
Data (VPD)
1.
2.
3.
4.
5.
AgencyModelName
Display the default and current printer
information. Change the current serial
number (for board change) or restore
default values.
1.
2.
3.
4.
BacklightBrightness
FrontPanel
Manufacturer
ModelName
PartNumber
SerialNumber
KeySenseLevel
LCDConfigMenu
LED CardsPickedTo
Cleaning
5. LED PrintheadCyclesTo
Cleaning
6. LED Ribbon Low
Display the default, current values, and
allowed ranges for the front panel
options. Change the current information
or restore the default values.
7. Speaker Enabled
1-29
Menu Option
Description
Purpose
Print
1. CableCompMaxStrobe
2. CardRegistration
3. CardRegistrationCalibratio
For printers with a printhead installed,
displays the default, current values, and
allowed ranges for the print options.
Change the current information or
restore the default values. See
descriptions of these items in “Print
Settings” on page 3-11. Some items may
not be available in the printer.
n
4. ColorManagement
5. FanTempOn
6. FPowerCalibration
7. FPowerCalibration
8. FPowerDuplex
9. KCustom1Power
10. KCustom1Power1200DPI
11. KCustom1Power600DPI
12. KFineText
13. KPower
14. KPower1200DPI
15. KPower600DPI
16. KPowerCalibration
17. KPowerCalibration1200D
PI
18. KPowerCalibration600DPI
19. KPowerDuplex
20. KWhiteShade
21. LeadTrim
22. RibbonOffset
23. RibbonStripeOffset
24. SettingsGroupPurpose
25. TPower
26. TPowerCalibration
27. TPowerDuplex
28. TrailTrim
29. TWhiteShade
30. VerticalOffset
31. YMCMinShade
32. YMCPower
33. YMCPower600
34. YMCPowerCalibration
35. YMCPowerCalibration600
36. YMCPowerDuplex
37. YMCPowerNosRGB
38. YMCWhiteShade
1-30
Introduction
Menu Option
Description
Purpose
Pick
1.
2.
3.
4.
5.
6.
allowed ranges for the pick offsets.
restore the default values.
Transport
MotorPWM
PickAutoTimeout
PickCardOffset
PickManualTimeout
PickReversePwm
PickReverseTime
1. BoostedTransportSpeed
2. EjectHopperSpeed
3. FinalEjectSpeed
Display the transport speed options.
StandardHopper
4. TransMedSpeed
5. TransportSpeed
Flipper (Duplex/
Transfer)
1. EmbossCardOut
2. FlipperEmbossAngle
3. FlipperFlippedAngle
4. FlipperHomeOffset
5. FlipperLaminatorAngle
6. FlipperRegistration Offset
7. FlipperRejectAngle
8. FlipperRotationSpeed
9. FlipperSmartAngle
10. FlipperTransRamp
limits for the transfer assembly (duplex/
flipper) that delivers cards to the
embosser. Change the current
information or restore the default values.
DownRegSpeed
11. LaminateCardOut
12. SmartInOffset
13. SmartOutOffset
1-31
Menu Option
Description
Purpose
MagStripeGeneral
1. Attempts
2. AutoCoercivity
3. Coercivity
4. DataFormat1
5. DataFormat2
6. DataFormat3
7. NoDataDisableTrack
8. ReadTrack1
9. ReadTrack2
10. ReadTrack3
11. SSA1
12. SSA2
13. SSA3
14. StripeEncoderMultiplier
15. StripeReadEntryOffset
16. StripeReadEventOffset
17. StripeReadReverse
limits for general magnetic stripe
options. Change the current information
or restore the default values.
Coercivity can be HICO, LOCO, NTT1,
NTT2, or NTT3.
Data Formats can be: IATA, ABA, TTS, JIS,
AAMVA, AAMVA-ECC, VING, SAFLOK,
TIMELOX, ONITY, CUSTOM, BINARY75,
BINARY210, or None.
SSA# values can be -4 to 4.
CamUpOffset
18. StripeReadSpeed
19. StripeWriteEventOffset
20. StripeWriteFwdEntry
Offset
21. StripeWriteFwdUp Offset
22. StripeWriteSpeed
23. WriteTrack1
24. WriteTrack2
25. WriteTrack3
1-32
Introduction
Menu Option
Description
Purpose
MagStripeCustom
Track(1-3)
1. Custom Char High (#)
2. Custom Char Length(#)
3. Custom Char Low(#)
4. Custom Char Mask(#)
5. Custom Char Max(#)
6. Custom Density(#)
7. Custom End Sentinel(#)
8. Custom Lrc(#)
9. Custom Parity(#)
10. Custom Sds Nulls(#)
11. Custom Sds Records(#)
12. Custom Sds Ss(#)
13. Custom Start Sentinel(#)
limits for custom magnetic stripe options
for tracks (#=1, 2, or 3). Allow changes to
be made to the current information or
the default values to be restored.
Options
Emboss Module Expected
Emboss Module Indent
Emboss Module Top
Indicate if embossing/indent/topping
and laminating are used.
1-33
Menu Option
Description
Purpose
Laminator
1. CardExitOffset
2. CardExitSpeed
3. CardExitSpeedWith
limits for the laminator component
operation.
Impress
4. CardExitWithImpress Offset
5.
6.
7.
8.
CardInputPosition
CardRejectOffset
CardRejectSpeed
DebowBottomHome
Offset
9. DebowDelay
10. DebowHomeOffset
11. DebowRegOffset
12. DebowSpeed
13. ExceptionCardDebow
Direction
DistanceDown
DistanceUp
DwellMs
17. ExceptionCardImpressDe
pth
18. ExceptionCardImpressDw
ellTime
19. ExceptionCardImpressPos
itionOffset1
itionOffset2
itionOffset3
22. ExceptionCardImpressTe
mperature
23. ExceptionCardNumberOf
Impresses
24. FlipperAngledAngle
25. FlipperEntrySpeed
26. FlipperExitSpeed
27. FlipperFlipAngle
28. FlipperHomeOffset
1-34
Introduction
Menu Option
Description
Laminator (Cont.)
29. FlipperL2LoadOffset
30. FlipperLoadOffset
31. FlipperRejectAngle
32. FlipperRotationSpeed
33. FlipperVerticalAngle
34. HeaterMinutesToPower
Purpose
Save
35. Hopper1CardDebow
Direction
DistanceDown
DistanceUp
DwellMs
39. Hopper1CardImpress
Depth
DwellTime
PositionOffset1
PositionOffset2
PositionOffset3
Temperature
45. Hopper1CardNumberOfI
mpresses
46. ImpresserHomeOffset
47. ImpresserRegister Speed
48. ImpresserSpeed
49. L2CoolingTime
50. MfgCardRegOffsetL1
51. MfgCardRegOffsetL2
52. MfgImpressDepth
53. MfgImpressPosition Offset
54. MfgOverlayRegOffset L1
55. MfgOverlayRegOffset L2
1-35
Menu Option
Description
Laminator (Cont.)
56. Model
57. RollerL1CustomSpeedOffs
Purpose
et
58. RollerL1CustomTemp
Offset
59. RollerL1RubberSpeed
Offset
60. RollerL1RubberTemp
Offset
61. RollerL2CustomSpeedOffs
et
62. RollerL2CustomTemp
Offset
63. RollerL2RubberSpeed
Offset
64. RollerL2RubberTemp
Offset
65. RollerTypeInstalledL1
66. RollerTypeInstalledL2
67. ScanBarCodeRetries
68. SerialNumber
1-36
Introduction
Menu Option
Description
Purpose
Laminate Type
1. CardPatchLength
2. CardRegOffsetL1
3. CardRegOffsetL2
4. CardStripDistance
5. DatabaseVersion
6. ExclusiveOverlayInL1
7. ExclusiveOverlayInL2
8. OverlayDisplayed Name
9. OverlayInitialStripLength
10. OverlayLoadedInL1
limits to control the overlay and topcoat
application to the card.
Name
11. OverlayLoadedInL2
Name
110. OverlayPartNumber
111. OverlayRegOffsetL1
112. OverlayRegOffsetL2
113. OverlaySpeed
114. OverlaySpeed
AdjustmentL1
115. OverlaySpeed
AdjustmentL2
116. OverlayStripStopped
Distance
117. OverlayTakeupLengthOf
fset
118. OverlayTemp
119. OverlayTemp
AdjustmentL1
120. OverlayTemp
AdjustmentL2
121. UserOverlay1Name
123. UserOver3Name
Update Password
Allows you to update and confirm a new password.
Note: Changing the service level password is not recommended.
Set Job Queue
State
Provides secure, remote control of print jobs.
1-37
Troubleshooting
The options on the TroubleShooting menu allow for testing motors, sensors, and
the fan. They provide access to audit and historical information.
Menu Option
Description
Description
Purpose
Sensors
Laminator Sensors:
Lam Angle Card Reg
Lam Debow Reg
Lam Debow Home
Lam Door Open
Lam Flip Card Reg
Lam Flip Home
Lam Impress Reg
Lam Impresser Home
Lam L1 Card Reg
Lam L1 Film Index
Lam L1 Film Motion
Lam L1 Heater Home
Lam L2 Card Reg
Lam L2 Film Index
Lam L2 Film Motion
Lam L2 Heater Home
Lam L2 Board Sense
Lam Vert Card Reg
Printer/Hopper Sensors:
Card Present
Card Input
Ribbon Motion
Ribbon Index
Head Latch (swingarm)
Cam Home
Card Exit
MS Encoder
Flipper Home
Smart Card Reg
Smart Card Contact
Displays the current
and historical value
along with the
jumper number and
type for each
sensor in the system.
Includes options to
start an update
and to reset the
sensor history. Reset
restores the current
settings. The
Continuous Update
Interval can be
adjusted from this
display.
Photocell sensors
change status
between 0 and 1;
encoders are
always indicated
with an X.
1-38
Introduction
Menu Option
Description
Purpose
Testcard
Input Hopper Number
Magnetic Stripe
Color
Monochrome
Topcoat
Second Topcoat
Test Pattern
Laminator Options
Debow
Impress
Description
Copies
Park Smart Card
Smart Card Park Time
Do Not Eject Card
Select from a number of test card
options and parameters for
instructions and possible cards and
patterns.
Test Transport
1. Direction
2. Speed
3. Steps
Display the default, current values,
and limits for the transport stepper
motor. Test the motor, make
changes to the current values, and
Test Pick
1. Direction
2. PWM
3. Time
and limits for the pick motor. Test
the motor, make changes to the
current values, and restore the
default values. Higher PWMs
increase speed but decrease
torque.
Test Cam
1. Direction
2. Speed
3. Steps
and limits for the cam motor. Test
default values.
Test Ribbon
1. PWM Value
2. Time
and limits for the ribbon motor. Test
default values.
1-39
Menu Option
Description
Purpose
Test Fan
Time
Display the default, current value,
and limits for the time to run the fan
in milliseconds. Test the fan, make
changes to the current value, and
restore the default value.
Test Flipper
1. Direction
2. Speed
3. Steps
and range for the flipper motor in
milliseconds and steps. Test the
flipper, make changes to the
current value, and restore the
default value.
Test Flipper Trans
1. Direction
2. Speed
3. Steps
and range for the flipper transport
motor in milliseconds and steps.
Test the stepper, make changes to
the current value, and restore the
default value.
SSA Test
Clicking Run starts the Start Sentinel Adjustment (SSA) Test command using
the settings. This calculates and stores the location of the magnetic stripe
start sentinel.
Activity Log
Download the audit information and save it to a text file. The Download
button is at the bottom of the window.
Reset Log
Reset the log. Clicking Run in the Reset Log submenu removes all of the
entries from the Audit Log.
Reset Counters
Reset only the Current Count counters in the printer. Life counters or total
card counts cannot be reset.
Printer Reset
Reset the card printer. Click Run in the Printer Reset submenu to perform a
cold reboot on the printer. This is the same as powering the printer off and
on again. After the printer has reset, you can resume using Printer Manager
without logging in again.
1-40
Introduction
Menu Option
Description
Purpose
Test Laminator
Select from these motors to test:
LamEntry
LamFlipper
LamFlipperTrans
LamL2Transport
LamL1Transport
LamL2Supply
LamL1Supply
LamDebower
LamImpresser
LamL2Heater
LamL1Heater
Test any of the motors in the
laminator component. Set the
direction, speed, and steps or time
to run the motor.
Maintenance
For more information about card printer maintenance see Chapter 6, “Preventive
Maintenance”.
Menu Item
Description
Cleaning
Allows you to run a cleaning card through the printer. Insert the card and
click Run.
Updates
Allows you to browse to a settings file and upload it to the printer.
Download
Settings
Allows you to browse to a settings file and upload it to the printer and
download settings.
Log Out
Select Log Out from the menu to close the current Printer Manager web session.
Click the “x” to close the browser window and go back to the previous session.
1-41
Firmware Update
The printers firmware can be updated using the Datacard firmware update
application, which is a Java based utility.
Make sure that your computer has Java JRE 7 or JRE 6 installed. The Java
firmware utility supports both 32 and 64 bit versions of JRE. If you do not
already have this installed on your computer, Java can be downloaded from:
•
•
http://www.oracle.com/technetwork/java/javase/downloads/jre7downloads-1637588.html
http://www.oracle.com/technetwork/java/javase/downloads/jre6downloads-1637595.html
Printer Manager updates are included with the Firmware Update.
1. Copy Datacard firmware update application to computer.
A. Download the 2 Datacard firmware update application files.
B. Choose a path where you will copy the 2 Datacard firmware update
application files.
The FirmwareUpdate.cmd file requires that either the folder that
contains the executable java.exe be on the system path or that you
modify the FirmwareUpdate.cmd file to add the path to java.exe in the
command line.
By default on Windows 7, java.exe is installed to:
•
JRE 6 (32 bit):
c:\Program Files (x86)\Java\jre6\bin
•
JRE 6 (64 bit):
•
JRE7 (32 bit):
•
JRE7 (64 bit):
Windows XP will not display (x86) with Program Files.
If you choose to change the system path environment variable, use
Windows Control Panel (for Windows 7):
a. Start-> Control Panel-> System and Security-> System-> Advanced
System Settings-> Environment Variables-> System Variables
b. Scroll down to the variable Path.
1-42
Introduction
c. Click Edit.
d. Add the path to java.exe to the end of the path entry.
e. Press OK twice to save the change and to back out of the window.
2. Start the Java utility.
A. Make sure the printer is connected to the computer, powered on and
displays ready on the front LCD panel.
B. Click FirmwareUpdate.cmd to start the Java utility.
3. Connect to the printer with the Java utility.
A. Enter the printers IP address into the Printer (IP Address or Name) dialog
box.
B. Select the check boxes required for specific user.
•
If you want the firmware update to use the https: secure port then
select the Use Secure Port option. In Printer Manager under the
Printer Setting menu, DPCL2Secure must be selected to Enabled in
order to use the secure port successfully.
•
If your printer has OpenCard installed and enabled, OpenCard must
be selected. In all other design set-ups, do not select this option.
•
Do not select Use Client Authorization.
C. Click Connect. Connection Established displays when the firmware utility
has established a link and is ready to continue.
4. Select the firmware package.
A. Click Select Package.
1-43
B. Browse to the location path and select firmware flash file (.fls).
C. Click OK.
D. After approximately 15 seconds, the component area will be populated
with files.
5. Start firmware update.
A. Click Update Printer.
B. The printer will display Downloading firmware on line 1 and 2 of the
front LCD panel. A percentage complete value will display on line 2 of the
front LCD panel to indicate the status of the update.
C. The printer will power off and restart when the update is complete.
1-44
Introduction
Chapter 2: Theory of
Operation
This chapter provides the theory of operation for the card printers.
Sequence of Operation ______________________________________________ 2-3
Power-On Initialization _____________________________________________ 2-3
Power Down Sequence ____________________________________________ 2-3
Default Card Production Sequence ________________________________ 2-4
Duplex Sequence _________________________________________________ 2-5
Smart Card Sequence _____________________________________________ 2-6
Single-Wire Smart Card Solution _________________________________ 2-7
Single-Wire Smart Card Solution or Loosely Coupled Solution _____ 2-7
Card Feed ___________________________________________________________ 2-8
Card Cleaning ____________________________________________________ 2-8
Acceptable Card Thickness and Types _____________________________ 2-8
Card Transport _______________________________________________________ 2-9
Card Printing________________________________________________________ 2-10
Color Printing Sequence __________________________________________ 2-10
Monochrome Printing Sequence __________________________________ 2-11
Ribbon Advance ____________________________________________________ 2-13
Magnetic Stripe Encoding ___________________________________________ 2-15
Magnetic Stripe Write Operation __________________________________ 2-16
Magnetic Stripe Read Operation __________________________________ 2-17
Color Management _________________________________________________ 2-18
Overview ________________________________________________________ 2-18
Color Variations __________________________________________________ 2-18
Other Color Variation Factors _____________________________________ 2-20
Differences in Monitor and Printed Images _________________________ 2-20
Monitor Calibration _______________________________________________ 2-21
Magnetic Cards_____________________________________________________ 2-22
Magnetic Data Principles _________________________________________ 2-22
Magnetism ___________________________________________________ 2-22
Magnetic Media______________________________________________ 2-23
Electrical Current and Magnetism _____________________________ 2-23
Writing Data __________________________________________________ 2-23
Reading Data ________________________________________________ 2-24
Magnetic Data _______________________________________________ 2-25
Encoding Format _________________________________________________ 2-26
2-1
Bit Density ____________________________________________________
Word Length _________________________________________________
Record Length _______________________________________________
Parity Check _________________________________________________
Data String ___________________________________________________
Leading/Trailing Clock Pulses __________________________________
Specific Data_________________________________________________
Start Sentinel/End Sentinel_____________________________________
Longitudinal Redundancy Check (LRC) ________________________
Magnetic Stripe Primary Data Standards ______________________________
ISO/IEC 7811 (Parts 2 and 6)_______________________________________
AAMVA DL/ID-2000 _______________________________________________
Saflok, Ving, and Timelox _________________________________________
Multiple Record Format (SDS) _____________________________________
JIS X 6302 (Type I and Type II Cards) _______________________________
Magnetic Media Locations _______________________________________
Data Track Locations _____________________________________________
Summary of Specifications ________________________________________
7-bit Alphanumeric Character Set as Defined by ISO/IEC 7811 __
5-bit Numeric Character Set as Defined by ISO/IEC 7811 ________
Smart Card Technology ______________________________________________
Contact Smart Cards _____________________________________________
Contactless Smart Cards _________________________________________
Communication ______________________________________________
Signal Modulation ____________________________________________
Signal Modulation Summary Diagram __________________________
Reader-to-Card Communication ______________________________
Card-to-Reader Communication ______________________________
2-2
2-26
2-26
2-27
2-27
2-27
2-27
2-28
2-28
2-28
2-29
2-29
2-29
2-29
2-30
2-30
2-31
2-32
2-33
2-34
2-35
2-36
2-37
2-38
2-39
2-39
2-39
2-40
2-41
Theory of Operation
Sequence of Operation
The laminator uses the following sequence of operation.
Power-On Initialization
1. When the power button on the front of the printer is pressed, the printer
begins its initialization routine.
2. As the print engine board is initialized, the display backlight turns on, the
card status and ribbon status lights and the user button on the front panel of
the printer are steady amber.
3. The display backlight turns off briefly to show that the board is beginning to
be initialized.
4. The display backlight turns on again and Initializing displays on line 1 on the
LCD with asterisk symbols scroll from left to right on line 2.
5. The card status lights, ribbon status lights, and the user button on the front
panel of the printer cycle from up to down green and then amber several
times.
6. The display shows Busy, and a series of tones play as the display shows
Ready while the user button flashes green and then turns steady green.
7. While the control board examines and initializes external components, the
user light flashes green.
A. The cam motor cycles and homes.
B. The transport is initialized and then operated for sufficient time to ensure
that the card track is clear.
C. The ribbon type is identified. This may or may not result in the ribbon
motor being energized for a short time to detect a ribbon encoder change.
8. The duplex (if applicable) is placed in the flipper reject angle.
9. When the printer finishes its initialization procedure and is ready to process
cards, the status light turns green.
Power Down Sequence
The printer requires a formal shutdown much like a computer. Do not interrupt
power from the printer until it completes the shutdown. A sudden shutdown
may damage the printer’s operating system.
1. When the power button on the front of the printer is depressed for about two
seconds, the printer begins its power down routine.
2-3
2. The display shows Shutting Down and the user button glows steady amber.
3. The backlight turns off and the display still indicates Shutting Down as the
user button still glows steady amber.
4. The message disappears and the user button goes dark.
5. The printer is now not drawing any current.
If upon powerup the printer displays the Improper Shutdown message, this
indicates power to the printer was interrupted.
Default Card Production Sequence
1. After the card data has been sent to the printer, it begins the card
personalization process.
2. The card is picked and passes through the cleaning rollers.
3. After the leading edge of the card passes through the cleaning rollers, the card
is detected by the input sensor. The trailing edge of the card is registered for
positioning.
4. The card is then sent toward the entrance of the printing area where it is sent
to the magnetic stripe module first, if applicable.
A. The leading edge of the card is registered by the magnetic stripe sensor.
B. The optical encoder measures the distance the card is traveling during the
encoding process.
C. All tracks on the card are written simultaneously.
D. The card data is verified on the return pass.
5. The card is returned to the input sensor and registered for graphics printing.
A. When the leading edge of the card reaches the platen roller, the cam
engages and lowers the printhead onto the card.
B. The ribbon motor is engaged. The motor is over-driven, and the spindle
clutch slips as needed to match the speed of the card.
C. After a panel is printed, the printhead is raised and the card is returned to
the input sensor.
D. The ribbon motor advances to the next panel by examining the ribbon
encoder.
E. The process is repeated for the remaining panels.
6. After printing, the card is moved into the output tray.
2-4
Theory of Operation
Duplex Sequence
1. Before the card enters the duplex module, the flipper rotates to the home
position to receive the card. It then proceeds through the following steps:
A. The flipper home flag passes through the flipper home sensor and moves
the distance defined by the Flipper Home Offset.
B. Depending on where the card needs to be, the flipper rotates and is
positioned using the flipper home sensor and either the flipper flag or the
flipped flag.
2. As a card leaves the main printer chassis and its trailing edge passes through
the card exit sensor, it is positioned in the flipper. The card moves the distance
defined by the Flipper Registration Offset so the card is in the flipper and no
jam occurs when the flipper rotates.
3. The flipper moves both clockwise and counterclockwise during normal
operation. (It can also be manually rotated in either direction without being
damaged.) Since the flipper moves in both directions, the edge of the flags
used for rotational positioning will be either the leading or trailing edge. View
the following chart for flag information.
4. The four flipper positions are:
•
Home: the flipper is close to horizontal.
•
Reject: the flipper is positioned here after initialization. It is also the
position the flipper is in during printing so that it does not interfere with
the card. This position has the drive roller closer to the printer chassis and
2-5
raised higher than the home position. A rejected card will hit the bottom
of the flipper and be deflected downward into the reject tray.
•
Flipped: position is approximately 180 degrees from the home position.
•
Smart Card: the drive roller further from the printer chassis is raised
higher than the home position to send the card upward into the smart
card module.
Smart Card Sequence
The smart card module sequence depends on the type of smart card installed. To
program a smart card, the card must be in the proper location to communicate
with the reader. Either the SCM Dual Smart Card Reader option or a contactless
only option (such as the iCLASS Read/Write) may be installed.
The Duali Smart Card Reader is supported which employs "single-wire"
communication so there does not need to be a separate USB connection to the
reader.
1. When the SCM dual reader is installed, it includes a contact block board with
the smart card contact switch. When the printer detects the SCM option, the
firmware calls a routine that uses the switch as follows:
A. The card is parked in the smart card module. The printer driver sends a
park command to the firmware.
a. As the card enters the module, the leading edge is detected by the
smart card registration sensor.
b. The card continues to move the distance defined by the SmartinOffset.
c. When the card has moved this distance, the smart card contact switch
is closed. The card is successfully parked and the firmware informs
the printer driver. (If it does not close the switch, the card is advanced
a small amount more. If the switch is not closed at this point, Error 102
is issued.)
B. When programming of the card is complete (or when an error is being
cleared), the card moves out of the module back into the flipper assembly.
C. When the trailing edge of the card clears the smart card registration
sensor, the card continues to move the distance defined by the
SmartoutOffset. When this distance has been reached, the card is centered
in the flipper assembly.
2. A contactless-only reader may be installed as part of a third-party integrator
option or the iCLASS option. Because there is no contact block board and
switch to detect, the firmware uses another routine and the smart card
registration sensor to position the card.
2-6
Theory of Operation
A. The printer driver sends a park command to the firmware.
B. As the card enters the module, the leading edge is detected by the smart
card registration sensor.
C. The card continues to move the distance defined by the SmartinOffset.
When it has moved this distance, the firmware informs the driver that the
card is parked and ready to be programmed.
D. When the trailing edge of the card clears the smart card registration
sensor, the card continues to move the distance defined by the
SmartoutOffset. When this distance has been reached, the card is centered
in the flipper assembly.
Single-Wire Smart Card Solution
The v3.1 SDK and above includes a single wire smart card sample in C++, C#,
VB.NET, and java the sample includes source code and also a compiled exe. It
shows personalization of both a contacted and contactless chip. The SDK manual
also has a section outlining single-wire smart card personalization.
•
All card personalization including smart card personalization uses the driver
SDK.
•
The SDK uses a built-in Microsoft Windows API to exchange commands and
data between the driver and the application.
•
Data and status are exchanged using XML structures.
•
Smart card personalization commands are 'tunneled' through the driver and
printer to the coupler inside the printer.
•
Smart card personalization commands are PCSC like to minimize the amount
of work needed to port an existing application.
Single-Wire Smart Card Solution or Loosely Coupled Solution
With the single-wire solution the smart card coupler is accessed through the
printer driver and is tightly integrated with the printer. This has three advantages
over a loosely coupled architecture.
•
There is no longer a need to poll smart card couplers looking for one that has
a card present. The elimination of the extra coordination between two loosely
coupled subsystems will make the solution more robust.
•
The single-wire solution allows multiple printers to print and personalize
smart cards in parallel. If there is a need for faster card issuance you can add a
second printer to the same computer. With the loosely coupled solution you
cannot associate a coupler and a printer so you cannot scale beyond one
printer without risking personalizing the wrong card.
2-7
•
The single-wire solution allows the printer to be placed on a network farther
from the computer than a USB connection will allow. This gives you more
freedom to deploy the printers separate from the computer.
Card Feed
The card is fed into the printer through the manual feed or from the automatic
card tray. With the manual feed option, a card present sensor detects the presence
of the card. If there is no card present, the card status light on the LCD flashes
amber. If a card is present, the printer picks the card.The card is fed into the
printer through the manual feed or from the automatic card tray. With the
manual feed option, a card present sensor detects the presence of the card. If there
is no card present, the card status light on the LCD flashes alternately green and
amber. If a card is present, the printer picks the card.
The card is fed into the printer through the automatic card tray. If a card is
present, the printer picks the card.
When a card feed is requested from an automatic card tray, the pick motor
powers the pick roller that draws the card into the printer toward the cleaning
rollers. The pick gate assembly ensures that only one card at a time may be fed to
the pick roller. The pick block assembly pushes a single card into the pick roller
assembly. After a successful feed or a time-out for an unsuccessful feed, the pick
motor reverses to return the pick block assembly to the home position. There is
no home sensor for the pick block assembly. The motor simply energizes for a
period of time.
For information about the settings and troubleshooting methods for the card feed
see “” on page 3-27 and “Testing the Ribbon and Pick Motors” on page 4-13.
Card Cleaning
The pair of cleaning rollers clean debris from the card as it enters the printer.
While the rollers clean the card, the cleaning sleeve (located on the ribbon
cartridge) cleans the cleaning rollers.
Acceptable Card Thickness and Types
Cards with a thickness of 0.254 to 0.762 mm (0.010 to 0.030 inch) can be used in
the card printer without any adjustments. The card must have a PVC or dye
receptor surface to print on.
2-8
Theory of Operation
Card Transport
The transport motor powers the rollers that move the card through the printer as
the card is processed. Each roller pair in the printer has a bracket and spring on
each side that provide tension to enable the rollers to grip a card.
Three sensors are used during card transport: the card input, card exit, and cam
home sensor. The card input sensor and the card exit sensor monitor card
movement through the printer. These sensors monitor for card jams and lost
cards. The card input sensor is located just after the cleaning rollers and can
detect a successful card feed. The cam sensor monitors the position of the cam
slide.
The cam stepper motor moves the cam and cam slide to raise and lower the roller
assemblies during the processing of a card. When the card is being transported
without any other operation, such as during printing or encoding, all of the
rollers are down and driving the card.
As the card moves through the printer the card guide and spring hold the card
toward the right side of the printer.
For information about the settings and troubleshooting methods for the card feed
see “Transport Settings” on page 3-32 and “Troubleshooting” on page 4-1.
2-9
Card Printing
Printing an image on the card is a complex process. There are more than 1000
possible lines to print and each line can have over 300 heating elements used in
the process. The card position must be precisely controlled to produce the desired
results.
The technology used by the card printer is dye diffusion thermal transfer (D2T2).
To transfer pigment (for monochrome), topcoat, or dye (with YMC printing) from
the print ribbon to the card, the respective thermal element (pixel) heats up until
the temperature reaches the transfer threshold. At this point, pigment from the
print ribbon adheres to the card.
The process for printing a full-color card is slightly different from a monochrome
card. The differences are explained in the following sections.
For information about the settings and troubleshooting methods for card printing
see “Print Settings” on page 3-11 and “Troubleshooting” on page 4-1.
Color Printing Sequence
The color print process places the card in the print position to print each of the
panels, reverses to place the card to the home position, and advances the ribbon
to the next panel between passes. The first pass prints the yellow panel, the
second pass prints magenta, the third pass prints cyan, the K panel for black, and
the last pass is for the topcoat.
2-10
Theory of Operation
When a card is requested, the pick and transport motors power on, and a feed
error check begins. When the leading edge of the card reaches the card input
sensor, the card is also between the cleaning rollers. At this point the pick motor is
no longer transporting the card, so it reverses to return the pick block assembly to
its home position. The feed error check is also terminated; however a jam check is
initiated.
When the trailing edge of the card passes the card input sensor, the jam check is
terminated and the card continues to move a fixed distance. Next, the transport
motor reverses direction and the card again covers the sensor. The card then
moves a fixed distance determined by the firmware and stops. The card is now
ready to be printed in full color. The back and forth movement is necessary to
ensure that the printer knows the precise location of the card. This precision is
required for printing each panel of the multi-panel full-color ribbon at exactly the
same location on the card to register the colors.
Monochrome Printing Sequence
The difference when preparing to print a monochrome card is that the transport
motor does not reverse during the feed process to register the card for printing.
Because only one panel of ribbon is printed, the extra accuracy gained by backing
up the card to register before initial printing is not necessary. This savings
increases throughput.
2-11
The figure below shows the process the printer uses to print a monochrome card.
2-12
Theory of Operation
Ribbon Advance
During the power-on initialization, the RFID antenna board receives ribbon
identification information that allows it to recognize the ribbon as one of the
proprietary ribbon types. If no tag is found, all other ribbons are identified as
black monochrome. The ribbon motor advances the ribbon until the ribbon index
is seen by the ribbon index sensor and then moves the ribbon an additional
amount as specified by the ribbon offset. All other ribbon movement is controlled
by the firmware monitoring the ribbon encoder board.
Ribbons for the card printer have a proprietary ribbon identification tag on the
take-up spool that can send signals to the RF antenna board. This communication
allows the printer to automatically identify the ribbon type and approximate
amount of ribbon remaining on the supply. These RFID tags must not be
removed. The card printer ribbon is not backward compatible; it cannot use
printer ribbons from non-SD/CD models.
When the ribbon cartridge is installed in the printer, the diametric magnet is
located next to the ribbon encoder board.
The diametric magnet is specially-built with its poles on opposites halves of the
round surface, as shown above. As the magnet rotates, the sections of the magnet
where the two poles meet pass the chip on the encoder board. This generates
2-13
pulses. An 8-bit chip monitors the magnitude of the magnetic field in order to get
true position. This way 256 interrupts per revolution can actually be measured.
Two sensors that affect the advancing of the ribbon are the ribbon motion and the
ribbon index. The ribbon index sensor detects the index mark on the ribbon and
the ribbon motion sensor monitors the movement of the ribbon. Cover and
uncover sensors to ensure that they change state.
See “Sensors” on page 4-5 for information on testing sensors. For information
about the settings and troubleshooting methods for the ribbon advance, see
“Print Settings” on page 3-11 and “Testing the Ribbon and Pick Motors” on page
4-13.
2-14
Theory of Operation
Magnetic Stripe Encoding
Magnetic stripe write operations are performed while the card is moving from the
card input sensor towards the card exit sensor. Read operations are performed
while the card is moving from the card exit sensor back towards the card input
sensor. The card input and card exit sensors monitor the card position.
During the read and write operations the cam motor moves the cam slide which
in turn raises and lowers the rollers and thermal printhead.
When the card is picked, it advances until the trailing edge clears the input
sensor. Then it reverses direction and the card moves towards the card input
sensor. When the card covers the sensor, the cam motor lifts the cleaning roller,
and the card continues moving towards the input hopper. When the card has
moved 225 steps (0.75 inch) the cleaning roller is lowered. This raising and
lowering is done to prevent stalls as the card enters the cleaning roller. The card
continues moving toward the input hopper until the new trailing edge clears the
card input sensor and then moves an additional 50 steps. Next, the card reverses
and moves toward the magnetic stripe head. This action is exactly like registering
the card for color printing.
The magnetic stripe encoder determines when to turn the magnetic stripe head on
and off for accurate positioning of the data on the magnetic stripe. It also
generates the write bits by reversing the direction of write current for each
transition while writing the data.
2-15
Magnetic Stripe Write Operation
The menu options in the following text are found in the Printer Manager. See
“Enabling the Proprietary Magnetic Stripe Option” on page 3-33 for settings
information.
When the leading edge of the card reaches the card input sensor, it continues to
move the number of steps defined by the StripeWriteFwdUpOffset. Then the cam
motor moves to raise the printhead, the cleaning roller, and the rear roller.
The card continues to move the number of steps defined by the
StripeWriteFwdEntryOffset, and then data is written on the magnetic stripe. Data is
clocked out based on encoder pulses. If the encoder is not turning or fails, the
data may be missing or incorrectly positioned.
Data continues to be written to the magnetic stripe while the card continues to
move the distance defined by the StripeWriteEventOffset (roughly the length of the
card). When this distance has been reached, the writing ceases; however the card
continues to move another 259 steps before stopping. This is to ensure that the
card is past the head drive rollers when stopped. Note that the card may not
actually be moving during those last steps after it clears the head drive roller
because the cam is up. Then the cam motor moves to lower the cleaning roller
and the rear roller.
When the leading edge of the card reaches the card exit sensor, the card stops and
reverses direction.
2-16
Theory of Operation
Magnetic Stripe Read Operation
The menu options in the following text are found in the Printer Manager. See
“Enabling the Proprietary Magnetic Stripe Option” on page 3-33 for settings
information.
When the trailing edge of the card clears the card exit sensor, the card continues
to move the number of steps defined by the StripeReadEntryOffset. Then the cam
motor moves to raise the printhead, the cleaning roller, and the rear roller. Now
the read process begins.
While the data is read back for verification, the card continues to move the
number of steps defined by the StripeReadEventOffset (roughly the length of the
card). When this distance has been reached, data read back ceases. Then the cam
motor moves to lower the cleaning roller and the rear roller.
If the read indicates the card is good, the card continues until the leading edge of
the card passes the card input sensor, and the print cycle begins. However, if the
read was bad, the card continues until the trailing edge passes, continues 50 more
steps, reverses, and then repeats the entire process.
For information about tools, troubleshooting methods, and remove and replace
procedures for magnetic stripe encoding, see page 5-3 and Chapter 4,
Troubleshooting.
2-17
Color Management
Overview
Color management is a process for enhancing color reproduction and increasing
accuracy and consistency of color over a variety of input and output devices. A
color management system maps colors between devices such as cameras,
monitors, scanners, and printers. This map helps to transform colors from one
color space to another (for example, RGB to CMYK), and provides a more
accurate on-screen or print preview. Color management cannot guarantee
identical color reproduction, but it allows more control over variations across
devices.
Devices have various color gamuts, or ranges of colors they can recognize or
reproduce. Some printing processes have much larger gamuts than others,
meaning there are more colors to choose from. The human eye can perceive many
more colors than devices can produce. Even when a device receives information
from another device in a language it understands, it may attach different
interpretations to the information. Color management serves as the translator of
languages so devices can communicate accurate, standard color information.
Communication is never perfect because device gamuts vary, but color
management helps achieve the best results on a given set of devices.
A color management system helps to overcome these limitations by providing a
communication framework for software and publishing devices. It helps to
decrease color differences and produce colors more predictably. The color
management setting in the card printer must be enabled for the printer to convert
colors using color management.
Color Variations
Without a standard color management system, color results can vary widely
among programs and hardware devices. You might adjust a color based on how
it appears on the monitor and then find that, when printed, the color is
2-18
Theory of Operation
considerably different from what you expected. A printed copy of a scanned
original document may have noticeable differences in color. Maybe the reds
appear pink and the blues become purples.
A color profile is installed when a new device is added to your PC, and this
profile is used every time colors are displayed or printed. Each program used to
input or output the color data supplies color profiles not only for the software
itself, but also for many kinds of devices. As a result, color consistency is achieved
through trial and error.
A color management engine maps the image data, using its current color space
from an input device, into an output color space that matches.
For simple publishing programs, color management can be configured to work
automatically. However, with color management set to None, the printer uses its
native interpretation of RGB. This provides full control for users with specialized
needs, such as graphic artists and desktop publishers, who can manually specify
which color profile the printer uses or which rendering intent is used for images
or pages with special requirements.
2-19
Other Color Variation Factors
Factors that affect variations in color printing:
•
Ribbon-to-ribbon variation - Although minimal, there is still variation from
one ribbon to another.
•
Printhead - The printhead angle is optimized in manufacturing, but there is
still a tolerance from printhead to printhead.
•
Card Stock - A white card is preferred, but there are variations in the “white”
of blank cards from various manufacturers. Some cards are slightly yellow or
have a slight tint. This affects how the dye is transferred to the card.
Differences in Monitor and Printed Images
Monitors have a black background and use additive colors RGB. Printers usually
print on a white card and use subtractive colors YMC. Because of this, monitors
and printers don't have exact color matching. Monitors show many more colors,
as indicated in the following color gamut comparison charts.
RGB monitors can display more colors than can be matched in print. Conversely,
some CMYK colors cannot be matched on-screen. Moreover, RGB gamuts vary
widely between devices with some gamuts being considerably wider than others.
While this may seem beneficial, wider RGB gamuts can be problematic when
outputting to a printer. The colors in the RGB gamut outside the CMYK gamut
must be compressed (that is, mapped to a space within the CMYK gamut). This
always entails a loss to the quality of the original design so what you see is not
what you get.
2-20
Theory of Operation
Monitor Calibration
To print digital images with colors and a tonal range that approximate what you
see on your monitor, you must do a basic monitor calibration. The simplest way
to accomplish this is to adjust your monitor's gamma. After this basic calibration
is done, it’s usually not very difficult to get a feel for the adjustments you’ll need
to make with your imaging program’s color and tonal range tools and your
printer’s tools to get a close match between the printed output and the color and
tonality of the image represented on your computer screen.
If you need exact color matching, you may want to consider buying a monitor
calibration software/hardware solution. A number of companies offer color
calibration products that allow you to make an ICC profile based on your
monitor's actual color characteristics.
Recommended reading for more on color management:
1. Adobe Technical Guide:
http://dba.med.sc.edu/price/irf/Adobe_tg/manage/cmsdef.html
2. Overview Of Color Management:
http://www.cambridgeincolour.com/tutorials/color-management1.htm
3. Digital Darkroom Imaging and Printing Tech Tips:
http://www.sphoto.com/techinfo/wdtech.html
2-21
Magnetic Cards
The information presented in the following section is not required for the card
printer but is presented to augment your training and knowledge base.
Magnetic Data Principles
This discussion is intended to be a primer for those who are not completely
familiar with the principles of writing data to and reading data from a magnetic
stripe. It covers some advanced theory, but is not intended to be a comprehensive
discussion into the physics of electromagnetism. Those wishing to delve deeper
into the physics of electromagnetism should be able to find additional
information on the Internet or from their local library (search topics include:
Electromagnetism, Gauss, Magnetic Stripe).
Magnetism
All magnets, including the Earth, have a North Pole and a South Pole. These poles
always appear in North/South pairs, and there will never be one without the
other. A magnetic field is comprised of Magnetic Lines of Force, or Magnetic Flux,
which travel from North to South between the poles. Even though magnetic flux
is invisible, the effects of these lines can be seen as they interact with particles of
iron.
If a piece of paper is placed over a common bar magnet, and iron filings are
sprinkled across the paper, the iron particles will line up in a fashion similar to
the figure below1. The greater the density of these lines, the stronger the
magnetism. In the following figure, note that the magnetic field is strongest near
the poles.
1.
2-22
This is the same principle used with magnetic stripe developing fluid. The fluid contains magnetic particles in an evaporative fluid. When the fluid evaporates, the particles align on the strongest magnetic areas.
Theory of Operation
Magnetic Media
Magnetic media (stripe material) contains small magnetic particles. Before
information is encoded on the stripe, the poles of the magnetic particles are
randomly oriented (top image below). To encode information, the poles of the
individual particles are oriented in the same direction (middle image below). The
effect of having all of the small particles oriented in the same direction is the same
as having one large magnet with a single North pole and single South pole
(bottom image below).
Electrical Current and Magnetism
There is an interrelationship between magnetic fields and electrical current. When
an electrical current moves through a wire, a magnetic field is generated around
the wire1. Reciprocally, when a magnetic field moves past a wire, a current2 will
be generated (induced) in the wire.
Note that in the case of magnetic stripe cards, a static (non-changing) magnetic
field is physically moving past the conductor. This would be analogous to flying
over the mountains in an airplane. The hills and valleys make the distance
between the airplane and the ground increase and decrease, but the landscape
itself does not change.
If the magnetic field (landscape) were changing, the result would be the same,
and induction would occur. What is important is that the magnetic field is either
changing or moving for induction to occur.
Writing Data
To write data to the magnetic material on a card, it is necessary to create a
magnetic field near the stripe. This aligns all of the magnetic particles nearby in
1.
2.
From Ampere's Law.
Mathematically, Faraday's Law of Induction states that a voltage is induced in the conductor. However, for reasons of
symmetry with Ampere's Law, it is common practice in discussion to refer to the energy transfer as “induced current.”
This is appropriate as long as the conductor forms a closed circuit and Ohm's Law can be applied.
2-23
the same orientation (polarity). The Magnetic Write Head contains a small coil of
wire wrapped around a semicircular iron core1. (The head coil and iron core are
used to focus and concentrate the magnetic field.) When electrical current passes
through the head coil, a small but concentrated magnetic field is generated across
the open ends of the core. The magnetic stripe on the card is magnetized with the
opposite magnetic polarity from the head. This is shown in the image below.
To change the polarity of the magnetic stripe under the magnetic head, the
polarity of the current in the head coil is reversed. This reverses the magnetic
polarity of the iron core, which in turn reverses the polarity of the magnetic
stripe.
Reading Data
To read the magnetic information from a card, the magnetic field on the card is
used to generate a current in the magnetic head. This is possible because a
moving magnetic field induces a current (or voltage) in a conductor.
The magnitude of the current is dependant on the rate of change of the magnetic
field passing by the head. The greater the change, the larger the current. A simple
way of understanding this is that current will be induced when the read head
cuts through a line of flux. When the read head is traveling parallel to a flux line,
no current will be induced.
Because the flux density is greatest at the poles of a magnet, the current will also
be greatest as the magnetic pole passes below the head. This is illustrated in the
figure below. If the magnetic stripe were comprised of a single North-to-South
magnet, no current would be induced in the magnetic head for the majority of the
length of the card.
1.
2-24
Other materials may also be used for magnetic cores.
Theory of Operation
When two North Poles or two South Poles are adjacent to one another, the
magnetic field is compressed and becomes even more dense. The higher the
density of the magnetic field, the larger the current that is induced in the
magnetic head.
For this reason, magnetic data is comprised of Transition Points where the polarity
of the magnetism reverses, which results in North-to-North or South-to-South
polarity.
Magnetic Data
The method for recording information on a magnetic stripe is called two-frequency,
coherent phase encoding (also known as F/2F). Although the name is complex, the
concept is simple: two signals are merged together and written as a single signal.
The significance of this format is that a timing signal is embedded in the data
stream (called self-clocking data). This method allows the data to be read properly
regardless how fast or slowly a person swipes the card past a read head.
The clock signal is evenly spaced pulses that are recorded for the whole length of
the stripe. The binary data is written between each of the clock pulses. These two
signals are merged together into a serial data stream and sent to the magnetic
head as an alternating current of varying frequency.
In the example below, the binary data to be written to the card is “011001.” When
this is merged with alternating clock pulses, the result is “1011111010111.” To
write this merged data string to the magnetic stripe, the polarity of the magnetic
head is reversed when a “1” is in the data stream, and left unchanged when a “0”
is in the data stream.
2-25
When this information is read back from the magnetic stripe, the current in the
magnetic head appears as alternating pulses. This is shown as the bottom graph
in the figure above.
Encoding Format
As described in the preceding section, the data on a magnetic stripe is nothing
more than a series of binary 1’s and 0’s. However, for this data to be usable, it is
necessary to know how to extract and interpret the information. By specifying
how information is recorded to the stripe, it can be assured that the read device
will extract and interpret the information correctly.
Bit Density
The lowest level encoding format is the recording density. This is typically
specified as bits per millimeter, or bits per inch. A high bit density will allow
more information to be stored on the magnetic track.
Word Length
Each piece of information written to the magnetic stripe is a binary coded
character. These characters (numeric or alphanumeric) are represented by a
binary number known as a binary word. Typically, these binary words are
between 4 and 8 bits in length.
The number of bits per word is determined by how many possible characters
there are in a character set. The common alphanumeric character set requires 6
bits for the binary character code, but a numeric character set requires only 4 bits
2-26
Theory of Operation
for the character code. Once the number of bits per word has been specified, all
characters in the same data string will have the same number of bits per word.
Record Length
The record length is the total number of binary words (characters) that can be
stored on a magnetic track. Bit density, word length, and the physical length of
the stripe determine the maximum record length.
Parity Check
A parity check is a method of determining if an error has occurred. This is
accomplished by adding one extra bit to the end of a binary character code. The
purpose of the parity bit is to make the sum of data bits in a binary word either
even or odd. This way, all words throughout the data string will have the same
parity. In the table below, note that the sum of all the bits in each row is an odd
number. This is called odd parity. With even parity, the sum of the rows would be
an even number.
Char
Parity Binary Char Code
5
4
3
2
1
0
Bit 2 2 2 2 2 2
Bit
Sum
$
0
0
0
0
1
0
0
1
A
1
1
0
0
0
0
1
3
B
1
1
0
0
0
1
0
3
C
0
1
0
0
0
1
1
3
S
1
1
1
0
0
1
1
5
W
0
1
1
0
1
1
1
5
Z
1
1
1
1
0
1
0
5
Data String
Regardless what type of information is written on a magnetic stripe, there is a
basic layout that is followed. This basic layout is shown below.
Leading
Clock
Pulses
Start
Sentinel
Specific Data
End
Sentinel
Longitudinal
Redundancy
Check
Trailing
Clock
Pulses
Leading/Trailing Clock Pulses
The actual information written to a magnetic stripe cannot extend fully to the
edges of the stripe. The main reason for this is because the card reader needs to
synchronize its timing to the speed at which the card is swiped through the
reader. Leading and trailing clock pulses permit the reader to gauge the speed of
the card without losing data. (The timing is continuously updated as the whole
card is read, but the leading and trailing clock pulses provide a starting point
without data loss.)
2-27
Specific Data
This is the actual data that personalizes the card. This data can represent a
person’s name, birth date, account number, etc. The actual content of this data is
determined by the card issuer or one of the many international standards. (Refer
to the Magnetic Stripe Primary Data Standards section for a description of some
common standards.)
Start Sentinel/End Sentinel
The specific data on a card is bracketed by a Start Sentinel and an End Sentinel.
These are used to identify where valid data begins and ends. These two sentinels
are reserved characters and cannot be used for any other reason on the magnetic
stripe. For this reason, the sentinel characters will not be standard letters or
numeric characters. (Just like any other character written to the card, the
sentinel’s binary word also includes a parity bit.)
Longitudinal Redundancy Check (LRC)
This is a final parity check for the entire data string. Unlike the parity bit
mentioned in the preceding section, the LRC is a complete binary word itself,
with the same number of bits as the specific data characters.
Each bit in the LRC binary word (except its own parity bit) represents a single
parity check for all of the preceding bits in the same position. This can best be
explained by examining the binary data in the tabular form shown below. Each
character’s parity bit makes the horizontal sum of bits an odd number. The LRC
makes the vertical sum of all the individual bits an even number. (The LRC’s own
parity bit sets the parity for the LRC word in the same manner as it would for any
other character.)
Name
Parity Binary Char Code
Bit Sum Char
Bit 25 24 23 22 21 20
Start Sentinel
1
0
0
0
1
0
1
3
%
Sample Data
1
0
1
0
1
1
1
5
7
Sample Data
0
1
0
0
0
1
1
3
C
Field Separator
0
1
1
1
1
1
0
5
^
Sample Data
1
1
1
0
0
1
1
5
S
Sample Data
1
1
1
1
0
1
0
5
Z
End Sentinel
0
0
1
1
1
1
1
5
?
4
5
3
4
6
5
0
1
1
0
0
1
4
6
4
4
6
6
Pre-LRC Sum
LRC
Post-LRC Sum
2-28
0
3
Theory of Operation
Magnetic Stripe Primary Data Standards
To maintain consistency, the magnetic stripe on a card stores binary data
following national and international standards. A primary data standard is one
that specifies how information is stored on a card. A secondary standard is one
that specifies the content of the information stored on a card.
ISO/IEC 7811 (Parts 2 and 6)
This is the primary standard for recording that most other formats and standards
are based on. This standard dictates how information is written to a card, but
does not describe the content of the information. It covers 2-track and 3-track
magnetic stripe cards, where 1, 2, or 3 tracks may be used.
In the past, this 3-track recording standard was referred to as IAT, which is an
acronym for IATA, ABA, and TTS. This acronym should not be used to describe a
3-track card, because it describes the “content” and not the “technique.” It is more
accurate to describe these tracks as ISO-1, 2, or 3.
Abbreviated
Name
Former
Designation
ISO/IEC 7811 part 2 or 6 Track 1
ISO-1
IATA
ISO-2
ABA
ISO-3
TTS
Full Name
Note that this standard permits the use of a single-track recording, but doing
so does not make the recording a JIS Type-II card. That is a completely
different standard and is discussed below.
AAMVA DL/ID-2000
This is the national standard for the U.S. driver license and identification card.
The specification is published by the American Association of Motor Vehicle
Administrators (AAMVA). It follows the ISO standard except for some changes in
data type and record length. Technically, this is not a primary standard, but since
it modifies some aspects of the primary ISO/IEC standard, it is treated as though
it were a primary standard.
Saflok, Ving, and Timelox
These are proprietary formats that the printer is capable of encoding; however,
the specifics of these formats cannot be published. For these standards you must
contact the format manufacturer.
2-29
Multiple Record Format (SDS)
This is a special format that is used most often by the casino industry. The main
purpose for the change in format is to introduce redundancy into the data to
protect against misreads at the card readers. Because the cards are not intended to
be universal from one provider to another, there is no specific standard format.
Each card issuer can have their own variations on the basic format. Some of the
aspects that may be encountered within this format are shown in the table below.
Parameter
Comments
Number of Records
Each track is permitted to repeat the primary data record as many
times as the issuer chooses. Each duplicate record contains its own
start and end sentinels and error checking characters.
Number of Start Sentinels
Each data record is permitted to repeat the start and end sentinel
any number of times. This is to ensure that the beginning and end of
the record has been detected.
Number of Nulls
Between duplicate data records, there can exist empty, nonrecorded space. This separates the records to ensure that two
adjacent records are not misread as one record.
JIS X 6302 (Type I and Type II Cards)
JIS X 6302 is the Japanese standard for magnetic stripe cards and identifies two
distinct card formats.
Type I:
A JIS Type I card is a 3-track card. As of the 1998/1999 revision of this standard,
the Type I card standard conforms to the ISO/IEC standard for 3-track cards. For
this reason, Type I cards are not discussed separately from ISO/IEC cards.
However, note that some card issuers may still be producing cards under the
1979/1988 version of JIS X 6302. This manual does not cover that standard, but
the system nonetheless supports the format.
Type II:
A JIS Type II card is a single-track card, and does not have an ISO/IEC
equivalent. In the past, this type of card has frequently been referred to as
J-Stripe, J-Track, NTT, or simply JIS Type II. (JIS Type II is now preferred.)
2-30
Theory of Operation
Magnetic Media Locations
The physical location and size of the magnetic stripe on a card follows the
specifications outlined in the two figures below. The first graphic is for a 2- or 3track card (ISO/IEC and JIS Type I). (Note that under the ISO and JIS standards,
even if only one of the three tracks is used, the minimum track size follows this
specification.)
2-31
Data Track Locations
The positions where data can be recorded on a 3-track stripe are described in the
graphic below. This applies to all three of the aforementioned standards, but does
not apply to a JIS Type II card.
2-32
Theory of Operation
Summary of Specifications
The preceding sections described where magnetic data can reside on a card. This
section describes the general format of that magnetic data. The following table
summarizes the data specifications for the primary standards.
ISO/IEC 7811
JIS Type I
Parameter
JIS Type II
Track 1
Track 2
Track 3
Single Track
Bit Density
210
75
210
210
Total Length
79
40
107
72
Record Length
76
37
104
69
7-bit A/N
5-bit N
5-bit N
7-bit A/N
Start Sentinel
%
;
;
DEL
End Sentinel
?
?
?
DEL
Field Separator
^
=
=
Data Type
Word Parity
ODD
EVEN
LRC Parity
EVEN
EVEN
N = Numeric character set
A/N = Alphanumeric character set
2-33
Character Encoding
7-bit Alphanumeric Character Set as Defined by ISO/IEC 7811
Note
H
H
R
S
H
H
H
H
H
H
H
H
H
H
E
Char
Parity
Space
!
“
#
$
%
&
‘
(
)
*
+
,
.
/
0
1
2
3
4
5
6
7
8
9
:
;
<
=
>
?
1
0
0
1
0
1
1
0
0
1
1
0
1
0
0
1
0
1
1
0
1
0
0
1
1
0
0
1
0
1
1
0
Binary
5
2
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
4
2
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
2
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
2
2
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
1
2
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
2
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
Note
Char
Parity
H
@
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
[
\
]
^
_
0
1
1
0
1
0
0
1
1
0
0
1
0
1
1
0
1
0
0
1
0
1
1
0
0
1
1
0
1
0
0
1
R
R
R
F
H
Binary
5
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
2
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
23 22 21 20
0 0 0 0
0 0 0 1
0 0 1 0
0 0 1 1
0 1 0 0
0 1 0 1
0 1 1 0
0 1 1 1
1 0 0 0
1 0 0 1
1 0 1 0
1 0 1 1
1 1 0 0
1 1 0 1
1 1 1 0
1 1 1 1
0 0 0 0
0 0 0 1
0 0 1 0
0 0 1 1
0 1 0 0
0 1 0 1
0 1 1 0
0 1 1 1
1 0 0 0
1 0 0 1
1 0 1 0
1 0 1 1
1 1 0 0
1 1 0 1
1 1 1 0
1 1 1 1
Code
Description
H
The following 14 characters !”&’*+,:;<=>@_ are reserved for hardware control and
cannot be part of the data content. (These may or may not be used by various
device manufacturers.
R
Additional reserved characters.
S,E,F
Reserved characters for Start Sentinel, End Sentinel, and Field Separator
2-34
Theory of Operation
5-bit Numeric Character Set as Defined by ISO/IEC 7811
Binary
Note Char
H
S
H
F
H
E
0
1
2
3
4
5
6
7
8
9
:
;
<
=
>
?
Parity 2
1
0
0
0
0
0
1
0
0
0
1
0
1
0
0
0
0
1
1
1
1
1
0
1
1
1
0
1
0
1
1
1
3
22 21 20
0 0 0
0 0 1
0 1 0
0 1 1
1 0 0
1 0 1
1 1 0
1 1 1
0 0 0
0 0 1
0 1 0
0 1 1
1 0 0
1 0 1
1 1 0
1 1 1
Code
Description
H
These characters are used to control the hardware and cannot be part of the
data content. (These may or may not be used by different device manufacturers.)
S,E,F
Reserved characters for Start Sentinel, End Sentinel, and Field Separator
2-35
Smart Card Technology
The information presented in the following section is not required for servicing
the printers but is presented to augment your training and knowledge base.
The underlying concept of smart cards is fairly simple: A chip is embedded inside
a plastic card. The chip may be microprocessor based or a simple memory device.
The capabilities of a smart card, however, are a little more complex. They can be
as simple as a means of identification, or as complex as a financial database.
Although it is not a mandated parameter (and some overlap may exist), all
smart cards have a unique identifier that indicates the card type, the
manufacturer, and the specific card. Most card manufacturers present this
unique identifier as part of the “answer to reset,” which is discussed below.
Even if the card protocol permits it, this identifier must not be altered.
There are two basic types of smart cards; Contact Smart Cards and Contactless
Smart Cards (or a combination of both types, as shown in the following graphic).
Contact smart cards connect to the external interface via a set of eight electrical
contact points. Contactless smart cards interact with the external interface
through a principle called inductive coupling. There are many variations on the
basics of smart cards, including proprietary designs. The following discussion is
limited to smart card architecture as defined under ISO/IEC 7816 (1-10) and ISO/
IEC 14443 (1-4).
2-36
Theory of Operation
Contact Smart Cards
A contact smart card must connect to an external interface to provide the
processor with power and to set up serial communication. The eight terminal
contacts are described in the table below. (Note that two contacts are reserved for
future use.)
There are two classes of contact smart cards: Type-A cards operate at 5 volts, and
Type-B cards operate at 3 volts.
No.
Name
Purpose
No.
Name
Purpose
C1
VCC
Supply voltage (3 or 5 V)
C5
GND
Ground
C2
RST
Resets the processor
C6
VPP
Variable voltage for
programming
C3
CLK
Provides the timing (clock)
signal
C7
I/O
Data line
C4
N/A
Reserved for future use
C8
N/A
Reserved for future use
Initiating Communication
When the card is inserted into a reader, it is initialized and has its communication
protocols defined. Note that steps 1 through 6 all occur while the card is forced to
remain in a reset state (no activity).
1. The card reader senses that the card is in position under the contacts. In most
cases, a mechanical switch detects the presence of a card (any type of card).
2. The reset line (C2) is held low. (The active-low reset forces the card to remain
in the reset state until released.)
3. Power is applied to the VCC and GND contacts.
•
Type-A reader applies 5 volts to the card. (Type-B cards must accept the
overvoltage, but are not allowed to respond.)
•
Type-B reader applies 3 volts to the card.
2-37
•
Type-A/B reader first applies 3 volts to the card. If no response is
received, it removes power, waits, and reapplies power at 5 volts.
4. The I/O line is held in the receive mode (high impedance).
5. If the card is a Type-A card, the programming voltage (VPP) is placed in the
pause value, which is equal to VCC.
6. The clock signal is activated.
7. The reader releases the reset by bringing it to a high voltage.
8. The card then issues its Answer To Reset (ATR). ATR is a hexadecimal string
of up to 32 characters and contains:
•
The format of the communication
•
Permissible baud rates
•
Parameters of the circuitry in the card
•
Required programming voltage on VPP
•
The make and model of the card
•
Other information the manufacturer chooses
9. With communication parameters known, the interface can begin to
communicate with the card.
10. Serial communication across the I/O line commences.
11. If necessary, the voltage on VPP is altered, and information can be written to
the card.
Contactless Smart Cards
There are multiple protocols for contactless smart cards. For example, during the
1980's there were as many personal computer types as there were manufacturers.
In time, the number of computer types dwindled as designs were standardized.
The same is true with smart card technology, except that many off-standard card
types still exist.
The primary information in this section is geared toward the ISO/IEC 14443
Type-A and Type-B cards although a few other formats are still widely used.
The photograph on page 2-36 shows a combicard with both a 125 kHz antenna
and the standardized 13.56 MHz antenna. This card helps facilitate the transfer
from the 125 kHz system to the common 13.56 MHz system. The lower frequency
format is not supported by any of the ISO/IEC standards. These low-frequency
cards are frequently referred to as Wiegand cards and generally provide a unique
ID only when energized.
2-38
Theory of Operation
The FeliCa® card format was developed by the Sony Corporation and is similar to
the standard Type-A card, except that it uses a 212 kb/s data rate instead of the
standardized 106 kb/s data rate. There are also some variations on the
modulation protocol.
The MIFARE® card is fairly common because it is based on an open standard
used by many manufacturers. According to the Phillips Corporation, this format
is fully compliant with the ISO/IEC 14443-A standard.
Communication
Communication with contactless smart cards is slightly more complicated
because there is no physical connection between the interface and the card. The
card reader sends out a radio frequency broadcast, which not only provides
power to the card, but also establishes communication. This is called inductive
coupling.
Inductive coupling works the same way as a transformer does, except that the
two coils are farther apart (called loosely coupled). The operating field of the card
reader has a frequency of 13.56 MHz. This is called the carrier frequency.
Signal Modulation
The concept of signal modulation arises from the relationship between frequency
and required antenna size. Namely, the antenna needs to be on the same order as
the wavelength of the signal. The lower the frequency and the longer the
wavelength, the larger the antenna required to transmit or receive the signal.
An audio signal, for example, would require an antenna of approximately 300 km
in length. This would not fit very well in the trunk of your car for listening to your
favorite music, and a portable radio would be totally out of the question.
Instead, the lower frequency (the data signal) is combined with a higher
frequency (the carrier). The higher frequency is more easily transmitted and
received. Combining two signals together is called modulation.
There are many types of signal modulation, but they all have three basic
parameters: amplitude, frequency, and/or phase of the carrier signal.
You are probably familiar with the terms Amplitude Modulation and Frequency
Modulation because these are used by most consumer radios. We know them as
AM and FM radios. Because of their nature, digital signals can utilize many
variations on these basic modulation schemes.
Signal Modulation Summary Diagram
The following diagrams show the two basic modulation schemes as well as the
variants used by digital signals. The AM and FM modulation diagrams are shown
2-39
with analog data signals, but phase-shift modulation is easiest to show with a
digital signal.
Amplitude Modulation:
The magnitude (height) of the carrier
signal is varied according to the height
of the data signal. This is what is used in
AM radio.
Note: The blue data signal is shown here
for clarity. It is not actually present in the
actual modulated signal.
Frequency Modulation:
The frequency of the carrier signal is
varied according to the height of the
data signal. This is what is used in FM
radio.
Note: The modulated frequency
remains close to the carrier frequency,
but the drawing is exaggerated for
clarity.
Amplitude Shift Keying:
This is a digital variant on the AM
modulation. It comes in two common
forms: 100% and 10%.
Note: 10% modulation (ASK10%) means
the carrier is modulated by only 10%.
100% modulation means that the carrier
signal is fully modulated. Both of these
variants are shown to the right.
Load Modulation:
The card switches the resistance of its
antenna, which alters the current in the
transmitter.
Note: This is a complex topic and will be
discussed in greater detail later.
Phase Modulation:
A data transition is signified by a shift in
the signal's phase. In this case, the
phase is shifted 180 degrees by inverting
the signal.
Reader-to-Card Communication
The reader communicates with the card by sending an amplitude modulated
signal at 13.56 MHz. The modulation variant depends on the class of card. Type A
2-40
Theory of Operation
cards use 100% Amplitude Shift Keying (ASK100%). Type-B cards use ASK10%
modulation. These two variants are shown in the previous graphics.
The benefit of ASK100 is that it is more immune to noise and errors because there
is a strong difference in amplitude at bit transitions. The drawback to this is that
the card does not receive power during the low cycle of the modulation. The card
does not turn off during these times, but the effect is that less overall (average)
power is being transmitted to the card.
ASK10 provides more power to the card because the modulated signal remains
within 10% of the maximum amplitude. The tradeoff is that the difference
between high and low amplitudes is minimal. This can lead to slightly more data
transmission errors.
Card-to-Reader Communication
The communication method back to the reader is a passive communication
because the card does not really send a signal back to the reader—it modifies the
signal emanating from the reader. This is called load modulation, and is based on
a loosely coupled transformer (two coils separated by distance and without an
iron core).
A normal transformer is frequently thought of as a method for changing one
voltage to another, such as a computer power supply that takes 120 volts and
reduces it to 12 volts. While the voltage decreases across the transformer shown
below, the current increases proportionally. The value of the current in the
secondary winding is dependant on the load being powered. Consequently, the
current in the primary winding is inversely proportional to the load on the
secondary winding. As a result, if the load is varying with time, the circuitry on
the primary side of the transformer can detect the change in current draw.
When the card engages and disengages (switches) resistance in its own antenna,
the reader detects this change by examining the current draw within its antenna.
Type-A Card Modulation
The type of return modulation from the card to the reader differs with the two
classes of cards (Type-A and Type-B). Type-A cards use a simple On-Off-Keying
2-41
modulation (OOK). This is the binary equivalent of amplitude modulation. The
card switches the resistance seen by the card reader at a frequency of 1/16th the
frequency of the carrier signal. This means that during a modulation period, the
carrier signal is attenuated every eight cycles. The data stream is even slower than
this (1/128th of the carrier frequency) so each data bit has several transitions from
modulation to non-modulation of the carrier.
Type-B Card Modulation
Type-B cards use a combination of amplitude modulation and phase modulation,
called Binary Phase Shift Keying (BPSK). This method sends a constant subcarrier
frequency of 847 kHz using amplitude modulation, but shifts the phase of the
subcarrier by 180 degrees (inverted) at each data transition. In other words, the
carrier is always modulated with the subcarrier, but during data transitions, the
subcarrier signal is altered (inverted). The subcarrier is permitted to invert only at
its own transition points (which is why the frequencies are even multiples of each
other).
2-42
Theory of Operation
Chapter 3: Adjustments
This chapter includes navigation and use of the Printer Manager
application to view and make changes and adjustments to the card
printer.
Factory and Power-On Settings _______________________________________ 3-3
Viewing Printer Status_________________________________________________ 3-3
Viewing and Changing Printer Settings ________________________________ 3-4
Communication ___________________________________________________ 3-4
Activity Log _______________________________________________________ 3-5
Activity Log Example ______________________________________________ 3-6
Behavior __________________________________________________________ 3-8
Vital Product Data_________________________________________________ 3-9
Front Panel Options________________________________________________ 3-9
Print Settings ________________________________________________________ 3-11
CableCompMaxStrobe ___________________________________________ 3-11
CardRegistration _________________________________________________ 3-12
CardRegistrationCalibration_______________________________________ 3-13
Color Management ______________________________________________ 3-14
FanTempOn______________________________________________________ 3-15
KPower __________________________________________________________ 3-15
Kpower1200______________________________________________________ 3-16
Kpower600 _______________________________________________________ 3-16
KpowerCalibration _______________________________________________ 3-16
KpowerCalibration1200 ___________________________________________ 3-17
KpowerCalibration600 ____________________________________________ 3-17
KPowerDuplex____________________________________________________ 3-17
KWhiteShade_____________________________________________________ 3-18
LeadTrim _________________________________________________________ 3-18
RibbonOffset _____________________________________________________ 3-19
RibbonStripOffset _________________________________________________ 3-20
SettingsGroupPurpose ____________________________________________ 3-20
TPower___________________________________________________________ 3-21
TPowerCalibration ________________________________________________ 3-21
TPowerDuplex ____________________________________________________ 3-21
TWhiteShade _____________________________________________________ 3-22
TrailTrim __________________________________________________________ 3-22
VerticalOffset ____________________________________________________ 3-23
3-1
YMCMinShade ___________________________________________________ 3-24
YMCPower_______________________________________________________ 3-24
YMCPower600 ___________________________________________________ 3-24
YMCPowerCalibration ____________________________________________ 3-25
YMCPowerCalibration600_________________________________________ 3-25
YMCPowerDuplex ________________________________________________ 3-25
YMCWhiteShade _________________________________________________ 3-26
Print Misadjustment __________________________________________________ 3-27
Pick Settings _________________________________________________________ 3-28
Motor PWM ______________________________________________________ 3-28
Pick Auto TimeOut________________________________________________ 3-28
Pick Card Offset__________________________________________________ 3-29
Pick Card Offset (1-6)_____________________________________________ 3-29
Pick Manual Timeout _____________________________________________ 3-30
PickReversePwm _________________________________________________ 3-30
PickReverseTime _________________________________________________ 3-31
Transport Settings ____________________________________________________ 3-32
Boosted Transport Speed _________________________________________ 3-32
TransMedSpeed__________________________________________________ 3-32
TransportSpeed __________________________________________________ 3-32
Magnetic Stripe Settings ______________________________________________ 3-33
Enabling the Proprietary Magnetic Stripe Option ___________________ 3-33
Magnetic Stripe General Settings__________________________________ 3-36
Magnetic Stripe Custom Track Settings ____________________________ 3-39
Magnetic Stripe Track Height Test _________________________________ 3-41
Start Sentinel Position Adjustment__________________________________ 3-43
Update Password ____________________________________________________ 3-44
Set Job Queue State _________________________________________________ 3-46
Flipper Adjustments __________________________________________________ 3-47
Emboss Card Out ________________________________________________ 3-48
Flipper Emboss Angle _____________________________________________ 3-48
Flipper Flipped Angle _____________________________________________ 3-49
Flipper Home Offset ______________________________________________ 3-49
Flipper Registration Offset _________________________________________ 3-50
Flipper Reject Angle ______________________________________________ 3-50
Flipper Rotation Speed ___________________________________________ 3-50
Flipper Smart Angle_______________________________________________ 3-51
Flipper Trans Ramp Down Reg Speed______________________________ 3-51
Smart in Offset ___________________________________________________ 3-51
Smart Out Offset _________________________________________________ 3-51
Laminator Offsets ____________________________________________________ 3-52
Laminator________________________________________________________ 3-52
Laminator Type __________________________________________________ 3-59
Updating Printer Settings______________________________________________ 3-61
3-2
Adjustments
Factory and Power-On Settings
The card printer is shipped with current value settings, but settings can be
changed as needed to customize how the printer operates.
•
•
•
Current Values are factory values that were used to setup the printer
(otherwise known as power-on values).
Default Values are safe engineering values which are used to setup the
printer.
Restore Default sets the printer back to engineering defaults.
Printer Manager option interfaces that contain changeable values have either a
drop-down menu to select from or a text box to enter a value. At the bottom of the
interface are the Set Current and Restore Default buttons.
The Set Current button allows you to save the changed settings on that page. If
you exit a Printer Manaqger page without clicking Set Current, any changes are
lost. The Restore Default button restores the engineering-default settings only to
the values on that page of the Printer Manager interface. The following sections
explain adjustments that can be made from the Printer Manager options menu.
Viewing Printer Status
Basic information about the printer and printer status can be viewed from the
submenus of the Status Option in Printer Manager. The Printer Manager Options
in the status menu show information about the printer but cannot be changed. See
the section titled “Status” on page 1-27 to see what information is available from
the Status submenus.
3-3
Viewing and Changing Printer Settings
Adjustments can be made in printer manager using the following menus.
Communication
The following settings on the communication menu can be adjusted.
Option
Description
EthAddressMethod
This is the method used to obtain the Ethernet network IP
Address. When the value is STATIC, EthIPAddress,
EthSubnetMask and EthGatewayAddress can be set. When the
value is DHCP, the EthIPAddress, EthSubnetMask, and
EthGatewayAddress are written automatically.
EthGatewayAddress
This is the Gateway IP Address for the Ethernet network. When
EthAddressMethod is STATIC, you can set this value. When
EthAddressMethod is DHCP, the DNS server controls this value.
EthIpAddress
IP Address of the Ethernet network. When EthAddressMethod is
STATIC, you can set this value. When EthAddressMethod is
DHCP, the DNS server provides this value.
EthMacAddress
This is the MAC address for the Ethernet network.
EthSubnetMask
This is the subnet mask for the Ethernet network. When
EthAddressMethod is STATIC, you can set this value. When
EthAddressMethod is DHCP, the DNS server controls it.
3-4
Adjustments
Activity Log
Enable or disable an internal or external activity log using this menu option. It
lists the activities that can be included in the logs and allows you to set the
severity level for when the activity should be written to the log. Severity level
options include: off, critical, error, warning, notice, information, and debug.
Option
Description
ExternalLog
Enable or disable writing the Activity Log to an external Syslog
server.
ExternalLogServer
Sets the IP Address of the external Syslog server.
FilterCardAction
Writes the start and completion of card action, with this severity
and higher, to the Activity Log. Values range from Critical to
Information similar to Syslog severities.
FilterConfigChanges
Write configuration change actions, with this severity and
higher, to the Activity Log. Values range from Critical to
FilterJobStates
Write changes to the state of a print or exception job, with this
severity or higher, to the Activity Log. Values range from Critical
to Information similar to Syslog severities.
FilterSoapMsgs
Write DPCL/Soap messages from the printer, with this severity
and higher, to the Activity Log. Values range from Critical to
FilterSystem
Write system information, with this severity and higher, to the
Activity Log. A value of Information results in most events being
written to the log. Values range from Critical to Information
similar to Syslog severities.
InternalLog
Enable or disable the Activity Log on the printer.
3-5
Activity Log Example
Following is an example of an external activity log using an application to
monitor the system log.
1. In Printer Manager select Printer Setting > Activity Log. In this example:
•
The ExternalLog option has been enabled
•
The external log server IP address has been entered
•
The FilterSOAPMsgs option has been set to filter for SOAP messages at the
Warning level or higher and add them to the log.
This example uses a free third-party application called Syslog Watcher for
Windows Personal Edition. This software is made by SNMPSoft Company
and can be downloaded for free from their website.
3-6
Adjustments
1. On the PC acting as the External Log Server, an application is running that
monitors messages from the printer. The following figure depicts the initial
screen before any messages have been received.
2. As errors occur, the log entries accumulate. If the log watcher is minimized,
messages like those shown at the bottom right displays above the Task Bar as
they are received.
3-7
Behavior
These options control the printer operation and magnetic stripe encoding. See
“Enabling the Proprietary Magnetic Stripe Option” on page 5-29 for information
about using proprietary magnetic stripe encoding.
Option
Description
Activity Log External
Enable or disable the external and/or internal activity logs.
Activity Log Internal
CPX
Enable or disable the CPX.
DPCL
DPCL is Datacard Printer Control Language. These options
disable DPCL (port 9100) or disable DPCL Secure (port 9111)
communications.
DPCL2
DPCL2 Secure
DPCL Secure
DPM
DPM Secure
DPM is Datacard Personalization Manager. These options
disable DPM (port 19001) or disable DPM Secure (port 19111)
communications.
Network Access Control
Enable or disable control by network access.
Plugin
Enable or disable the plug-in feature for the printer to enable
installed options such as Opencard.
Reject Hopper
Put rejected cards in the reject hopper (otherwise front
hopper).
Remake
Remake Method
If enabled, and a print request fails, a new card is picked and
the print request tries again. A remake card is only retried once.
Remake method chooses the algorithm used for performing a
remake.
Ribbon Initialize
Enable or disable initialization of the ribbon at power on.
SNMP
Enable or disable SNMP service.
Web Server Secure
Allows access to the web server through the secure port.
3-8
Adjustments
Vital Product Data
This option displays the default and current values of vital product data.
Option
Description
AgencyModelName
Agency model
Manufacturer
Name of printer manufacturer
ModelName
Printer model name, assigned by the manufacturer
PartNumber
Printer part number, assigned by the manufacturer
SerialNumber
The serial number setting may need to be reset if replacing the
print engine board.
Front Panel Options
This option has settings for the LCD panel, buttons, and the indicator lights. See
“LCD Panel” on page 1-18 for information on the LCD panel.
Option
Description
BacklightBrightness
Sets the LCD backlight intensity.
Range: 0 to 100
Default: 100
KeySenseLevel
Sets sensitivity of front panel keys.
Range: 0 to 10
Default: 5
LCDConfigMenu
Hide the Front Panel LCD Configuration Menu.
Maintenance and Status menus cannot be disabled.
LedCardsPickedToCleaning
Set the number of cards picked between cleaning. Card
LED shows steady Amber when the printer reaches this
value. When this value is 0 (zero), cards between cleaning
are not tracked.
Range: 0 to 1000000 cards
Default: 1500 cards
3-9
Option
Description
LedPrintheadCyclesToCleaning
Set the number of printhead cycles between cleaning.
Card LED shows steady Amber when the printer reaches
this value. When this value is 0 (zero), cycles between
cleaning are not tracked.
Range: 0 to 1000000 cycles
Default: 2500 cycles
Explanation:
When the printer is using a 5-panel ribbon (YMCKT), there
are 5 printhead cycles per card. Logically you would set
the LedPrintheadCyclesToCleaning setting to 5 times that
of the LedCardsPickedToCleaning setting.
LedRibbonLow
Set the percentage of ribbon remaining that would
indicate the ribbon was low. The ribbon LED shows steady
Green when the printer reaches this value.
Range: 0 to 100%
Default: 10%
SpeakerEnabled
3-10
Use the speaker to provide sound indicators along with text
and lights on the front panel.
Adjustments
Print Settings
The print options that control the quality of the printing are listed in the following
table. The Print density is the overall lightness or darkness of the printing and is a
result of a combination of the CableCompMaxStrobe, the
YMCPowerCalibration, and the YMCPower. The first two,
CableCompMaxStrobe and YMCPowerCalibration, are factory adjustments. The
third, YMCPower, is adjustable in the field.
CableCompMaxStrobe
Adjust the CableCompMaxStrobe setting to balance print density where areas of
strong contrast come together. This adjustment is applied to all panels and affects
overall lightness and darkness. It is used to remove any transition lines.
This is a factory adjustment. The default value determined by Engineering
does not need adjustment in the field.
Range: 0 to 100 special units
Default: 25 special units
Symptoms:
•
Increase to increase density in most areas.
•
Decrease to reduce unexpected lightness in smaller areas.
3-11
CardRegistration
This customer setting is the distance in millimeters (1 mm is 0.040 inch) to move
the card after the sensor event before printing. The printer registers the card on
the trailing edge.
Range: -0.5 to 50.8 mm (-0.019 to 2 inches)
Default: 0 mm (0 inches)
Symptoms:
•
Increasing the CardRegistration adjustment adds to the total card movement.
•
Decreasing the CardRegistration adjustment subtracts from the total card
movement.
Avoid setting this distance too short. If the card is not under the printhead when
it heats up to print, the ribbon breaks cleanly because no card is there to absorb
the heat.
The card registration adjustments control the horizontal print margin on the card
by adjusting the distance the card moves after the trailing edge of the card clears
the Card Input sensor.
The CardRegistration calibration is done at the factory and can also be adjusted
by the technician in the field. The CardRegistration adjustment compensates for
slight variations in card stock. The sum of the values of these two adjustments
determines the amount of card movement. For example, StickIcards are slightly
shorter than standard CR80 cards. When this adjustment is set at the default of
zero, the value of the previous adjustment, CardRegistrationCalibration, is solely
responsible for the position of the card.
Since the distance to the thermal printhead is fixed, varying the distance the card
moves determines where on the card the printhead begins printing when it is
lowered.
3-12
Adjustments
CardRegistrationCalibration
This is a factory setting that can be adjusted by the technician. It sets the distance
in millimeters (1 mm is 0.040 inch) to move the card after the sensor event before
printing. The printer registers the card on the trailing edge.
The sum of the CardRegistrationCalibration and the CardRegistration setting
equals the horizontal print margin.
Range: 0.5 to 100 mm (0.019 to 3.937 inches)
Default: 1.905 mm (0.075 inch)
Increasing this value moves the card further into the printer before the printhead
is lowered. This moves the alignment bar farther from the leading edge of the
card.
Procedure:
To adjust the CardRegistrationCalibration:
1. Set the CardRegistration to its default value of zero.
2. Print Test Card Pattern 5 using the K panel.
3. The trailing edge of the alignment bar should be exactly 5 mm (0.196 inch)
from the leading edge of the card. If it is not, adjust the CardRegistration
Calibration value.
3-13
Color Management
Use color management in the printer. The sRGBColorSpace renders images to
look similar to those displayed on PC monitors using sRGB color. MatchSP
results in printing that closely matches the legacy printers. None causes the
printer to use its native interpretation of RGB. Select the type of color
management or none.
Options: None, sRGBColorSpace, MatchSP
Default: sRGBColorSpace
Explanation:
With None selected the printer uses its native interpretation of RGB. If enabled,
there are two choices. The sRGBColorSpace is a standard that makes sure that
input colors are correctly mapped to output colors. The result is that the printer
output closely matches the colors viewed on the monitor. If you select MatchSP,
the result is printing that more closely matches the legacy printers. You may opt
to use this if you are replacing a legacy printer with the new card printer.
The figure below shows solid red, green, and blue cards using each of the Color
Management options. Since these were scanned, their appearance is affected not
only by your monitor, but also by the scanner’s profile. For additional
information on color management refer to “Color Management” on page 2-18.
3-14
Adjustments
FanTempOn
The printhead temperature in degrees Centigrade at which to operate the fan. The
fan goes on when the temperature is at or above this level. The fan turns off when
temperature drops 2 degrees below this value.
Range: 20° to 100°C (68° to 212° F)
Default: 42°C (107.6°F)
Note: Setting the fan temperature too high may affect color balance of the first
cards in the run.
KPower
This customer setting increases or decreases print intensity for K panel (black) or
K ribbon. Increase the value to make single-color printing thicker. Decrease for
crisp bar codes or if the ribbon breaks when printing the K panel. This adjustment
controls the overall lightness or darkness of the K panel.
Range: -100 to 100 special units
Symptoms:
•
Increase the value to make printing more intense.
•
Decrease the value to reduce intensity or to prevent ribbon breaks while
printing.
Example: In this example, the card on the left has the KPower set too low,
resulting in voids in the bar code. The card on the right may have the KPower set
too high.
Printing a bar code in the landscape orientation, as shown here, could cause bar
width growth in which the bars are printed wider than they should be and get
even wider toward the trailing edge.
The correct method to adjust the KPower is to reduce the power until there are
voids in the bar code. Then increase the KPower until they just fill in. The printing
may look a little light to the eye, but this provides the best results for a bar code
reader.
3-15
Kpower1200
This customer setting increases or decreases print intensity for K panel or K
ribbon printed at 1200 dpi. Increase it to make printing thicker. Decrease for crisp
bar codes or if the ribbon breaks when printing the K panel. This adjustment
controls the overall lightness or darkness of the K panel.
Symptoms:
•
Increase to make printing more intense.
•
Decrease to reduce intensity or to prevent ribbon breaks while printing.
Kpower600
This customer setting increases or decreases print intensity for K panel or K
ribbon printed at 600 dpi. Increase it to make printing thicker. Decrease the value
for crisp bar codes or if the ribbon breaks when printing the K panel. This
adjustment controls the overall lightness or darkness of the K panel.
Symptoms:
•
Increase the value to make printing more intense.
•
printing.
KpowerCalibration
Change intensity of printing for the K ribbon or panel. Increase the power used to
print the K panel and make printing thicker. Decrease the value for crisp bar
codes or if the ribbon breaks while printing the K panel.
Note: This is a factory setting.
3-16
Adjustments
KpowerCalibration1200
Change intensity of printing for the K ribbon or panel at 1200 dpi. Increase the
power used to print the K panel and make printing thicker. Decrease for crisp bar
KpowerCalibration600
Change intensity of printing for the K ribbon or panel at 600 dpi. Increase the
power used to print the K panel and make printing thicker. Decrease for crisp bar
KPowerDuplex
This customer adjustment is for increasing or decreasing the print intensity for
the back side K panel or K ribbon.
Range: -100 special units
Default: 100special units
Symptoms:
•
Increase the value to make printing thicker.
•
Decrease the value for crisp bar codes or if the ribbon breaks when printing
the K panel.
3-17
KWhiteShade
KWhiteShade is power applied to the printhead to reduce ribbon friction without
transferring topcoat. This adjustment affects the melting of the wax-like ribbon
backcoating to provide a slippery surface for the printhead. This prevents the
printhead from chattering (slightly catching and releasing) as it moves across the
ribbon.
Range: -100 to 100 shades
Default: 0 shades
Symptoms:
Reduce this value if material transfers to the card.
LeadTrim
The LeadTrim is the number of millimeters (1 mm is 0.040 inch or about 1.25 dot
rows) to remove from the leading edge of a full-size image to keep it within the
print area.
Range: 0 to 5.08 mm (0 to 0.2 inch)
Explanation:
Image trimming settings are used to achieve the best results for edge-to-edge
printing. Not all applications send an image that is exactly the same size as the
card. LeadTrim affects the left edge of the card when viewed in the landscape
mode as shown here.
3-18
Adjustments
RibbonOffset
The RibbonOffset value is the distance in millimeters (1 mm is 0.040 inch) to move
the ribbon after the Index Sensor event to start printing.
The printhead is physically downstream from the ribbon index sensor. The
ribbon offset setting represents the distance that the print ribbon is advanced after
the trailing edge of the index bar is detected.
This positions the ribbon so that the printing begins about 8 mm (0.315 inch) into
the yellow panel.
To adjust the ribbon offset, make sure that the printer is set for edge-to-edge
printing and then print a test card that has printing on the leading edge. When the
card is complete, examine the ribbon panels used.
The gap from the end of the index mark to the beginning of print in the yellow
panel must be approximately 8 mm (0.315 inch). If it is not, increase or decrease
the RibbonOffset value as indicated and repeat the process.
Range: 0.254 to 25.4 mm (0.01 to 1 inch)
Symptoms:
•
If the value is set too low or high, the card can be discolored on the left or
right edge.
•
If the value is set too high or low, part of the ribbon index mark can stick to
the card and cause a jam.
Possible mechanical causes:
•
Loose screws that secure the printhead to heatsink/housing.
•
Swingarm spring not secure.
•
Printhead not installed correctly in printer.
3-19
RibbonStripOffset
The RibbonStripOffset is the distance in millimeters (1 mm is 0.040 inch) that the
transport motor moves the card, in addition to the image length, to strip the
ribbon from the card. Increase this value if ribbon sticks to the trailing edge of the
card.
During the printing process the print ribbon can stick to the card when the
printhead heats up to transfer the dye from the ribbon to the card. While the card
and ribbon are both moving, this movement peels the ribbon from the card. At
the end of the printing process, the card moves an additional distance to complete
the process of peeling the ribbon (stripping it) from the card. The RibbonStrip
offset determines the distance the card continues to move after the printing is
complete.
Note: Engineering states that this does not require adjustment.
Range: 0.762 to 25.4 mm (0.03 to 1 inch)
Symptoms:
•
If the value is set too low, the ribbon can stick to the card.
•
If the value is set too high, throughput can be decreased.
SettingsGroupPurpose
Use the SettingsGroupPurpose to describe the purpose of the settings group.
Group names are not changeable, so use this setting to state the reason for
creating the settings group.
Default: Print
Explanation:
In the future there will be 10 user groups available to save customized groups of
settings. This setting is a means to provide a description for the group. If you
were to customize several print settings for a particular job, you could save them
as a group and use this setting to define the purpose.
3-20
Adjustments
TPower
The TPower is a customer setting to modify the intensity of printing for the T
ribbon panel.
Settings:
•
Increase the value to make printed topcoat thicker or more uniform.
•
Decrease the value to prevent ribbon breaks while printing topcoat.
Be aware that low energy settings can yield acceptable topcoat edges but
can affect long term durability due to poor adhesion.
TPowerCalibration
Use the TPowerCalibration setting to modify the intensity of printing for the T
ribbon panel. Increase this setting to increase the power used to print the topcoat
ribbon panel and make printed topcoat thicker or more uniform. Decrease to
prevent ribbon breaks while printing topcoat.
TPowerDuplex
This customer adjustment is for increasing or decreasing the print intensity for
the back side T ribbon panel.
Range: -100 special units
Settings:
•
Increase the value to make topcoat thicker and more uniform.
•
Decrease the value if the ribbon breaks when printing the topcoat.
3-21
TWhiteShade
The TWhiteShade setting adjusts power applied to the printhead to reduce ribbon
friction without transferring material. This adjustment is to melt the wax-like
ribbon backcoating to provide a slippery surface for the printhead. This prevents
the printhead from chattering (or slightly catching and releasing) as it moves
across the ribbon.
Default: 0 shades
Setting: Reduce this value if extra material transfers to the card.
TrailTrim
Number of millimeters (1 mm is 0.040 inch or about 1.25 dot rows) to remove
from the trailing edge of a full-size image to keep it within the print area.
Range: 0 to 5.08 mm (0 to 0.2 inch)
Explanation:
The TrailTrim setting affects the right edge of the card when viewed in the
landscape mode as shown in the figure. These trim settings do not affect the
horizontal print margin. When you perform the card registration adjustments,
the values of the trim settings do not matter.
3-22
Adjustments
VerticalOffset
This offset aligns printing with the long edges of the card. It is the number of
printhead dots to shift printing toward the top or left side of the card. You cannot
change the number of dots between the long edges of the card.
Range: -100 to 100 dots
Default: 17 dots
Explanation:
The Vertical Offset positions the image on the card by changing the elements used
to print the image. The printhead has more heating elements than required to
cover the card vertically. The image’s serial data is clocked into a shift register
within the printhead. The outputs of the shift register are tied to the inputs to the
drivers in the printhead. To position the image higher on the card, the serial data
is loaded higher in the shift register, which causes higher heating elements to be
used. To lower the printed image, the serial data is loaded lower in the shift
register.
3-23
YMCMinShade
This is the minimum shade value at which YMC color begins to transfer from the
ribbon to the card.
Default: 0 shades
Settings:
•
If a white shirt in a photo does not print, increase this value.
•
If highlights are washed out (grayish), decrease this value.
YMCPower
This is a customer setting to modify the intensity of printing for the Y, M, and C
ribbon panels. This adjustment controls the overall lightness or darkness of the
YMC panels.
Settings:
•
Increase the value to make color printing more intense.
•
printing colors.
YMCPower600
This is a customer setting to modify the intensity of printing for the Y, M, and C
ribbon panels at 600 DPI. This adjustment controls the overall lightness or
darkness of the YMC panels.
Symptoms:
3-24
•
Increase to make color printing more intense.
•
Decrease to reduce intensity or to prevent ribbon breaks while printing colors.
Adjustments
YMCPowerCalibration
This setting changes intensity of printing for the Y, M, and C ribbon panels. This
is a factory setting made using a densitometer. This value affects the overall
lightness or darkness of the YMC panels printing. Prior to making this
adjustment, set the field adjustment of YMCPower to zero.
Settings:
•
Increase the power used to print the color panels to make colors stronger.
•
Decrease to reduce intensity or prevent ribbon breaks while printing color
panels.
YMCPowerCalibration600
This setting changes intensity of printing for the Y, M, and C ribbon panels at 600
DPI. Increase the power used to print the color panels to make colors stronger;
decrease to reduce intensity or prevent ribbon breaks while printing color panels.
This is a factory setting made using a densitometer. It affects the overall lightness
or darkness of the YMC panels printing. Prior to making this adjustment, the field
adjustment of YMCPower600 is set to zero.
YMCPowerDuplex
This is a customer setting to modify the printing of the backside Y, M, and C
ribbon panels. Increase the power to print stronger color panels; decrease to
reduce intensity or prevent ribbon breaks while printing color panels.
This is set using a densitometer. It also affects the overall lightness or darkness of
the YMC panels printing. Prior to making this adjustment, the field adjustment,
YMCPower, is set to zero.
3-25
YMCWhiteShade
This setting affects power applied to the printhead to reduce ribbon friction
without transferring color. It affects the melting of the wax-like ribbon
backcoating to provide a slippery surface for the printhead. This prevents the
printhead from chattering (or slightly catching and releasing) as it moves across
the ribbon.
Default: 0 shades
Settings:
Reduce this value if unprinted or white areas of the card have color applied to
them. If you decrease this setting too much, you may notice transition lines where
the image changes from a non-printed area to a printed area.
3-26
Adjustments
Print Misadjustment
Misadjustment of CardRegistrationCalibration, CardRegistration, LeadTrim, or
TrailTrim can also cause ribbon registration problems. This happens because the
ribbon is advanced by the thermal printhead when the card is not in position to
prevent the printhead from traveling further than it should.
For example, if the TrailTrim is set too long, the printhead remains down after the
end of the card has passed. This causes the printhead to push downward on the
ribbon and advancing it slightly. First ensure that the horizontal print margin is
correct. Then adjust the trim settings.
3-27
Pick Settings
The printer pick settings control the pick motor and time frames for picking
cards. These adjustments are all related to feeding a card into the printer.
Sensors that can affect the picking of cards are the card input sensor and the card
present sensor. To test sensors and the pick motor, refer to “Troubleshooting” on
page 4-1.
Motor PWM
This offset sets a pick motor speed to a percentage. Use this adjustment to match
the pick motor speed to the transport motor speed transport motor. Stalling may
occur if the speed is too low.
Range: 0 to 100%
Default: 85%
Symptoms:
•
If the value is set too high, excessive noise is produced.
•
If the value is set too low, motor can stall.
Pick Auto TimeOut
This is the number of milliseconds to attempt to pick a card (when the Pick
Method is automatic). If picking fails, one more attempt is made before a cardnot-picked error occurs. This offset rarely needs adjustment after it has been set in
the factory.
Range: 750 to 10000 ms
Typical Value: 1000 ms
Symptoms:
3-28
•
If the value is set too high, excessive noise can be detected due to extended
run time of the motor.
•
If the value is set too low, there may not be enough time to feed the card into
the printer, causing false errors.
Adjustments
Explanation:
A printer makes two attempts to pick the card. When the pick command is
received, the pick motor runs for the time designated by this setting. The card
must reach the card input sensor within this time frame. If it does not, the pick
was unsuccessful. The time resets, and the pick motor runs a second time. When
the time period of this setting is reached on the second attempt and no card has
been received, an error is issued.
Pick Card Offset
This is the distance to move the card using the pick motor after the input sensor
detects a card from the hopper. The unit is millimeters (1 mm is 0.040 inch) and
the value is a floating point decimal with up to three significant digits, such as
0.812.
Engineering recommends you do not increase this setting.
Range: 2.54 to 400 mm (0.1 to 15.75 inches)
Symptoms:
•
If the value is set too high, double card picking occurs.
•
If the value is set too low, the transport motor may stall and there may be
excessive pick roller wear.
This setting controls the amount of pre-picking of a second card that is allowed.
Decrease this setting if a second card is being picked.
Pick Card Offset (1-6)
Distance to move the card using the multi-hopper pick motor, after the input
sensor event. The unit is a millimeter (1 mm is 0.040 inch) and the value is a
floating point decimal with up to three significant digits, such as 0.812.
Range: 2.54 - 400
Default: 400
3-29
Pick Manual Timeout
This is the umber of seconds to attempt to pick a card (when the PickMethod is
Manual) before declaring a card-not-picked condition.
Range: 1 to 300 seconds
Default: 120 seconds
Symptoms:
•
If the value is set too high, there is excessive wait time before an error is
issued.
•
If the value is set too low, there may not be enough time to push the card into
the printer, resulting in false errors.
Explanation:
A printer with the manual feed option has a card inserted into the manual feed
input that covers the card present sensor. The action turns on the Transport
motor and triggers this time period to begin. The card must reach the Card Input
sensor within this time frame or an error is issued.
PickReversePwm
PWM at which the pick motor will run in reverse.
Range: 0 to 100%
Default: 50%
3-30
Adjustments
PickReverseTime
Milliseconds to run the Pick motor in reverse after picking a card to prevent
picking of two cards.
Default: 200 ms
Symptoms:
•
If set too high, picking errors occur, especially for thin cards.
•
If set too low, cards may not be picked.
Explanation:
This setting is to make sure that the pick mechanism returns to the home position.
If cards are not being picked, this setting should be increased. If there are picking
errors with more than one card, decrease this setting.
3-31
Transport Settings
The transport motor moves the cards through the printer.
Boosted Transport Speed
This is the transport speed when using the boost circuit.
Range: 800 - 4000 steps per second
Default: 3250 steps per second
TransMedSpeed
Speed at which to run transport motor when clearing errors.
Range: 300 to 1800 steps per second
TransportSpeed
This is the transport motor speed for moving the card when not printing,
encoding, or doing other personalization. Normally this setting is left at the
default value and not adjusted.
Symptoms:
•
If the value is set too high, the motor may stall.
•
If the value is set too low, reduced throughput may result.
This setting does not affect the CD series, printers as they have a boost circuit to
achieve this.
3-32
Adjustments
Magnetic Stripe Settings
Use Printer Manager to adjust magnetic stripe settings.
Enabling the Proprietary Magnetic Stripe Option
New printers require this procedure to set the magnetic stripe option. If a print
engine (main control) board is replaced, this procedure must be used to restore
magnetic stripe settings.
Downloading the Settings File
Follow the steps below to download the settings update file from PartnerPage to
use when you are enabling proprietary magnetic stripe options.
1. Log on to www.PartnerPage.com.
2. Hover over Services & Support on the top menu.
3. Select Card Printers under Desktop ID Solutions.
4. Click the printer model.
5. Click Enable Options.
6. Click Click Here to Continue.
7. Enter the Auth Key for the main control board and the Serial Number of the
printer (on a label attached to the side of the swingarm and in VPD data) and
select the appropriate magnetic stripe option from the list. Click Submit.
3-33
8. Click the link to download the file.
9. Save the file to the hard disk on your PC and proceed to the next section.
Updating Settings
Apply the magnetic stripe option settings file that you downloaded. Then use the
following procedure to verify that the option has been enabled.
Verifying Proprietary Magnetic Stripe Option
This procedure is required after a proprietary magnetic stripe option has been
enabled.
1. In Printer Manager, select Printer Setting > Behavior.
3-34
Adjustments
2. Verify that the appropriate magnetic stripe option has a current value of
Enabled.
3-35
Magnetic Stripe General Settings
The Magnetic Stripe General settings are described in the following table.
Option
Description
Attempts
Number of times to attempt writing magnetic data if verify is not
successful. Also used for the number of times to attempt reading
magnetic stripe data. A value of 1 means no retries.
Range: 1 to 5 attempts
Default: 3 attempts
AutoCoercivity
If the Coercivity is HiCo or LoCo and magnetic stripe read or
verify fails, automatically change the Coercivity and read or
encode the data again. Using this feature doubles number of
retries and can affect how quickly cards are processed.
Disabled by default.
Options: Disable or Enable
Default: Disable
Coercivity
Coercivity defines the resistance of magnetic material to
remove encoded data. HICO (High Coercivity) requires more
electrical force (current) to encode data and is more resistant to
magnetic interference.
Options: HICO, LOCO, NTT1, NTT2, NTT3
Default: HICO
Data Format x
Name of the data format for track 1, 2, or 3.
(x=1, 2, or 3)
Options: IATA, ABA, TTS, JIS, AAMVA, AAMVA_ECC, VING,
SAFLOK, TIMELOX, ONITY, CUSTOM, BINARY75, BINARY210, NONE
3-36
Adjustments
Option
Description
NoDataDisableTrack
Do not activate the magnetic stripe write head for a track if
there is no data for that track. When this is disabled any track
which was not given data will be erased.
ReadTrack x
Allows magnetic stripe read actions to read from track 1, 2, or 3.
(x=1,2, or 3)
SaflokBitOrder
Selections: LSB, MSB
Default: MSB
SSA x
(x=1, 2, or 3)
Start sentinel adjustment for track 1, 2, or 3. The value is
determined by the SSA test.
Range: -4 to 4 mm (-0.157 to 0.0157 inch)
Default: 0 mm (0 inches)
StripeEncoderMultiplier
Enter a multiplier value to compensate for encoder variations.
Range: 0.9 - 1.1
Default: 1.0
StripeReadEntryOffset
Used to set the start of the read transition locations. Must be
bigger than StripeWriteEntryOffset but not past the start bit
location.
Note: Engineering does not recommend changing this setting.
Range: 0 to 500 steps
Default: 97 steps
StripeReadEventOffset
Number of steps to move the card after the start of the sensor
event when reading or verifying magnetic stripe data.
Default: 1150 steps
StripeReadSpeed
Transport motor speed when reading or verifying magnetic stripe
data.
3-37
Option
Description
StripeWriteEventOffset
Number of steps to move the card during the write magnetic
stripe operation.
Default: 1050 steps
StripeWriteFwdEntryOffset
Number of steps to move the card after the start of the sensor
event, followed by running the cam motor as specified by
StripeWriteFwdUpOffset.
Default: 450 steps
StripeWriteFwdUpOffset
Number of steps to move the cam motor to reach the option
position. When complete, the magnetic stripe data can be
written to the card.
Default: 420 steps
StripeWriteSpeed
Transport motor speed while writing the magnetic stripe.
WriteTrack x
Allows magnetic stripe write actions to write to track 1, 2, or 3.
(x=1,2, or 3)
3-38
Adjustments
Magnetic Stripe Custom Track Settings
All of the MagStripeCustom track adjustments are either user- or administratoraccess level adjustments. Use Printer Manager to make these magnetic stripe
related adjustments. They are located in the Printer Setting menu in the
MagStripeTrack1 submenu. There is an identical submenu for each mag stripe
track. Track 3 settings are for track 3 or single track.
Option
Description
CustomCharHigh#(1-3)
Numeric value of the highest ASCII character supported for
input data on track.
Range: 1 to 255
Default: 95
CustomCharLength#(1-3)
The number of bits to represent one byte of data on track,
also called bits per character or bpc.
Range: 1 to 8
Default: 6
CustomCharLow#(1-3)
Numeric value of the lowest ASCII character supported for
input data on track.
Range: 1 to 255
Default: 32
CustomCharMask#(1-3)
Encoding mask for track. This mask is added to the ASCII
numeric value for data sent to equal the encoded value.
Range: 1 to 255
Default: 32
CustomCharMax#(1-3)
Maximum number of data characters for track 1. This value
does not include the start sentinel or end sentinel.
Range: 1 to 255
Default: 76
CustomDensity#(1-3)
Number of data bits per inch of magnetic stripe media for
track, also called bits per inch or bpi. Allowed values are 75
bpi or 210 bpi.
Range: 1 to 255 bits per inch
Default: 210 bits per inch
3-39
Option
Description
CustomEndSentinel#(1-3)
The last character encoded, which identifies the end of
the encoded data for track.
Range: 1 to 255
Default: 63
CustomLrc#(1-3)
Cumulative parity bit for track. It is encoded after the end
sentinel, provides simple error checking, and is also called
Longitudinal Redundancy Check or LRC.
Range: Allowed values are EVEN, ODD and NONE.
Default: EVEN
CustomParity#(1-3)
Character-level parity bit for track. It is encoded after
each character, provides simple error checking, and is also
called Vertical Redundancy Check or VRC.
Range: Allowed values are EVEN, ODD and NONE.
Default: ODD
CustomSdsNulls#(1-3)
The number of nulls between each copy of the data
record. The default value is 0. Change this value only if you
are setting up the SDS meta-format for track.
Range: 0 to 255
Default: 0
CustomSdsRecords#(1-3)
The number of times to encode the data record. The
default value is 1. Change this value only if you are setting
up the SDS meta-format for track.
Range: 0 to 255
Default: 1
CustomSdsSs#(1-3)
The number of start sentinels before each data record. The
default value is 1. Change this value only if you are setting
up the SDS meta-format for track 2. Use track 3 settings for
a single-track option.
Range: 1 to 255
Default: 1
CustomStartSentinel1(-3)
The first character encoded, which identifies the start of
the encoded data for the track.
Range: 1 to 255
Default: 37
3-40
Adjustments
Magnetic Stripe Track Height Test
Magnetic stripe encoding must be verified to conform to industry standards. The
card printer uses the same head to write (encode) the magnetic stripe and to read
back for verification. This dual-use could cause the card to work properly on the
card printer but not be readable for a customer.
Refer to “For Magnetic Stripe Option” on page 5-3 for the required tools used in
this procedure.
Symptom
Various magnetic stripe read errors.
Prerequisite Actions
•
Clean the magnetic stripe roller.
•
Clean the magnetic stripe head (if necessary).
3-41
Test Procedure
1. Print a magnetic stripe test card in Printer Manager by selecting
Troubleshooting > Testcard.
2. Check the vertical track alignment (track height) with an alignment gauge.
A. Wipe the card with a clean, lint-free cloth.
B. Apply developer to the card.
C. Using the alignment gauge, check the vertical track alignment. Refer to
specifications in “Start Sentinel Position Adjustment” on page 3-43.
•
Encoding should be centered within the etched lines that define each
track. The encoding for each track should not touch the etched lines
above or below.
•
If each of the three tracks is vertically centered within the three sets of
etched lines, the positioning of the magnetic stripe head is correct.
Follow-up Adjustment
•
3-42
“Start Sentinel Position Adjustment” on page 3-43
Adjustments
Start Sentinel Position Adjustment
Refer to “For Magnetic Stripe Option” on page 5-3 for the required tools used in
this procedure. The SSA Test adjustment values are added to or subtracted from
the StripeWriteFwdEntryOffset.
Symptom
Various magnetic stripe start sentinel errors.
Prerequisite Adjustment
•
“Magnetic Stripe Track Height Test” on page 3-41
Procedure
1. Print a magnetic stripe test card in Printer Manager by selecting
Troubleshooting > Testcard.
2. Check the vertical track alignment (track height) with an alignment gauge.
A. Wipe the card with a clean, lint-free cloth.
B. Apply developer to the card.
C. Using the alignment gauge, check the vertical track alignment. Refer to
specifications in “Start Sentinel Position Adjustment” on page 3-43. The
first bit of each start sentinel should lie between the vertical etched lines
on the alignment gauge.
3. If adjustment is required, display the Troubleshooting menu and use the SSA
Test option to let the printer find and adjust the start sentinel positions. The
value of a test can be up to five decimal places (for example, 1.12345, and 1
mm is equal to 0.040 inch). The range for each SSA value is -4 to 4.
4. The SSA Test automatically adjusts the position of the start sentinel for each
track. The adjusted value is written into the magnetic stripe general printer
settings in Printer Manager.
3-43
Update Password
Use this procedure to change Printer Manager passwords for the site.
Caution: Do not change the WebService password.
1. Login to Printer Manager.
A. Open an Internet browser and enter the static IP address set from the front
panel of the printer as described in “Logging in to Printer Manager” on
page 1-26.
Make sure to enter the Static IP address after https://.
Example: https://172.17.1.113
B. Select WebService to login to Printer Manager with service options.
C. At the password prompt, enter the default service password of 926918.
3-44
Adjustments
2. Change WebUser and WebAdmin passwords to match customer access
requirements.
A. Select Printer Setting and Update Password.
B. Select WebUser or WebAdmin and enter a new password for the user or
administrator level of Printer Manager. Passwords may either be blank (0
characters) or contain 4 to 32 characters. The characters allowed are a-z, AZ, 0-9, +, and /.
a. Enter the previous password for that login.
b. Enter and reenter the same new password.
c. Click Update Password.
3-45
Set Job Queue State
This option is used for setting passwords to be used for remote access to the
printer.
3-46
Adjustments
Flipper Adjustments
The Flipper (Duplex, Transfer) module has adjustments on the Printer Setting
menu. The positions of the flipper are as follows.
Home – accepts card from printer
Flipped – returns flipped card to printer
Smart Card – sends card to and from the smart card assembly
Reject – sends card to reject bin
Laminator – sends card down to Laminator
The following figure depicts the flipper drive gear with the window positions.
When properly adjusted, the black bar in the center of the window is aligned with
number 4 in the scale on the side wall. If the adjustment is somewhat off, but still
between the numbers 2 and 6, it must be close enough for the card to transfer
properly. However, if the alignment is at or beyond 0 or 8, it can negatively affect
operation.
3-47
Emboss Card Out
This offset advances the card until the trailing edge leaves the flipper and the
leading edge enters the laminator interstage drive rollers. There is no sensor to
detect an error for this movement. The detection occurs when the card continues
into the interstage.
Default: 250 steps
Symptom: Card jams
Flipper Emboss Angle
This offset adjustment positions the flipper card track for alignment with the card
track of the laminator interstage station.
Default: 143 steps
Symptom: Card jams
Procedure:
1. Defeat the interlocks and remove the ribbon cartridge. Be ready to open the
swingarm.
2. Send a test card to the system.
3. To cause a Lost Card error, open the swingarm just after the card enters the
flipper and the flipper has rotated to send a card into the embosser.
4. The flipper is in the FlipperEmbossAngle. View the card within the flipper to
evaluate proper alignment.
3-48
Adjustments
Flipper Flipped Angle
This is the offset from home when the flipper is upside down. Do not adjust this
offset, as it is referenced from the FlipperHomeOffset.
Range: 1 to 500
Default: Typical is 250
Symptom: Card jams
Flipper Home Offset
This offset sets the number of motor steps to execute, after the home sensor is
covered during the flipper homing operation. Incorrect adjustment, either high or
low, of any of these rotational offsets causes card jams. At the home position the
flipper is in-line to receive a card from the printer chassis. All flipper rotational
movement is referenced from this home position. Therefore, changing the home
position without changing the other flipper position offsets would probably
result in a jam condition. This is the offset from the sensor to put the duplex at
home position.
Range: -001 to 100
Default: 27
Symptom: Card jams
Procedure:
1. Defeat the interlocks and remove the ribbon cartridge.
2. Be ready to open the swingarm as you send a test card to the system.
3. Open the swingarm just before the card enters the flipper to causes a Card not
in Position error. The Flipper is in the Home Position. View the scale to
determine the proper home position. You can also use the manual advance
knob to move the card up to the flipper entrance for evaluation.
3-49
Flipper Registration Offset
This is the offset from the Exit sensor to load the flipper. Engineering
recommends that this not be adjusted.
Range: -100 to 100
Default: 40
Symptom: Card jams
This adjustment cannot be done in the field at this time because there is no test to
put a card in the Flipper. Evaluate the adjustment by printing a card.
Flipper Reject Angle
Do not adjust this offset because it is referenced from the FlipperHome Offset and
because this model printer has no reject tray. This is the offset from home
clockwise for deflecting cards into the reject tray. As the card leaves the printer
chassis, it does not enter the Flipper. Instead the Flipper is positioned so that the
card defects off the bottom of the Flipper into the Reject tray.
Range: 1 to 500
Symptom: Card jams
Flipper Rotation Speed
Engineering recommends that this not be adjusted. This is the speed of the flipper
as it rotates. If it needs adjustment, there is probably a mechanical problem.
Range: 200 to 1200
Symptoms:
3-50
•
If set too high, excessive noise is generated.
•
If set too low, motor can stall.
Adjustments
Flipper Smart Angle
(Engineering recommends that this not be adjusted.) This is the angle relative to
the homed Flipper for smart card position. The card is sent and received in the
same angle. This offset adjustment positions the flipper for alignment with the
card track of the smart card assembly. The same position receives the card after
encoding.
Range: 1 to 500
Symptom:
•
If set too high, may cause excessive noise.
•
If set too low, motor stalling can occur.
Flipper Trans Ramp Down Reg Speed
Not implemented.
Smart in Offset
Offset into the smart card module from the leading edge.
Range: 1 to 300
Symptom: Card jams
Smart Out Offset
(Engineering recommends that this not be adjusted.) Offset out of the smart card
module from the trailing edge. This is the distance that the card moves after the
trailing edge clears the Smart Card sensor. When module is properly adjusted,
the card is centered in the Flipper.
Range: 1 to 300
Symptom: Card jams
Testing can be done only by producing a test card.
3-51
Laminator Offsets
The optional laminator module adjustments are on the Printer Setting menu in
the Laminator and Laminator Type submenus of Printer Manager. Refer to the
Laminator Service Manual for detailed instructions on using the options.
Laminator
Option
Description
1) CardExitOffset
Distance in steps to move to eject the card without an impresser.
Default: 750 steps
2) CardExitSpeed
Speed in steps per second to eject a card.
Range: 50 to 2500 steps/sec
Default: 2000 steps/sec
3) CardExitSpeedWith
Impress
Speed in steps per second to eject a card if the laminator has an
impresser.
4) CardExitWithImpress
Offset
Distance in steps to move to eject the card with an impresser.
Default: 1500 steps
5) CardInputPosition
Vertical or Angled input position.
Options: Vertical or Angled
Default: Angled
6) CardRejectOffset
Distance to move card to reject to reject hopper.
Default: 500 steps
7) CardRejectSpeed
Motor speed to move cards to reject hopper.
3-52
Adjustments
Option
Description
8) DebowBottomHome
Offset
Offset from debow home for moving debower to bottom home
position.
Range: 0 to 500 (offset)
Default: 146 (offset)
9) DebowDelay
Time in milliseconds before debow action is applied.
Range: 0 to 1500 ms
Default: 1000 ms
10) DebowHomeOffset
Offset from debow home sensor for homing debower.
Range: 0 to 100 (offset)
Default: 69 (offset)
11) DebowRegOffset
Offset from debow Registration sensor for card registration.
Range: 0 - 1000 steps
Default: 495 steps
12) DebowSpeed
Speed to move debower motor for debowing.
Default: 350 steps
13) ExceptionCardDebow
Direction
Direction to debow for exception slot card, up or down.
Options: Up or Down
Default: Down
DistanceDown
Distance for exception card to move debower arms down for
proper debow action.
Default: 15 steps
DistanceUp
Distance for exception card to move debower arms up for
Default: 105 steps
DwellMs
Time in milliseconds for exception card to spend debowing.
Range: 0 to 5000 ms
Default: 1000 ms
3-53
Option
Description
17) ExceptionCardImpress
Depth
Distance in steps (in addition to factory setting) to move the
impresser die for proper impress depth on a card picked from
the printers exception slot.
Range: -200 to 200 steps
Default: 0 steps
DwellTime
Time in milliseconds to spend impressing a card picked from the
printers exception slot.
Default: 2000 ms
19-21) ExceptionCard
ImpressPositionOffsetx
(x =1,2 or 3)
Distance from the back edge of the card to place the center of
the first, second or third impression for a card picked from the
printers exception slot.
Default: 2000 steps
Temperature
Temperature in degrees Celsius at which to impress on a card
picked from the printers exception slot.
Range: 50 to 160 C
Default: 130 C
23) ExceptionCard
NumberOfImpresses
Number of impresses to put on a card picked from the printers
exception slot.
Range: 1 to 3 impresses
Default: 1 impression
24) FlipperAngledAngle
Angle from home to angled input position.
Default: 42 steps
25) FlipperEntrySpeed
Speed in steps per second for flipper for moving card between
interstage and flipper.
26) FlipperExitSpeed
Speed in steps per second for flipper for moving card between
flipper and L2.
3-54
Adjustments
Option
Description
27) FlipperFlipAngle
Steps to rotate the flipper 180 degrees.
Default: 10 steps
28) FlipperHomeOffset
Steps from flipper home sensor to home position.
Range: 1 to100 steps
Default: 10 steps
29) FlipperL2HomeOffset
Steps from l2 card sensor for loading flipper from L2.
Range: 1 to 100
Default: 16 steps
30) FlipperLoadOffset
Offset from Interstage sensor for loading from vertical or angled
input.
Default: 17 steps
31) FlipperRejectAngle
Flipper angle offset from home clockwise for deflecting cards to
the reject bin.
Default: 50 steps
32) FlipperRotationSpeed
Speed of the flipper when rotating.
33) FlipperVerticalAngle
Angle from home to vertical input position.
Default: 70 steps
34) HeaterMinutesTo
PowerSave
Idle time before shutting off heated rollers.
Range: 15 to 240 minutes
Default: 15 minutes
35) Hopper1CardDebow
Direction
Direction to debow for hopper 1 card, up or down.
Options: Up or Down
Default: Down
3-55
Option
Description
DistanceDown
Distance for hopper 1 card to move debower arms down for
Default: 15 steps
DistanceUp
Distance for hopper 1 card to move debower arms up for proper
debow action.
Default: 105 steps
DwellMs
Time in milliseconds for hopper 1 card to spend debowing.
Range: 0 to 5000 ms
Default: 1000 ms
39) Hopper1CardImpress
Depth
Distance in steps (in addition to factory setting) to move the
impresser die (punch) for correct impress action on a card
picked from the printers primary input hopper.
Default: 0 steps
40) Hopper1CardImpress
DwellTime
Time in milliseconds to spend impressing a card picked from the
printers primary input hopper.
Default: 2000 ms
41-43) Hopper1Card
ImpressPositionOffsetx
(x=1,2 or 3)
Distance from the back edge of the card to place the center of
the first, second or third impression for a card picked from the
printers primary input hopper.
Default: 2000 steps
44) Hopper1Card
ImpressTemperature
Temperature in degrees Celsius at which to impress on a card
picked from the printers primary input hopper.
Range: 50 to 160 C
Default: 130 C
45) Hopper1CardNumber
OfImpresses
Number of impresses to put on a card picked from the printers
primary input hopper.
Range: 1 to 3 impresses
Default: 1 impression
3-56
Adjustments
Option
Description
46) ImpresserHomeOffset
Distance in steps from the impresser home sensor to the
impresser home position.
47) ImpresserRegister
Speed
Speed in steps per second for registering card for impressing.
48) ImpresserSpeed
Speed in steps per second of the impresser motor.
Default: 2500 ms
49) L2CoolingTime
Amount of time for the card to cool after L2 application.
Range: 0 to 5000
Default: 1000
50-51) MfgCardRegOffset
Lx
Manufacturing distance to move card after registering in L1 or
L2.
(x= 1 or,2)
Default: 110 steps
52) MfgImpressDepth
Manufacturing offset is steps to set the correct depth for
impressing.
Default: 755 steps
53) MfgImpressPosition
Offset
Manufacturing offset in steps from the impresser card sensor to
the back edge of the card for impress positions.
Default: 0 steps
54-55) MfgOverlayReg
OffsetLx
Manufacturing distance to move supply after registering patch
in L1 or L2. This is added to OverlayRegOffsetLx.
(x= 1 or,2)
Default: 120 steps
56) Model
Model name of the laminator.
Options: None, SLM or CLM
Default: None
3-57
Option
Description
57, and 61) RollerLx
CustomSpeedOffset
Overlay speed offset for laminating in L1 or L2 with the custom
roller.
(x=1 or 2)
Range: -60 to 60 (offset)
Default: 0 (offset)
58, and 62) RollerLx
CustomTempOffset
Overlay temperature offset for laminating in L1 or L2 with the
custom roller.
(x=1 or 2)
Default: 0 (offset)
59, and 63) RollerLxRubber
SpeedOffset
Overlay speed offset for laminating in L1 or L2 with the rubber
roller.
(x=1 or 2)
Default: -45(offset)
60 and 64) RollerLxRubber
TempOffset
Overlay temperature offset for laminating in L1 or L2 with the
rubber roller.
(x=1 or 2)
Default: 15(offset)
65 and 66) RollerType
InstalledLx
(x= 1 or,2)
67) ScanBarCodeRetries
Heated roller type currently installed in L1 or L2.
Options: Standard, Rubber or Custom
Default: Standard
Number of retries performed by the optional bar code scanner.
Range: 0 to 5 retries
Default: 0 retries
68) SerialNumber
3-58
Laminator serial number, assigned by manufacturer.
Adjustments
Laminator Type
Option
Description
1) CardPatchLength
Length of the patch or laminate to be applied.
Default: 3340 steps
2 and 3) CardRegOffsetLx
(x= 1 or,2)
Adjustment to the distance the card must move after seeing
card registered for L1 or L2.
Default: 0 steps
4) CardStripDistance
Distance to move card for stripping.
Default: 700 steps
5) DatabaseVersion
Version number of the laminator’s overlay database.
Range: 1 to 999
Default: 1
6 and 7) ExclusiveOverlay
InLx
(x= 1 or,2)
Name of the overlay that must be loaded in L1 or L2. The printer
will raise an error before the card is picked if the wrong overlay is
loaded.
Options: Clear_Topcoat, 0.5_mil_ClearDG,
1_mil_Holo_DG_Serialized, 1_milHolo_DG, 1_mil_Clear_DG,
.5_mil_Clear_DG_sc, Disabled
Default: None
8) OverlaydisplayName
Name of the overlay whose information is currently being
accessed.
Options: Clear_Topcoat, 0.5_mil_ClearDG,
1_mil_Holo_DG_Serialized, 1_milHolo_DG, 1_mil_Clear_DG,
.5_mil_Clear_DG_sc, Disabled
Default: None
9) OverlayInitialStrip
Length
Initial distance to move supply before creating bubble.
Default: 500 steps
10 and 11) Overlay
LoadedLxName
Name of the foil overlay loaded in L1 of L2 station.
(x= 1 or,2)
3-59
Option
Description
110) OverlayPartNumber
Part number of the overlay type. This setting applies only to the
overlay type specified by the OverlayDisplayedName setting,
whether it is loaded or not.
111 and 112) Overlay
RegOffsetLx
Adjustment to the distance the overlay must move after seeing
overlay registration, for L1. This is added to
MfgOverlayRegOffsetLx.
(x= 1 or,2)
Default: 0 (offset)
113) OverlaySpeed
Speed at which to apply the overlay.
Range: 100 - 250
Default: 160
SpeedAdjustmentLx
(x= 1 or,2)
116) OverlayStrippedStop
Distance
Speed Adjustment for L1 for L2 or this family of overlay types.
Range: -40 to 40
Default: 0
Distance in millimeters to move the card while the supply is
stopped to create slack for stripping.
Range: 50 to 300 mm
Default: 100 mm
117) OverlayTakeup
LengthOffset
Distance in millimeters to move the overlay after lamination to
retension supply.
Range: 0 to 1000 mm
Default: 450 mm
118) OverlayTemp
Temperature in degrees Celsius at which to apply the overlay.
Range: 100 - 200 C
Default: 160 C
TempAdjustmentLx
Temperature adjustment for L1 or L2 for this family of overlay
types.
(x= 1 or,2)
Range: -40 - 40 (offset)
Default: 0 (offset)
121-124) UserFoilxName
3-60
Foil name from which user-defined foil type 1 - 4 is derived.
Adjustments
Updating Printer Settings
Use the following procedure to back up your current printer settings file and
restore it to the printer or to download the one with the settings with which the
original printer was shipped.
Use this procedure if you have changed the print engine drive board and need to
restore the offsets.
Backing Up Printer Settings
The offsets for the Embosser and Printer are stored in a memory disk on the print
engine drive board. If the site changes offsets, changes can be recorded manually
or backed up using the DPCL Service Utility. Use this procedure if you have
made changes to your offsets and want to be able to restore them if the print
engine drive board fails.
1. If you have not already done so, install the DPCL Service Utility from the
Service Library CD. It creates an icon on the Desktop.
2. Connect a PC with the software program loaded to the Internet and set the IP
Address to the Printer’s address.
3. Click the icon to start the DPCL Service Utility.
4. Select Diag > Settings > Save All Settings.
5. Browse to a location to save the file.
Downloading a Settings File
If the site has not backed up printer settings, use this procedure to download the
as-shipped settings for that printer from PartnerPage.
1. Log on to www.PartnerPage.com.
3. Select Card Printers under Desktop ID Solutions.
4. Click the printer model and then on Board Replacement.
3-61
3-62
Adjustments
Chapter 4: Troubleshooting
This chapter provides troubleshooting information for the card
printer.
General Troubleshooting Procedures __________________________________ 4-4
Non-Clearing Repetitive Messages____________________________________ 4-4
Sensors ______________________________________________________________ 4-5
Test the Sensors____________________________________________________ 4-5
Test the Sensors Using Continuous Update___________________________ 4-5
Determine if the Sensor Has Failed __________________________________ 4-6
Test Card ____________________________________________________________ 4-7
Troubleshooting Motors ______________________________________________ 4-12
Testing the Ribbon and Pick Motors ________________________________ 4-13
Testing the Cam and Transport Motors _____________________________ 4-13
Other Troubleshooting Procedures ___________________________________ 4-14
Placing Cam in Uninstall Position___________________________________ 4-14
Testing the Thermal Printhead (TPH) Fan____________________________ 4-14
Diagnosing the Ribbon RFID Antenna ______________________________ 4-14
SSA Test __________________________________________________________ 4-14
Testing Smart Cards _________________________________________________ 4-15
Dual Contact/Contactless ________________________________________ 4-15
HID iClass Reader/Writer __________________________________________ 4-18
Indentive Smart Card _____________________________________________ 4-23
Basic Smart Card Integrator _______________________________________ 4-26
Performance Problems ______________________________________________ 4-27
Printer Initialization Errors __________________________________________ 4-27
Card Jams at Card Input _________________________________________ 4-28
Card Stalls at Output Stacker______________________________________ 4-28
Card Jams in Printing Area ________________________________________ 4-29
Ribbon Break Errors _______________________________________________ 4-29
Messages and Conditions ___________________________________________ 4-30
Messages on the Printer LCD ______________________________________ 4-30
Respond to Messages ____________________________________________ 4-34
Printer Messages__________________________________________________ 4-34
100: Request not supported ___________________________________ 4-34
101: Job could not complete __________________________________ 4-34
4-1
102: Card not in position ______________________________________
103: Printer problem __________________________________________
104: Critical problem __________________________________________
105: Magstripe data error _____________________________________
106: Magstripe data not found ________________________________
107: Magstripe read data error ________________________________
108: Magstripe read no data __________________________________
109: Print ribbon problem______________________________________
110: Print ribbon out or missing _________________________________
111: Card not picked _________________________________________
112: Card hopper empty ______________________________________
113: Close cover to continue __________________________________
114: Cover opened during job_________________________________
116: Magstripe not available __________________________________
117: Reader not available _____________________________________
118: Print ribbon type problem_________________________________
119: Print ribbon not supported ________________________________
120: User paused the printer ___________________________________
121: Print ribbon not identified _________________________________
122: Magstripe format problem ________________________________
149: Option not installed ______________________________________
150: Print while unlocked ______________________________________
151: Failed to lock ____________________________________________
172: Insert cleaning card ______________________________________
173: Improper shutdown ______________________________________
Laminator Messages______________________________________________
177: Laminator not available __________________________________
196: Laminator error critical____________________________________
197: Laminator entry card problem ____________________________
200: Laminator exit card problem______________________________
201: L1 supply problem ________________________________________
206: L2 supply problem ________________________________________
4-2
4-34
4-35
4-35
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4-36
4-36
4-37
4-37
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4-38
4-38
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4-40
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4-44
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4-44
4-44
4-44
4-45
4-45
4-45
4-45
4-45
Troubleshooting
208: L2 supply type problem ___________________________________ 4-45
209: L2 supply not supported __________________________________ 4-45
210: L2 supply not identified ___________________________________ 4-46
211: L1 heater problem _______________________________________ 4-46
212: L2 heater problem _______________________________________ 4-46
213: L1 heater sensor problem _________________________________ 4-46
214: L2 heater sensor problem _________________________________ 4-46
217: Debow problem _________________________________________ 4-47
218: Impresser problem _______________________________________ 4-47
219: Impresser sensor problem _________________________________ 4-47
220: Impresser heater problem ________________________________ 4-47
221: Bar code scanner problem _______________________________ 4-47
222: Firmware version mismatch _______________________________ 4-47
223: Laminator system mismatch ______________________________ 4-48
Driver-Only Messages_____________________________________________ 4-48
500: The printer is not available ________________________________ 4-48
501: The printer connection was lost ___________________________ 4-48
505: USB communication issue _________________________________ 4-49
506: A card is currently processing _____________________________ 4-49
508: The printer is shutting down _______________________________ 4-49
509: The printer is offline or suspended _________________________ 4-50
Driver SDK Messages______________________________________________ 4-50
511: Cannot lock or unlock the printer. Locks are not installed. __ 4-50
512: Cannot lock or unlock the printer. The password is incorrect or
invalid. _______________________________________________________ 4-50
513: Cannot lock or unlock the printer. The printer is busy. _______ 4-50
514: Cannot lock or unlock the printer. The cover is open._______ 4-50
515: Failed to lock or unlock the printer. The locks did not function. 4-50
516: Timeout expired before bar code could be read. __________ 4-50
517: Wrong printer job ID. _____________________________________ 4-51
Using the DPCL Service Utility _________________________________________ 4-51
Install the Utility on the PC_________________________________________ 4-51
Connect the PC and Printer over a Network _______________________ 4-51
View Printer Message Log_________________________________________ 4-53
Lock and Unlock Card Production ________________________________ 4-53
Back Up and Restore Settings _____________________________________ 4-54
Print Misadjustment _______________________________________________ 4-55
4-3
General Troubleshooting Procedures
The following guidelines help in isolating the cause of a failure. These scenarios
do not cover every aspect of the devices but do provide enough information to
isolate the root cause. Many of these procedures assume a familiarity with the
printer’s diagnostic software described in this chapter.
The help file contains a great deal of information for troubleshooting the
system—such as print quality and software communication problems. To
view help, click the desktop icon that was installed with the driver.
CAUTION: This section is written for a fully-trained technician. Performing
these procedures in an inappropriate manner damages the printer. Even a
trained technician must use care in applying these procedures to avoid
permanent damage to the printer.
Unless instructed otherwise, always disconnect the power from the printer
before connecting or disconnecting an electrical device from a circuit board.
Non-Clearing Repetitive Messages
If the printer encounters an error that does not allow it to begin production and
you have cleared the error message, the printer may continue to test for the same
error condition. This causes a repetitive error message that prevents the customer
engineer from performing diagnostic routines to troubleshoot the error. This type
of situation may be caused by a failed cam motor, card input sensor, card exit
sensor, etc.
When the error message is displayed and the printer beeps, do not clear the error
message from the computer's screen. Instead, hold the User button in until the
light turns green. The printer cancels its present job and enters suspend mode.
Press the User button again to go back on-line. The printer ignores the error until
a task is performed to reveal the error again. You may need to repeat this
procedure as you troubleshoot.
4-4
Troubleshooting
Sensors
The Sensors option on the Printer Manager Troubleshooting menu shows a list of
all sensors in the printer with their jumper number, current state (not real-time),
history and type. It also has options to start an update and reset the sensor
history. The continuous update interval can be adjusted from this display.
The current state is not updated to real time until you perform a test of the
sensors. To test the card printer sensors follow the procedures below.
Test the Sensors
1. Using Printer Manager, navigate to TroubleShooting > Sensors.
2. Click Run.
3. The screen blinks while the card printer runs the sensor test.
4. The Current and History columns are updated to reflect any changes detected
during the test.
Test the Sensors Using Continuous Update
1. Using Printer Manager, navigate to TroubleShooting > Sensors.
2. Enter the interval time in seconds and click Start Update.
3. The sensors are sampled at the interval indicated until you click Stop Update.
4. To reset Sensor History click Reset.
Printer Function
Associated Sensors
Card Feed and Picking
Card Present, Card Input
Card Transport
Card Input, Card Exit, Cam Home
Card Printing
Card Input, Cam Home
Ribbon Advance
Ribbon Index, Ribbon Motion
Magnetic Stripe Read/Write
Card Input, magnetic stripe encoder, card exit
Smart Card
none
Flipper
Duplex Home
4-5
Determine if the Sensor Has Failed
This procedure determines if a sensor has failed or if the main control board is not
seeing the sensor properly. The first step in troubleshooting a sensor is to
determine if the sensor is toggling from an active state to an inactive state as a
physical condition changes.
1. Verify that the sensor is fully plugged into the control board. In some cases,
an unplugged sensor is displayed as “active” in the Printer Manager window.
2. Using Printer Manager, observe the sensor status indicator. Unplug the
printer and swap the sensor with another sensor:
•
Because this is a test of the sensor, the original sensor does not need to be
removed. Simply unplug the original sensor from the control board and
plug in a replacement sensor.
•
If a spare sensor is not available, you can use a compatible sensor from
within the printer. (Except for the ribbon encoder and magnetic stripe
encoder sensors, all sensors are electrically compatible.)
•
The sensor does not need to be the same type. For example, a transmissive
sensor can be used in place of a reflective sensor. (The transmissive sensor
is easier to block and unblock.)
Do not swap the ribbon encoder or magnetic stripe encoder sensors with any
other sensor. These sensors are not electronically compatible.
3. If the replacement sensor functions, the original sensor is defective. Verify
this by reconnecting the original sensor.
4. If the replacement sensor is non-functional and other sensors in the printer
are observed to be functional, the main control board is defective. (If none of
the sensors are functional, you may have a communication problem between
the printer and Printer Manager.)
4-6
Troubleshooting
Test Card
The Test Card selections allows you to choose from several Test Patterns and Test
Card Options. You may choose whether or not to encode the mag stripe and also
which ribbon panels will be used. You may also opt to print additional copies.
Option
Description
Test Cards
Note: No values selected will reset the cam and act like a pick
and eject test.
Options: MagStripe, Color, Monochrome, or Topcoat
Default: Color
Copies
Range: 1 - 10
Default: 1
TestPattern1
Full color test card.
4-7
Option
Description
TestPattern2
Halfcolor testcard.
TestPattern3
Dense blue testcard.
4-8
Troubleshooting
Option
Description
TestPattern4
Color step testcard (RGBK/YMC)
TestPattern5
Used to set up card registration.
4-9
Option
Description
TestPatternRegistration
Used to test card registration mechanically. Side/side or lead/
trailing may indicate a chassis, card guide, or roller problem.
TestPatternCheckered
Used to test card registration mechanically. Side/side or lead/
trailing may indicate a chassis, card guide, or roller problem.
TestPatternShort
Used to print short panel YMCKT.
4-10
Troubleshooting
Option
Description
TestPatternGrid
Full K panel test card.
The TestPatternManufacturing test cards are used only in manufacturing
setup.
4-11
Troubleshooting Motors
Each of the motors of the card printer has a submenu option on the
Troubleshooting Menu. For each motor you can set the parameters and run the
test. The parameters are described in the list below.
Opening the swingarm cancels the motor test for the transport, pick, cam and
ribbon motors.
Motor
Description
Transport
You can adjust the Direction, Speed, and Steps. The steps
setting determines the amount of time the motor runs.
Pick
You can adjust the Direction, PWM, and Time. The PWM
controls speed and torque. Decreasing the PWM means
less speed and torque.
Caution: Before running this test make sure you remove all
cards from the Card Hopper. If you do not, you will feed
several cards and jam the printer.
Cam
You can control the Direction, Speed, and Steps. The cam
motor can be set to an uninstall position, see “Other
Troubleshooting Procedures” on page 4-14.
Ribbon
You can adjust the PWM and Time.
Note: Remove the ribbon cartridge before running this test
so no ribbon in wasted in the process.
Duplex Flipper
Use the Test Flipper submenu to verify function of this
motor.
Duplex Transport
Use the Test Flipper Trans submenu to test this motor, which
moves the Drive Rollers to transport the card. (This motor is
the upper one on the duplex chassis.)
Fan
Use this test to run the printhead fan. You can control only
Time using this test.
The best way to determine if a motor has failed versus a main control board, is to
swap the motor with a similar motor. If a motor has failed, a replacement motor
should function. If the motor’s driver has failed, a replacement motor will not
function either.
4-12
Troubleshooting
Testing the Ribbon and Pick Motors
The ribbon and pick motors are identical, so swapping the two motors can isolate
whether the motor or the print engine board is faulty.
1. Using Printer Manager, test the motor.
Testing the Cam and Transport Motors
The cam and transport motors are identical, so swapping the two motors can
isolate whether the motor or the print engine board is faulty.
1. Swap motor connectors on the print engine board, J12 for the cam motor and
J11 for the transport.
2. In Printer Manager, test the motor.
4-13
Other Troubleshooting Procedures
Placing Cam in Uninstall Position
To place the cam in the correct position for uninstalling the cam slide, use the
following procedure.
1. Select the Test Cam option from the troubleshooting menu in Printer
Manager.
2. Set the Speed to 600 and the Steps to 310 and click Run.
Testing the Thermal Printhead (TPH) Fan
The printhead fan begins to run when it reaches the correct temperature. See
“FanTempOn” on page 3-15 in the Print Settings. If the fan is not working, the
best way to test it is to connect another fan. There is no compatible jumper on the
board to use to test. If the other fan does not work, the board is the problem.
The fan makes little noise while running so if you are in a noisy location, it
may be difficult to rely on sound to determine if the fan is working.
Diagnosing the Ribbon RFID Antenna
The circuit board for the RFID antenna is very simple and not prone to failure. If a
failure exists in identifying a ribbon, the most likely cause is with the ribbon’s tag.
Test it by replacing the supply spool with a new spool.
If the printer cannot read any ID tags, check the cable leading to the print engine
board. If the cable is connected properly, the print engine board is likely at fault.
SSA Test
This option on the Troubleshooting menu performs a Start Sentinel adjustment
(SSA) test. Use the SSA test to automatically adjust the position of the start
sentinel for all 3 tracks simultaneously. The adjusted values will be written to the
magstripe general setting in Printer Manager for all three tracks.
4-14
Troubleshooting
Testing Smart Cards
The following procedures are for testing types of smart cards.
Dual Contact/Contactless
Smart PC/SC Diagnostics is reads the ATR of the smart card. The diagnostics can
be downloaded from SCM Microsystems at:
www.scmmicrosystems.com.
Test Procedure
1. Install the SCM diagnostics (SmartPCSCDiag V2.04 or higher) and the SCM
driver.
2. Connect the USB port on the rear of the printer to a USB port on the PC.
3. Open SCM diagnostics as shown:
4. Click on Connected Readers.
5. Click on SCR331-DI Smart Card Reader.
4-15
6. Open Print Manager and display the Troubleshooting tab. Choose the
Testcard test.
7. Clear all Test Card Print Options check boxes to avoid printing on a smart
card.
8. Put a contact smart card into the input tray. Scroll down to Test Card Other
Option. Select the Park Smart Card check box. If desired, change Copies as
well as Smart Card Park Time.
X
9. Click on Run. The card is picked and enters the smart card module. The ATR
of the card is read.
4-16
Troubleshooting
10. Click on SCR331-DI USB Contactless Reader.
11. Put a contactless smart card into the input tray. Click on Run. The card is
picked and enters the smart card module. The ATR of the card is read.
4-17
12. The test is complete.
HID iClass Reader/Writer
The RFID1356i Configuration Utility reads the Filter Mask, Facility Code and ID
Code from the HID iClass card. The configuration utility can be downloaded
from RFIDeas Inc at: www.rfideas.com.
Test Procedure
1. Install the RFID 1356i configuration utility.
3. Open the RFID 1356i configuration utility.
4. Place an HID iClass card into the input tray.
Testcard test.
6. Clear all Test Card Print Options check boxes to avoid printing on the HID
iClass card.
4-18
Troubleshooting
7. Scroll down to Test Card Other Option. Select the Park Smart Card check
box. If desired, change Copies as well as Smart Card Park Time.
8. Click on Run. The card is picked and enters the smart card module.
9. From the Advanced Configuration tab, click on the Get ID button to get the
Filter Mask, Facility Code, and ID Code from the card.
4-19
10. If necessary, change the time in data is valid for to another elapse time. When
this time elapses, the card data is discarded. The minimum value is 900. The
figure shows a value of 2500 (or 2.5 seconds).
4-20
Troubleshooting
Duali Single-Wire Smart Card
Use the Dpcl2Test.exe configuration utility to test the Duali single-wire smart
card.
1. Install the Dpcl2Test.exe configuration utility.
2. Make sure the printer is powered on and connected to the computer.
3. Open the Dpcl2Test.exe configuration utility.
4. Enter the printers IP address and click Connect.
5. Pick the test smart card options.
•
Hopper – Enter hopper number (1 for single input hopper).
•
Exception card – Prompts to insert card.
•
Contact – Select for contacted cards.
•
Contactless – Select for contactless cards.
•
Always eject – Deposits card into the good hopper when done.
•
Always reject – Deposits card into the reject hopper when done.
•
Reject on failure – Deposits Card into Reject when failure occurs (not used
on any SD/CD series printer).
•
Pause on smart card error – Waits for operator intervention.
4-21
6. Enter 1 for hopper, select card type (contact or contactless) and always eject
and click Run.
7. The card is run and tested.
•
4-22
Success and good ATR and APDU messages display when the test smart
card procedure succeeded.
Troubleshooting
•
Error: Card is not present: and Get card status... displays when the test smart
card procedure failed.
Indentive Smart Card
1. Use the Printer Manager to park test card.
A. Open the Printer Manager and log on with WebService access.
B. Select the Troubleshooting tab and select Testcard.
C. Click to clear the check boxes for all Test Card Print Options to avoid
printing on the smart card.
D. Place a test card in the input hopper. Place each test card in the input
hopper by itself and run the smart card test.
E. Scroll down to Test Card Other Option and select Park Smart Card.
F. Click Run. The card is picked and is moved into the smart card encoding
area.
4-23
4-24
Troubleshooting
2. Verify that the smart card ATR can be read for reader type (contact or
contactless).
A. Open the PC/SC Diagnostic tool.
B. From the Connected Readers entry in the left hand column, select the
Indentive Cloud 4000 F Reader (Contacted or Contactless).
•
The ATR of the card is read and the results display in the PC/SC
Attribute column of the PC/SC Diagnostic Tool.
•
Testing is complete.
4-25
Basic Smart Card Integrator
Use the diagnostics/smart card driver from the 3rd party smart card
manufacturer to read the ATR on the smart card. Use the configuration utility of
the 3rd party reader or reader/writer manufacturer to read the Filter Mask,
Facility Code, and ID Code from the card.
Test Procedure
1. Install the 3rd party diagnostics/smart card driver or configuration utility.
3. Open the 3rd party diagnostics or configuration utility.
4. Place the 3rd party card into the hopper.
Testcard test.
6. Clear all Test Card Print Options check boxes to avoid printing on the 3rd
party card.
7. Scroll down to Test Card Other Option. Select the Park Smart Card check
box. If desired, change Copies as well as Smart Card Park Time.
8. Click on Run. The card is picked and enters the smart card module.
9. Verify the 3rd party card can be read.
4-26
Troubleshooting
Performance Problems
Printer Initialization Errors
Symptom
The printer initializes but reports
a card stuck in the transport,
and the transport runs more
than expected.
Comments
•
•
The printer initializes but reports
a broken print ribbon.
•
•
Check the operation of the card input sensor using the
sensor screen in printer diagnostics. If the sensor is
always blocked, it is either disconnected or not fully
seated (obscured by part of the chassis).
Check the operation of the magnetic stripe registration
sensor using the sensor screen in printer diagnostics. If
the sensor is always active (non-reflecting):
- The sensor may be disconnected.
- The sensor may not be seated (doesn't reflect off of
rocker).
- The sensor has failed.
Check the encoder on the ribbon cartridge for
damage.
Make sure the encoder board is connected and
functioning.
The printer initializes and the
ribbon is advanced, but the
printer reports that the index
mark could not be found.
Remove the ribbon and close the cover. Check the sensor
setting in Diagnostics. If the sensor is not active:
• Make sure the reflective tape is present on the
printhead.
• Make sure the sensor is plugged in.
• Replace the sensor.
Frequent time-out errors occur
at the beginning of printing.
If there are other USB devices on the same computer, they
can interfere with timely communication with the printer.
Specifically look for the following:
• Is the card creation program saving its file or database
to a USB device?
• USB mass storage devices, where some program
application is set to auto-save to the device.
• A program application that is using or referencing a USB
device on a regular basis.
4-27
Card Jams at Card Input
Symptom
A card is not picked from the
input hopper.
Comments
•
Clean the printer.
Use graphic quality cards.
Fan cards properly.
Inspect the pick roller for buildup or debris.
Test the pick motor using Diagnostics.
Inspect the card gate to make sure it is securely
fastened.
Inspect the card stock for burrs and excessive static
buildup.
Inspect the pick roller and test the motor function.
The card is picked but stalls at
the cleaning rollers.
•
•
•
Clean the printer.
Inspect the cleaning rollers for excessive debris.
Transport not working.
A card is picked and appears to
be properly positioned, but the
error is still reported.
•
•
Clean the card input sensor.
Check the position of the card input sensor and make
sure it is fully and firmly seated into the transport.
Check the operation of the card input sensor using the
sensor diagnostics.
If the sensor is always blocked, it is either disconnected,
or not fully seated (obscured by part of the transport).
If the sensor never blocks, either the cable has a short
circuit, or the sensor is not seated at all (outside of the
card track).
•
•
•
•
•
•
•
•
•
•
Card Stalls at Output Stacker
Symptom
Completed cards frequently fail
to drop into the card output
stacker.
Comments
•
•
•
•
•
•
4-28
Clean the rollers in the printer.
This situation is more likely to occur with thinner cards or
cards printed on one side only.
Reduce static in the area of the printer by increasing the
relative humidity.
Use thicker cards.
Empty output tray often.
Make sure the static brushes are installed.
Troubleshooting
Card Jams in Printing Area
Symptom
Card stops prior to reaching the
platen roller.
Comments
•
•
Card stops under the printhead. •
•
•
Clean the rollers in the printer.
Increase the card registration distance.
Inspect the card for improper print ribbon panel
placement. Printing with the wrong panel can cause the
ribbon to adhere to the card.
Decrease the printing brightness setting.
Inspect the card guide for placement and damage.
Card stops past the printhead.
Ribbon Break Errors
Symptom
Ribbon did not break, but the
error is reported.
Comments
•
•
•
•
•
•
•
•
•
The ribbon frequently breaks.
•
•
•
•
•
Clean the printhead. It may be preventing the ribbon
from advancing.
Check the ribbon encoder wheel. Verify that it is
positioned in the sensor and is not damaged.
Check the ribbon encoder sensor cable to make sure it is
connected.
Check the sensor to make sure it is functional and
correctly aligned.
Check the ribbon motor and make sure it is functional.
Check the ribbon motor gear and take-up spool gear for
damage or broken teeth.
Check the ribbon cartridge clutch.
Check that the ribbon is attached to the take-up ribbon
core.
Check to see that the ribbon is not sticking to the card.
Check the Card Registration Offset.
Adjust the image trimming farther from the edge of the
card.
Make sure the printing intensity is not too dark. On an
edge-to-edge image when the leading edge of the
image uses 100% of a color (Y, M, or C), the ribbon can
get burned if the card is not fully under the printhead to
absorb the heat.
Check for burrs on the edges of the cards.
Make sure the cards being used are not already printed.
4-29
Messages and Conditions
When the printer cannot process the card sent, it issues a condition. The LCD
panel on the front panel shows these conditions. If you use the XPS Card Printer
Driver, the printer driver also displays the condition as a message on the PC. In a
shared printer environment, messages might differ slightly from the messages
and conditions described in this section.
Messages on the Printer LCD
All messages are associated with a print job. The printer issues messages that
focus on recovering from problems.
•
The printer displays a message number and a short description for each
message.
•
If more than one message was issued, the next message displays after you
correct the problem and press the User button.
•
The lights on the front panel flash while messages display on the LCD panel.
Printer Messages
No.
LCD Message
User Light
Supply Light
Card Light
Sound
–
Close and lock doors
Color Cycle
Off
Off
Error
100
Request not supported
Amber Flash Off
Off
Error
101
Job could not complete
Amber Flash Off
Off
Error
102
Card not in position
Amber Flash Off
Amber Flash Error
103
Printer problem
Amber Flash Off
Off
104
Critical problem
Amber Flash Amber Flash
Amber Flash Error
105
Magstripe data error
Amber Flash Off
Off
106
Magstripe data not found
Amber Flash Off
Amber Flash Error
107
Magstripe read data error
Amber Flash Off
Off
108
Magstripe read no data
Amber Flash Off
Amber Flash Error
109
Print ribbon problem
Amber Flash Off
Off
None
110
Print ribbon out or missing
Amber Flash Off
Off
Warning
4-30
Error
Error
Error
Troubleshooting
No.
LCD Message
User Light
111
Card not picked
Amber Flash Off
Amber Flash Warning
112
Card hopper empty
Amber Flash Off
Amber Flash Warning
113
Close cover to continue
Amber Flash Off
Amber Flash Attention
114
Cover opened during job
Amber Flash Off
Off
Error
116
Magstripe not available
Amber Flash Off
Off
Error
117
Reader not available
Amber Flash Off
Off
Error
118
Print ribbon type problem
Amber Flash Off
Off
None
119
Print ribbon not supported
Amber Flash Off
Off
None
120
User paused the printer
Amber Flash Off
Off
Warning
121
Print ribbon not identified
Amber Flash Off
Off
None
122
Magstripe format problem
Amber Flash Off
Off
Error
123
Insert new card side 1 up
Amber Flash Off
Amber Flash None
124
Insert same card side 2 up
Amber Flash Off
Amber Flash None
149
Option not installed
Amber Flash Off
Off
Error
150
Print while unlocked
Amber Flash Off
Off
Error
151
Failed to lock
Amber Flash Off
Off
Error
152
Amber Flash Off
Off
Warning
153
Amber Flash Off
Off
Warning
170
Amber Flash Off
Off
Warning
171
Amber Flash Off
Off
Warning
172
Insert Cleaning Card
Amber Flash Off
Off
Warning
173
Improper Shutdown
Amber Flash Off
Off
Warning
Supply Light
Card Light
Sound
4-31
Laminator Messages
Supply
Light
Card Light
Green
Flash
Off
Off
Laminator error critical
Green
Flash
Amber
Flash
Green
Flash
Red Flash
Error
197
Laminator entry card
problem
Green
Flash
Off
Off
Red Flash
Error
198
L1 area card problem
Green
Flash
Off
Off
Red Flash
Error
199
L2 area card problem
Green
Flash
Off
Off
Red Flash
Error
200
Laminator exit card
problem
Green
Flash
Off
Off
Red Flash
Error
201
L1 supply problem
Off
Amber
Flash
Off
Red Flash
Error
202
L1 supply out or missing
Off
Amber
Flash
Off
Red Flash
Warning
203
L1 supply type problem
Off
Amber
Flash
Off
Red Flash
Error
204
L1 supply not supported
Off
Amber
Flash
Off
Red Flash
Error
205
L1 supply not identified
Off
Amber
Flash
Off
Red Flash
Error
206
L2 supply problem
Off
Amber
Flash
Off
Red Flash
Error
207
L2 supply out or missing
Off
Amber
Flash
Off
Red Flash
Error
208
L2 supply type problem
Off
Amber
Flash
Off
Red Flash
Error
209
L2 supply not supported
Off
Amber
Flash
Off
Red Flash
Error
210
L2 supply not identified
Off
Amber
Flash
Off
Red Flash
Error
No.
LCD Message
User Light
177
Laminator not available
196
4-32
Laminator
Light
Sound
Error
Troubleshooting
Supply
Light
Card Light
Laminator
Light
Sound
Green
Flash
Off
Off
Red Flash
Error
L2 heater problem
Green
Flash
Off
Off
Red Flash
Error
213
L1 heater sensor problem
Green
Flash
Off
Off
Red Flash
Error
214
L2 heater sensor problem
Green
Flash
Off
Off
Red Flash
Error
215
L1 heater roller problem
Green
Flash
Off
Off
Red Flash
Error
216
L2 heater roller problem
Green
Flash
Off
Off
Red Flash
Error
217
Debow problem
Green
Flash
Off
Off
Red Flash
Error
218
Impresser problem
Green
Flash
Off
Off
Red Flash
Error
219
Impresser sensor problem
Green
Flash
Off
Off
Red Flash
Error
220
Impresser heater problem Green
Flash
Off
Off
Red Flash
Error
221
Bar code scanner
problem
Green
Flash
Off
Off
Red Flash
Error
222
Firmware version
mismatch
Green
Flash
Amber
Flash
Green
Flash
Error
223
Laminator system
mismatch
Green
Flash
Amber
Flash
Green
Flash
Error
No.
LCD Message
User Light
211
L1 heater problem
212
4-33
Respond to Messages
You can respond to printer messages using the printer front panel buttons or by
clicking the appropriate response in the message box displayed by the Card
Printer Driver on the PC.
Printer Messages
The following messages display on the printer LCD panel and in a message box
on the PC that issued the card print job when you use the Card Printer Driver.
100: Request not supported
The printer does not support the personalization being requested for the card.
The card will be canceled.
Change the card data to match the printer’s options and settings, or print to a
printer that is configured to support the personalization being requested.
Press the User button on the printer, or click OK in the message box to clear the
message.
101: Job could not complete
The card took too much time to complete.
message.
102: Card not in position
The card is not positioned in the printer correctly.
1. Open the printer and remove the ribbon cartridge.
2. Turn the knob to remove the card.
3. Replace the ribbon cartridge and close the printer.
Press the User button on the printer. In the message box, click Retry, or click
Cancel to cancel the card.
4-34
Troubleshooting
103: Printer problem
The printer had an error. The card will be canceled.
1. Press the printer Power button to power off the printer.
2. Press the Power button again to power on the printer.
Click OK in the message box to clear the message.
104: Critical problem
The printer had a serious error. The card will be canceled.
1. Press the printer Power button to power off the printer.
2. Request service.
The system must remain powered off.
105: Magstripe data error
The printer failed to verify that the correct magnetic stripe data was written on
the card.
1. Make sure that you are using magnetic stripe cards that match the printer
settings.
2. Make sure that the cards are placed in the printer correctly.
Hints & Tips
•
The card might have been turned the wrong way.
•
The card might not have a magnetic stripe.
4-35
106: Magstripe data not found
The printer did not find magnetic stripe data on card.
settings.
Hints & Tips
•
The card might not match printer settings or the data sent.
•
Ask the system administrator to verify that the card, the data, and the printer
settings match.
107: Magstripe read data error
The printer failed to read the magnetic stripe data from the card. The card will be
canceled.
settings.
message.
Hints & Tips
4-36
•
The data might use a different format than the current printer setting.
•
Ask the system administrator to verify that the card, data, and printer settings
match.
Troubleshooting
108: Magstripe read no data
The printer did not find any magnetic stripe data on card. The card will be
canceled.
settings.
message.
Hints & Tips
•
The card might have been turned the wrong way.
•
The card might not have a magnetic stripe.
109: Print ribbon problem
The print ribbon is not moving properly.
2. Reposition, repair, or replace the ribbon and advance the repaired area one
full turn.
3. Replace the ribbon cartridge and close the printer.
110: Print ribbon out or missing
The printer does not have usable ribbon. To complete the current card:
2. Install a new ribbon and cleaning roller.
3. Replace the cartridge and close the printer.
Press the User button on the printer. In the message box, click OK, or click Cancel
to cancel the card.
Hints & Tips
Used ribbon has negative images of printed data. To keep the data confidential,
follow your company policy to discard used ribbon.
4-37
111: Card not picked
The printer did not pick a card. To complete the current card:
For printers with an input hopper, open the input hopper, add or reposition
cards, and close the hopper.
For printers with single card feed, push the card in until the printer picks it.
to cancel the card.
112: Card hopper empty
The printer did not detect cards in the input hopper.
Add cards to the input hopper.
to cancel the card.
113: Close cover to continue
The printer cover must be closed to print.
Push down on the cover to latch it.
to cancel the card.
Hints & Tips
Make sure that the ribbon cartridge is installed properly with the cartridge
handle even with the edges of the printer.
114: Cover opened during job
The printer cover was opened while printing.
Push down on the cover to latch it.
Hints & Tips
Make sure that the ribbon cartridge is installed properly with the handle even
with the edges of the printer.
4-38
Troubleshooting
116: Magstripe not available
The printer does not have a magnetic stripe option. The card will be canceled.
Remove magnetic stripe data from the card or use a printer that has a magnetic
stripe option installed.
message.
Hints & Tips
To remove magnetic stripe data, you or your system administrator may need to:
•
Clear a check box in the card production application.
•
Change the font from Mag Track X XPS Card Printer to a printable font such
as Arial, Verdana, or Calibri. Refer to “Magstripe Formats” in your printer’s
Installation and Administrator’s Guide.
117: Reader not available
Change the card data to match the printer’s options and settings or print to a
message.
Hints & Tips
To remove the reader request, you or your system administrator may need to
clear a check box in the card production application.
118: Print ribbon type problem
The printer cannot use the ribbon installed. The card will be canceled.
Use ribbon designed for this printer.
message.
Hints & Tips
•
Purchase ribbon from your dealer or authorized reseller.
•
Check the website for newer firmware that supports new ribbon types.
4-39
119: Print ribbon not supported
message.
Hints & Tips
•
Purchase ribbon from your dealer or authorized reseller.
•
Check the website for newer firmware that supports new ribbon types.
120: User paused the printer
The printer was paused while printing.
To complete the current card press the printer’s User button.
In the message box, click OK to clear the message and complete the current card,
or click Cancel to cancel the card.
Hints & Tips
•
If the user pressed the User button for several seconds, the card has been
canceled.
•
If this message occurs often, ask your system administrator to set the button
sensitivity to a lower value.
121: Print ribbon not identified
message.
Hints & Tips
Ask your dealer or authorized reseller for a replacement.
122: Magstripe format problem
The magnetic stripe data sent does not match the format set in the printer. The
card will be canceled.
message.
4-40
Troubleshooting
123: Insert new card side 1 up
1. Insert a new card in the printer with side 1 facing up.
2. If the card is not immediately picked, press the printer’s User button or click
OK.
Click Cancel in the message box if you want to cancel the card.
124: Insert same card side 2 up
1. Take the card from the printer.
2. Turn the card over end to end so side 2 is facing up.
3. Insert the card in the printer.
OK.
149: Option not installed
Change the card data to match the printer’s options and settings, or print to a
message.
Hints & Tips
Don’t include references in the card format to hardware that cannot be accessed
by the system. For more information, refer to your ID software documentation or
ask your system administrator.
150: Print while unlocked
The printer is unlocked. The card will be canceled.
Make sure that all access doors are closed securely and locked.
4-41
151: Failed to lock
An attempt to lock the printer failed. The card will be canceled.
1. Make sure that all access doors are closed securely.
2. Try locking the printer again.
1. Turn a new card over end to end so side 2 is facing up.
OK.
1. Take the card from the printer and turn it over end to end so side 2 is facing
up.
OK.
1. Insert a new card in the printer with side 1 facing up.
OK.
1. Take the card from the printer and turn it over end to end so side 1 is facing
up.
OK.
4-42
Troubleshooting
172: Insert cleaning card
1. Insert cleaning card.
OK.
Click Cancel in the message box if you want to cancel the cleaning card.
173: Improper shutdown
Always use the power button to power off the printer.
Laminator Messages
The following messages display on the printer LCD panel when you are using a
SD460 laminating system. They also display in a message box on the PC that
issued the card print job.
177: Laminator not available
The printer and laminator cannot communicate. The card will be canceled.
1. Make sure the data cable from the laminator to the printer is securely plugged
in.
2. Press the printer Power button to power off the system.
3. Press the Power button again to power on the system.
196: Laminator error critical
The laminator has encountered a critical error. The card will be canceled.
2. Request service. The system must remain powered off.
197: Laminator entry card problem
The card is not where it should be in the laminator.
1. Open the laminator.
3. Close the laminator.
4-43
198: L1 area card problem
1. Open the laminator and remove the L1 supply cartridge.
3. Replace the supply cartridge and close the laminator.
199: L2 area card problem
1. Open the laminator and remove the L2 supply cartridge.
3. Replace the supply cartridge and close the laminator.
200: Laminator exit card problem
201: L1 supply problem
The L1 supply is not moving properly. To try another card:
1. Open the laminator and remove the L1 cartridge.
2. Reposition, repair, or replace the supply and advance the repaired area one
full turn.
3. Replace the cartridge and close the laminator.
202: L1 supply out or missing
The laminator does not have usable supplies.
2. Replace the supply.
4-44
Troubleshooting
203: L1 supply type problem
The laminator cannot use the supply installed.
Use supplies designed for this laminator.
204: L1 supply not supported
205: L1 supply not identified
206: L2 supply problem
The L2 supply is not moving properly. To try another card:
2. Reposition, repair, or replace the supply and advance the repaired area one
full turn.
207: L2 supply out or missing
The laminator does not have usable supplies.
2. Replace the supply.
208: L2 supply type problem
209: L2 supply not supported
4-45
210: L2 supply not identified
211: L1 heater problem
212: L2 heater problem
213: L1 heater sensor problem
214: L2 heater sensor problem
215: L1 heater roller problem
216: L2 heater roller problem
4-46
Troubleshooting
217: Debow problem
The laminator has encountered an error in the debow area.
1. Remove the card.
3. Press the printer Power button again to power on the system.
4. If the problem occurs again, request service.
218: Impresser problem
219: Impresser sensor problem
220: Impresser heater problem
221: Bar code scanner problem
2. Verify the supply has bar codes printed on it.
4. Try the card again.
If the problem occurs again, request service.
222: Firmware version mismatch
The printer and laminator firmware versions are not compatible. The system
cannot laminate cards until the firmware has been updated.
Update both the printer and laminator to the latest firmware versions.
4-47
223: Laminator system mismatch
The printer and laminator are not compatible.
The laminator is not supported by your printer model. Contact your service
provider for the correct laminator model.
Driver-Only Messages
The following messages are issued by the Card Printer Driver and display in a
message box on the PC that sent the card print job. These messages do not display
on the printer LCD panel.
500: The printer is not available
The computer cannot communicate with the printer. To complete the current
card:
1.
Make sure that the printer is powered on and in the Ready state.
2. Make sure the printer is connected to the computer using a USB or network
cable, but not both.
When the printer is ready, click OK.
Click Cancel if you want to cancel the card
501: The printer connection was lost
The computer lost communications with the printer during printing. The card
will be canceled.
1. Make sure the printer is powered on.
2. Make sure the printer connection to the computer is secure.
Click OK to clear the message.
502: The card data is missing or is not usable
The printer driver has detected invalid or missing data. The card will be canceled.
Make sure the data being sent is formatted properly and matches the options and
settings in the printer.
4-48
Troubleshooting
504: The card data is missing or is not usable
The printer driver has detected invalid or missing data. The card will be canceled.
Make sure the data being sent is formatted properly and matches the options and
settings in the printer.
505: USB communication issue
An important driver component is not running. The card will be canceled.
1. Restart the computer. The component should start automatically.
2. If this message is displayed after restarting, notify your printer support
contact.
506: A card is currently processing
The printer is busy processing an interactive job. The card will be canceled.
Wait until the current card is complete and then try again.
507: The printer is unlocked
The printer must be locked to print.
To complete the current card make sure that all access doors are closed securely
and locked.
Click OK to clear the message, or click Cancel to cancel the card.
508: The printer is shutting down
The printer is shutting down or resetting. The card will be canceled.
When printer is powered back on, try again.
4-49
509: The printer is offline or suspended
The printer must be online to print.
To complete the current card press the printer’s User button until the printer
returns to the Ready state.
510: The printer is unlocked
The printer must be locked to resume printing.
Make sure that all access doors are closed securely and locked.
Driver SDK Messages
The following messages are issued when you use the Card Printer Driver
Software Development Kit (SDK) to define your card printing. The messages are
returned by the SDK to the application that sent the print job. These messages do
not display on the printer LCD panel or in a message box on the PC that sent the
job.
511: Cannot lock or unlock the printer. Locks are not installed.
Severity: Critical
512: Cannot lock or unlock the printer. The password is incorrect or invalid.
Severity: Critical
513: Cannot lock or unlock the printer. The printer is busy.
Severity: Notice
514: Cannot lock or unlock the printer. The cover is open.
Severity: Notice
515: Failed to lock or unlock the printer. The locks did not function.
Severity: Critical
516: Timeout expired before bar code could be read.
Severity: Notice
4-50
Troubleshooting
517: Wrong printer job ID.
Severity: Critical
Using the DPCL Service Utility
Access the DPCL Service Utility installation file from the Service Library menu.
The utility is useful for firmware upgrades, backing up and restoring settings,
and viewing the printer log file in error conditions.
The service utility will install with the limited service option by default. To enable
service mode, select File > Service Mode, enter password 926918, and click OK.
Select Settings and click OK to make the service mode default.
Install the Utility on the PC
From the start menu of the Service Library CD, click Install Service Utility. When
the installation is done, the following icon displays on the desktop.
Read the Help button for more information on the tool.
Connect the PC and Printer over a Network
The following figure shows how to physically connect the PC and Embosser to a
switchbox to make a TPC/IP connection.
4-51
Use the following procedure to set the TCP/IP address in the software.
1. Determine the IP address of the printer.
2. Start the Service Utility. The current IP address is displayed at the right.
3. If it is not correct, use the following procedure to set the TCP/IP address of
the printer.
A. Select Setup > Settings.
B. With DPCL Used checked, edit the TCP/IP value to that of the printer and
click OK to connect to the CE series system.
Check Open Card box if printer is in Open Card Mode.
4-52
Troubleshooting
View Printer Message Log
Sometimes printer errors prevent you from viewing the status logs on the printer
through Printer Manager. On such occasions use the Service Utility to
troubleshoot.
1. With the printer connected to the PC and the Service Utility running and
communicating, select the Diag menu.
2. Select Cedar Log and Read (for non-secured printers) or DPCL2
(RetrieveLogs) (for secured printers). Wait a few moments until the log file is
displayed in Notepad.
Lock and Unlock Card Production
If a printer will not be used for awhile, you can lockout card production as an
extra security feature.
2. Select Security and Lock Printer (or Unlock Printer).
3. A status message confirms a successful change to offline or online.
4-53
Back Up and Restore Settings
If you have not saved the printer’s settings and need to restore settings from
Datacard service, refer to the procedure in “Updating Printer Settings” on page
3-61. This procedure is for backing up and restoring the printer settings if changes
were made at the site.
The setting file does not contain wheel information. It is required to backup
wheel settings if you replace the embosser board.
The wheel tables are saved as an XML file. Default wheel kits are included with
the service utility. Wheel tables can not be saved or restored using the web pages.
You can only change individual characters only.
Back Up Settings
2. Select Settings and Save All Settings.
3. Create a descriptive name with the xml extension, and save the file to a
convenient storage location.
4-54
Troubleshooting
Restore Settings
1. With the printer connected to the PC and the DPCL Service Utility running
and communicating, select the Diag menu.
2. Select Settings and Restore All Settings.
3. Find the previously saved backup file and select it.
Print Misadjustment
Misadjustment of the CardRegistrationCalibration, CardRegistration, LeadTrim, or
TrailTrim can also cause ribbon registration problems. This happens because the
ribbon is advanced by the printhead when the card is not in position to prevent
the printhead from traveling further than it should. For more information and an
example see “Print Misadjustment” on page 3-27.
4-55
4-56
Troubleshooting
Chapter 5: Routine
Maintenance
This chapter provides card printer maintenance procedures for
both the operator and the service technician.
Required Tools and Supplies __________________________________________ 5-2
For Remove and Replace Procedures ______________________________ 5-2
For Magnetic Stripe Option ________________________________________ 5-3
For Smart Card Option _____________________________________________ 5-3
Avoiding Electrostatic Discharge ______________________________________ 5-4
Screw Torque Specifications __________________________________________ 5-5
Preventive Maintenance Procedures __________________________________ 5-6
Mechanical Inspection ____________________________________________ 5-6
Cleaning the Interior of the Printer _________________________________ 5-12
Lubricating the Grease Points _____________________________________ 5-12
Lubricating the Magnetic Stripe Assembly _________________________ 5-16
Cleaning the Rollers ______________________________________________ 5-17
Maintaining the Smart Card Module _______________________________ 5-19
Visual Inspection for Card Quality _________________________________ 5-21
Maintaining the Magnetic Stripe Module __________________________ 5-21
Operator Maintenance ______________________________________________ 5-22
Cleaning the Thermal Printhead (TPH) _____________________________ 5-22
Using the Cleaning Card __________________________________________ 5-23
Updating Printer Settings _____________________________________________ 5-25
Replacing the Print Engine Drive Board _______________________________ 5-27
Downloading Settings File for Board _______________________________ 5-27
Updating Settings_________________________________________________ 5-28
Enabling the Proprietary Magnetic Stripe Option ______________________ 5-29
Downloading Settings File for Magnetic Stripe Option_______________ 5-29
Updating Settings_________________________________________________ 5-30
Verifying Proprietary Magnetic Stripe Option _______________________ 5-30
5-1
Required Tools and Supplies
The following tools and supplies are needed for routine maintenance procedures.
Description
Compressed air (canned)
General purpose, non-abrasive cleaner
Part Number
TUL001-018
Any
Lint-free cloth
TUL001-020
Isopropanol cleaning swab
507377-001
Isopropanol cleaning card (10-pack)
552141-002
Cleaning sleeve (5-pack)
569946-001
Molykote DX grease
807421-001
Cleaners used on the printer’s exterior should not contain any abrasives, oils,
fragrances, antibacterial agents, solvents, or isopropanol. Do not use softscrubbing cleansers, products with petroleum, or products with mineral,
pine, or lemon oil.
Caution: Use only canned compressed air on this printer. Do not use facility
air as it will have trace amounts of oil and moisture that will accumulate on
surfaces and possibly damage electronic components.
For Remove and Replace Procedures
The following tools and supplies are needed for the remove and replace
procedures.
Description
Part Number
T-6 Torx Driver
T-10 Torx Driver
Needle-nose Pliers
ESD Grounding Kit
TUL006-006
Protective Eye wear
5-2
Cable Ties
803190-010
Enclosure Release Tool
571712-001
Routine Maintenance
For Magnetic Stripe Option
The following tools and supplies are needed for a printer with the magnetic stripe
option.
Description
Part Number
Small Phillips Screwdriver (Jewelers Type)
Four Flute Spline Wrench 0.048-Inch Diameter Bristol
Wrench Part Number
®
804267-918
KY Read dip magnetic tape developer
or equivalent such as TXC, Magna See
TUL001-014
804267-915
Kit, Glass Card Gauge, ISO ID-1; or
Magnetic Stripe Alignment Gauge
560585-001
513739-001
Magnetic stripe cards (blank)
HICO
LOCO
803229-034
803229-024
Clean, lint-free cloth
Magnifying glass
Molykote DX grease
807421-001
For Smart Card Option
The following card supplies are needed for a printer with the smart card option.
Description
Part Number
Contact Smart Card
504322-001
Contactless Smart Card
504323-001
5-3
Avoiding Electrostatic Discharge
While working around control boards and other sensitive components, use
proper equipment and procedures to reduce the possibility of damaging the
components.
This section describes the procedure for protecting against damage due to
electrostatic discharge. For more safety information see “Safety” in the Revision
Log at the beginning of this manual and “Precautions” on page 1-3.
Caution: Static electricity can destroy components in a circuit board. Use the
following precautions when handling the board, its components, or tools in
contact with the board or its components.
To avoid electrostatic discharge you can use the tools in the static-grounding kit
(Part No: TUL006-006):
•
•
•
Static-grounding mat
Mat-grounding cable
Static-grounding wrist strap
•
•
Wrist strap grounding cable
Grounding plug
Procedure:
1. Wear appropriate clothing. Avoid wool and synthetic fabrics.
2. Remove movable carpet and rugs.
3. Apply the grounding strap to a wrist. Ensure that there is no clothing
between the strap and skin and that the strap is snug enough to maintain
contact with the skin.
4. Connect one end of the grounding cable to the wrist strap.
5. Using the grounding plug, connect the other end of the grounding cable to
the earth ground of a facility AC outlet.
6. Clear a work area, lay the static-grounding mat on the work area, and connect
the movable end of the long grounding cable to the mat.
7. Always set unshielded static-sensitive materials on the grounded anti-static
mat. Whenever possible, place components into static-shielded bags.
8. When bringing two objects into contact (tool to circuit board or board to mat),
first simultaneously touch both objects with fingers.
5-4
Routine Maintenance
Screw Torque Specifications
Torque
(in-lbs) +/- 10%
Torx Bit
Pick Motor
1.5
T6
Ribbon Motor
1.5
T6
Transport Motor
8
T10
Cam Motor
8
T10
TPH Heat Sink
8
T10
TPH Adjustment
8
T10
Screw Location
5-5
Preventive Maintenance Procedures
Perform preventive maintenance procedures to extend the life of the printer each
time the printer is serviced.
Caution: Static electricity can destroy components on a circuit board. Follow
the precautions in the section titled “Precautions” on page 1-3 and the section
in this chapter “Avoiding Electrostatic Discharge” on page 5-4, when
handling the board, its components, or tools in contact with the board or its
components.
Refer to removal and replacement procedures in “Removal and
Replacement” on page 6-1 of this manual for more information on
disassembly and reassembly of the card printer.
Caution: Do not spray or pour cleaner directly on or into any electrical
device.
Mechanical Inspection
Inspect the following components and replace as needed.
1. Check the fixed cleaning rollers to make sure they are not nicked or gouged.
Replace them if they are brittle.
2. Check all other rollers for wear or damage.
3. Check springs to verify they are in position and not damaged.
4. Inspect the transport system:
A. Inspect the timing belt for wear and missing teeth.
B. Inspect the idler pulleys and make sure they are securely seated.
C. Inspect the drive pulleys for wear and broken teeth.
D. Inspect the platen roller gear and pulley for wear and broken teeth.
5-6
Routine Maintenance
E. Inspect the static brushes for wear and improper placement. The two
located on the chassis are on the ribbon bridge and on the smart card
module. They are meant to be in close proximity to, but not touching, the
card. The static brushes act as a lightning rod to provide a ground for
static electricity. The static is neutralized so it does not harm the machine.
The other brush is located on the duplex module as depicted in the figure
on the following page.
5-7
5. Inspect the ribbon drive gear for wear and broken teeth. Make sure it is
securely seated on the motor shaft.
6. Inspect the ribbon cartridge.
A. Inspect the spindle gear for wear and missing teeth.
5-8
Routine Maintenance
B. Check the spindles for proper movement and ensure that the clutch
provides a slight drag.
7. Check to see that the cooling fan is running properly by running a test card.
5-9
8. If applicable, inspect the duplex module drive and idler rollers for wear and
damage.
9. If applicable, inspect the smart card module.
5-10
Routine Maintenance
A. Inspect all the gears depicted in the following figure for wear and missing
teeth.
B. Verify smooth transition of cards through module.
5-11
Cleaning the Interior of the Printer
1. Turn the printer off if necessary.
2. Unplug the printer.
3. Remove the printer enclosures.
4. Remove the chassis from the base enclosure.
5. Using canned compressed air:
A. Blow out any debris near the sensors
B. Blow out any dust from the control board and other surfaces of the base.
C. Blow out any dust and debris from the underside of the chassis.
Lubricating the Grease Points
1. Look to see if the grease points have accumulated dirt and debris.
2. For each of the following points, wipe off the grease with a dry cloth, and regrease the surfaces with Molykote DX grease.
Caution: Do not add more lubrication than is indicated.
5-12
Routine Maintenance
A. Lubricate the platen roller.
5-13
B. Lubricate the registration roller.
5-14
Routine Maintenance
C. Lubricate the cam shaft.
5-15
Lubricating the Magnetic Stripe Assembly
Apply Molykote grease (1) and rotate shaft (2) to spread grease. Apply an
additional amount of grease at (3) while rotating shaft (4) to lubricate encoder
bracket at (5) when assembled.
Caution: Do not apply grease directly on bracket to prevent grease from
accumulating on the end of shaft.
5-16
Routine Maintenance
Cleaning the Rollers
The cleaning card is not adequate to clean all of the rubber rollers thoroughly. Use
the following procedure to clean the rollers. Continue cleaning the rollers until
the cleaning cloth no longer becomes discolored after contact with the roller.
Do not use any type of solvent on the cleaning rollers. Use only 90% or greater
isopropyl alcohol. (Do not use 75% alcohol as it has too much water.)
1. Apply isopropyl alcohol to a lint free cloth and then rub directly on the
rollers, wiping them while the rollers are in motion. To activate the rollers, use
the following tests in Printer Manager:
•
Use the Test Pick test to move the Pick motor and clean the pick roller
•
Use the Test Transport test to move the Transport motor and clean the
cleaning rollers, registration rollers, print platen roller and rear rollers (top
and bottom).
5-17
•
Use the Test Flipper Trans test to move the duplex drive and idler rollers.
.
Take care to remove any contamination from the drive rollers to prevent
card slippage. This is particularly important if the card stock being used
contains a signature panel.
5-18
Routine Maintenance
Maintaining the Smart Card Module
•
Clean the smart card registration sensor (simplex or duplex).
•
Inspect and clean the rubber rollers (duplex only).
•
Inspect all the gears (duplex only).
•
Verify contact switch operation, if applicable (simplex or duplex).
•
Verify smooth operation (simplex or duplex).
•
Using Printer Manager, verify a smart card goes into the smart card module
(simplex or duplex).
•
Using third-party smart card diagnostics, verify ATR or other information can
be read (simplex or duplex).
Simplex Assembly
5-19
Duplex Assembly
5-20
Routine Maintenance
Visual Inspection for Card Quality
Print several test cards to verify that the card transport functions properly and
that the horizontal margin is in the proper place. See “Test Card” on page 4-7 for
more information on the test card options. Inspect the test card(s) for obvious
flaws in quality. If you find problems, refer to “Troubleshooting” on page 4-1.
•
Vertical Offset must not be greater than 0.254 mm (0.010 inch).
•
Card Registration must place the first row of printing at 0.254 ± 0.0762 mm
(0.003 inch).
•
If topcoat is used, it must completely cover the card from edge to edge.
•
Check the card for obvious quality flaws including wrinkling.
Maintaining the Magnetic Stripe Module
Print a few magnetic stripe test cards. See “Test Card” on page 4-7 for more
information. For a list of tools see “For Magnetic Stripe Option” on page 5-3. Then
do the following:
•
Clean the magnetic stripe head
•
Verify the magnetic stripe track height. See “Magnetic Stripe Track Height
Test” on page 3-41 for the procedure.
•
Verify the start sentinel position. See “Start Sentinel Position Adjustment” on
page 3-43 for the procedure.
5-21
Operator Maintenance
These procedures are usually done by the operator and are included in this
service manual for reference and in case operator training is required.
Cleaning the Thermal Printhead (TPH)
On systems that print the cards the operator cleans the printhead using an
isopropanol cleaning swab. (Refer to Service Tools and Supplies on the CD
library for the part number to order.)
Open the swingarm and use gentle pressure as you move the isopropanol tip of
the swab back and forth along the edge of the printhead.
5-22
Routine Maintenance
Using the Cleaning Card
The cleaning card cleans particles from the cleaning rollers so they do not damage
the printhead. The cleaning card is pre-saturated with isopropanol and must be
used immediately after removing it from the package. Follow the steps below to
use the cleaning card to clean the printer.
1. Remove the print ribbon and cleaning sleeve from the printer.
2. Remove any cards from the printer.
3. To clean the card printer use the procedure in either Printer Manager or the
LCD Panel. Use one of the procedures below.
Procedure 1
Run the cleaning card using Printer Manager:
1. Select Cleaning from the Maintenance menu.
2. Click Run.
5-23
Procedure 2
Run the cleaning card using the LCD panel:
1. Begin with the display showing Ready.
2. Press the User button once.
3. At the Suspended Menu available prompt touch Enter lightly.
4. At the Main Menu | Maintenance prompt touch Enter.
5. At the Maintenance | Cleaning Card prompt touch Enter.
6. At the Cleaning Card | Start prompt touch Enter.
7. At the Insert cleaning card prompt, remove the cleaning card from its
wrapper and insert it into the card feeder.
5-24
Routine Maintenance
Updating Printer Settings
Use the following procedure to update the printer settings file.
1. Open Printer Manager.
2. Log in as WebService.
3. Select Updates from the Maintenance Menu.
4. Click Browse to select the directory that contains the settings file.
5. Select the settings file and click Open.
5-25
6. Click on Upload File.
7. The user status light flash green as the file is being sent to the printer. When
the process is completed, the LCD panel displays the message, File Upload
Complete.
5-26
Routine Maintenance
Replacing the Print Engine Drive Board
Follow the procedure for removing and replacing the main control board (see
“Print Engine Drive Board” on page 6-49), and then use the following steps to
download the new settings file from www.PartnerPage.com and to apply the new
settings file to the printer.
Downloading Settings File for Board
Use the following steps to download the settings update file from PartnerPage for
use when replacing the main control board.
1. Log in to www.PartnerPage.com.
3. Choose Card Printers under Desktop ID Solutions.
4. Click on the printer model (SD260L or SD360) to display its menu.
5. Click on Board Replacement.
5-27
6. Click on Click Here to Continue.
7. Enter the Auth Key from the new Board and the Serial Number of the printer
(on a label attached to the side of the swingarm). Click Submit.
8. Click on the link to download the file.
9. Save the file on the hard disk of your PC.
Updating Settings
Use Updating Printer Settings as described on page 5-25 to apply the new main
control board settings file that you downloaded.
Then update the Magnetic Stripe option as described in the following section.
5-28
Routine Maintenance
Enabling the Proprietary Magnetic Stripe Option
New printers require this procedure to set the magnetic stripe option. If a print
engine (main control) board is replaced, this procedure should be used to restore
magnetic stripe settings.
Downloading Settings File for Magnetic Stripe Option
Follow the steps below to download the settings update file from PartnerPage to
use when enabling proprietary magnetic stripe options.
1. Log in to www.PartnerPage.com.
3. Choose Card Printers under Desktop ID Solutions.
4. Click on the printer model.
5. Click on Enable Options.
6. Click on Click Here to Continue.
7. Enter the Auth Key for the main control board and the Serial Number of the
printer (on a label attached to the side of the swingarm) and select the
appropriate magnetic stripe option from the list. Click Submit.
8. Click on the link to download the file.
9. Save the file to the hard disk on your PC and proceed to the next section.
5-29
Updating Settings
Use Updating Printer Settings as described on page 5-25 to apply the magnetic
stripe option settings file that you downloaded. Then use the following
procedure to verify that the option has been enabled.
Verifying Proprietary Magnetic Stripe Option
This procedure is required after a proprietary magnetic stripe option has been
enabled.
1. Click MagStripeGeneral from the Printer Setting menu in Printer Manager.
2. In the DataFormat1 dialog, select the proprietary magnetic stripe option
installed on your printer.
5-30
Routine Maintenance
Chapter 6: Removal and
Replacement
This chapter provides procedures for removing and replacing
components and assemblies in the card printer.
Introduction to this Chapter ___________________________________________ 6-4
General Notes_____________________________________________________ 6-4
Required Tools_____________________________________________________ 6-4
Safety ____________________________________________________________ 6-4
Symbols ___________________________________________________________ 6-4
Printer Components _______________________________________________ 6-5
Cable Routing_____________________________________________________ 6-5
Transport Cables _______________________________________________ 6-5
Smart Card and Duplex Cables _________________________________ 6-6
Swingarm Cable Routing _______________________________________ 6-7
Freeing Cables from Clamps _______________________________________ 6-8
Functional Block Diagrams _________________________________________ 6-8
Exterior Components _________________________________________________ 6-9
Ribbon Cartridge __________________________________________________ 6-9
Ribbon Cartridge Lid______________________________________________ 6-10
Swingarm Lid and Enclosure Flap __________________________________ 6-12
Enclosures________________________________________________________ 6-13
Card Tray ___________________________________________________________ 6-15
100-Card Input Lid and Cover _____________________________________ 6-15
Tray Assembly and Manual Feed __________________________________ 6-16
Front Bezel, LCD Interface Panel, and 25-Card Output ______________ 6-17
LCD Interface Panel Routing ______________________________________ 6-18
Simplex Base _____________________________________________________ 6-19
Tray ________________________________________________________________ 6-20
Pick Gate and Pick Gate Spring ___________________________________ 6-20
Pick Roller Assembly ______________________________________________ 6-21
Picker Crankshaft, Pick Block Assembly ____________________________ 6-22
Transport Components ______________________________________________ 6-23
Timing Belt _______________________________________________________ 6-23
Belt Plate_________________________________________________________ 6-24
Platen Roller Assembly ____________________________________________ 6-25
Card Guide/Spring and Registration Drive Assembly ________________ 6-26
Drive Pulleys and Idler Pulleys______________________________________ 6-28
Backup Roller, Registration Backup and Top Cleaning Rollers _______ 6-29
Backup Roller Springs and Brackets, Capstan Roller Sleeve__________ 6-30
Belt Tensioner and Spring, Idler Pulleys _____________________________ 6-31
6-1
Cam Slide _______________________________________________________
Cam, Cam Shaft, Cam Gear, Cam Idler Gear _____________________
Swingarm Components ______________________________________________
Ferrite Bead______________________________________________________
Thermal Printhead (TPH) __________________________________________
Fan ______________________________________________________________
Swingarm, Torsion Spring, Damper_________________________________
Print Engine Sensors __________________________________________________
Head Latch Sensor _______________________________________________
Ribbon Index Sensor, Ribbon Bridge _______________________________
Card Input Sensor ________________________________________________
Card Exit Sensor __________________________________________________
Cam Home Sensor _______________________________________________
Print Engine Motors ___________________________________________________
Pick Motor and Pick Drive Gear ___________________________________
Ribbon Motor, Ribbon Drive Gear _________________________________
Cam Drive Motor Assembly _______________________________________
Transport Motor Assembly_________________________________________
Circuit Board Components ___________________________________________
Print Engine Drive Board __________________________________________
Sensor Encoder Cable Assembly (RFID) ____________________________
Ribbon Motion Magnetic Encoder Board __________________________
Magnetic Stripe Option ______________________________________________
Magnetic Stripe Board ISO (IAT) and JIS (NTT) ______________________
Magnetic Stripe Optical Encoder and Mounting ___________________
Magnetic Stripe Rocker Assembly and Read/Write _________________
Smart Card Options __________________________________________________
Smart Card Assembly, Simplex ____________________________________
Smart Card Assembly, Duplex _____________________________________
Smart Card Circuit Board _________________________________________
Smart Card Lid Assembly, Duplex__________________________________
Smart Card Contact Board _______________________________________
Smart Card Station Spring_________________________________________
Smart Card Gate Roller ___________________________________________
Smart Card Cable Connector_____________________________________
Card Guide ______________________________________________________
Dual Reader Board (Contact/Contactless) ________________________
i-Class Read/Write or PC Prox Board _______________________________
Duali Single Wire Smartcard _______________________________________
Duplex Components _________________________________________________
Duplex Frame ____________________________________________________
Duplex Home Sensor _____________________________________________
Duplex Transport and Flipper Motors_______________________________
Duplex Circuit Board _____________________________________________
Duplex Backup Idler Roller, Springs ________________________________
6-2
6-32
6-33
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6-34
6-35
6-36
6-37
6-40
6-40
6-41
6-42
6-43
6-44
6-45
6-45
6-46
6-47
6-48
6-49
6-49
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6-53
6-54
6-54
6-55
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6-60
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6-64
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6-74
6-75
6-76
6-77
Removal and Replacement
Flipper Assembly and Transport Gear ______________________________ 6-78
Duplex Drive Rollers and Body Gear _______________________________ 6-79
6-3
Introduction to this Chapter
General Notes
•
One or more procedures that either precede or follow your procedure may be
needed to access or reassemble the area of the printer where you need to
work.
•
Unplug the printer and follow the instructions for removing the before
servicing the printer.
•
Test motors and sensors to verify that the printer functions correctly after
replacing these parts.
•
After completing replacement procedures, always perform preventive
maintenance as described in “Preventive Maintenance Procedures” on page
5-6.
•
After completing replacement procedures, run several test cards or a limited
customer production run to verify that the printer functions correctly.
Required Tools
The required tools for the card printer are listed in the maintenance chapter of
this manual. See “Required Tools and Supplies” on page 5-2.
Safety
For safety and precaution information refer to the “Safety” section in the Revision
Log, “Precautions” on page 1-3, and “Avoiding Electrostatic Discharge” on page
5-4.
Symbols
The appearance and purpose of the symbols used in this chapter are presented
below.
ESD
This symbol is used to designate a procedure that involves electrostatic
discharge sensitive components. ESD procedures should be used.
Caution: This symbol indicates a strong cautionary message to avoid
serious damage to the printer.
This symbol indicates a reminder message or other additional
information for the customer engineer.
Safety glasses should be worn when performing this procedure.
6-4
Printer Components
See “Introduction to Printers” on page 1-4 for a diagram of the components in
each printer.
Cable Routing
Transport Cables
For more routing information see “Swingarm Cable Routing” on page 6-7 and
“LCD Interface Panel Routing” on page 6-18.
The following figure illustrates the routing of cables in the printer using
one colored strand following the path of the cable through the printer.
The actual cables used in the printer may have multiple strands of
different colors.
6-5
Smart Card and Duplex Cables
6-6
Swingarm Cable Routing
Note routing of the cables for fan (1), printhead (2), and the ribbon motor (3). See
“Ribbon Motor, Ribbon Drive Gear” on page 6-46, “Fan” on page 6-36, and
“Thermal Printhead (TPH)” on page 6-35 for more information.
Note: Leave 2.5 inches
(6.35 cm) of slack in the
cable so there is room
to reconnect the printh
Note: Feed the cables through the opening.
The printhead cable must be bent to the side
to fit through the opening. It may be easier to
feed the fan and motor cables through the
hole first.
6-7
Freeing Cables from Clamps
Use this procedure to remove wires from cable clamps as needed.
1. Group the wires in a line.
2. Slide them out.
Functional Block Diagrams
See “Functional Block Diagrams” on page 1-9 for diagrams of the boards and
connections.
6-8
Exterior Components
Ribbon Cartridge
1. Push button (1) to release the swingarm latch (2).
2. LIft the ribbon cartridge out of the printer (3).
Replacement
1. With the swingarm open, place the ribbon cartridge in the printer.
2. Push down the front edge of the swingarm until it latches.
3. Lift the cartridge.
6-9
Ribbon Cartridge Lid
Remove the cartridge lid (1) by spreading the sides (2) slightly to free them from
the tabs on the cartridge (3).
6-10
Replacement
Attach one tab and then the other by slightly spreading the sides.
When installing the cartridge back into the printer, place the diametric
magnet next to the Ribbon Encoder Board.
6-11
Swingarm Lid and Enclosure Flap
1. Remove the lid (1) by pushing in on the tabs on the side opposite the manual
advance knob.
2. Remove the enclosure flap (2) by spreading the enclosure slightly and lifting
the flap off of the pin. Then the opposite side will come off.
Replacement
1. When reassembling, replace enclosure flap before the swingarm lid. Place the
flap around the pins (3) on one side and then the other.
2. Replace the swingarm lid (4) by inserting the tabs into the side with the
manual advance knob first.
6-12
Enclosures
The enclosure is held onto the base at four points. The following method uses a
card, cut into halves lengthwise, to keep the enclosure tabs from reattaching.
1. Cut a card in half lengthwise (1).
2. Open the swingarm.
3. Unlatch the four tabs (2) that secure the enclosure to the base by lifting up
gently on the enclosure (3a) while working the tabs free from the slots and
inserting a card half into each of the two slots on the display or front end (3b,
3c).
4. Lift the enclosure again (4a), while working the rear tabs free from the slots
and placing the card halves into the slots toward the rear of the printer.
5. Lift the enclosure from the base (5). Be careful to clear the manual advance
knob (6). Lift the enclosure up and back over the swingarm.
6-13
Replacement
1. Open the swingarm and slide the enclosure down over it. Be careful to clear
the manual advance knob (6).
2. Snap enclosure into the base in all four locations.
6-14
Card Tray
100-Card Input Lid and Cover
1. Lift the lid (1) and push in on the release tab (2). Lift the lid and cover up and
off the tray.
2. Remove the lid from the cover by lifting the arm from the hinge pin on one
side and then the other.
Replacement
1. Place the arms of the lid (1) onto the pins.
2. Slide the cover onto the tray until it snaps into the tab (2).
The tray can be removed from the printer chassis without removing the cover
and lid.
6-15
Tray Assembly and Manual Feed
1. Push both latches (1a, 1b) of the input tray frame (2) and lift it
up and off the hooks (3).
2. Carefully disconnect the cables from the main board (4).
Replacement
1. Reconnect cables and close the display panel connector securely after
reconnecting.
2. Place the four openings in the tray over the hooks (3) on the printer and slide
down until it latches in place.
The process is the same for the manual feed option.
The tray can be removed with the enclosures installed.
6-16
Front Bezel, LCD Interface Panel, and 25-Card Output
1. Push out on both clips (1) and slide the bezel forward (2) to remove it from the
input tray (3).
2. The interface panel (4) sits in the front bezel. Slide out to remove.
3. Lift the clips on either side (5) and slide the output tray forward (6).
Replacement
1. Slide the output tray (6) back into the slot until it clips into place.
2. Place the interface panel into the front bezel, tip forward (to hold in place),
and slide the bezel back onto the tray until it clicks into place.
6-17
LCD Interface Panel Routing
6-18
Simplex Base
1. Simultaneously p+ress the tabs (1a) and pull on the printer
(1b).
2. Lift and remove it from the base (2).
Replacement
1. Line up the four points.
2. Push the printer toward the front until the tabs lock into place.
Caution: If you run the printer without the enclosures or base, do not tip the
printer to the side (the side with timing belt). The power and USB and/or
Ethernet cables could act as levers and damage the board connections.
6-19
Tray
Pick Gate and Pick Gate Spring
1. Hold spring (1a) while separating the tabs (1b) of the pick gate from the hinge
pins on both sides.
2. Hold spring (2a) lift pick gate (2b) and pull out of hopper frame.
3. Separate spring (3) from pick gate.
Replacement
1. Place spring on pick gate.
2. Hold spring in place, push pick gate into hopper frame and attach each side
to the hinge pins.
6-20
Pick Roller Assembly
1. Pull up on pick roller assembly (1).
2. Remove pick roller assembly (2) from input hopper frame.
Replacement
1. Replace pick roller assembly and snap into place.
See also, “Pick Motor and Pick Drive Gear” on page 6-45.
6-21
Picker Crankshaft, Pick Block Assembly
1. Push picker crankshaft (1) forward into larger slot (hard snap).
2. Separate picker crankshaft (2) from pick block assembly (3) and slide block
out of the hopper frame; then slide picker crankshaft (4) from hopper frame.
3. Separate picker crankshaft (5) from pick roller clutch and drive pick gear.
Replacement
1. Replace pick roller clutch and drive pick gear on the crankshaft. Surfaces
must be flush.
2. Slide picker crankshaft into hopper frame and reattach to pick block
assembly, and then snap back into place.
See also, “Pick Motor and Pick Drive Gear” on page 6-45.
6-22
Transport Components
Timing Belt
Removal
1. To remove the timing belt (1) push the belt tensioner (2) upward to lock it in
place. This removes tension from the belt.
2. Remove the belt from the three drive pulleys (3), the manual advance knob
(4), and the five idler pulleys (5).
Replacement
1. Replace the belt with the routing shown below.
2. Pull out on the tab (6) to lower the belt tensioner.
Do not stretch or twist the belt. This can break the belt fibers and cause the
belt to wear prematurely.
6-23
Belt Plate
Push the tab (1) on the inside of the rear of the printer to release the belt plate (2).
Replacement
Line up the holes with the pins and snap the tab into place.
6-24
Platen Roller Assembly
1. See “Ribbon Index Sensor, Ribbon Bridge” on page 6-41 for ribbon bridge
removal.
2. Push to loosen the tabs on the platen roller plate (1) while lifting the manual
advance knob (2) and lift plate (3) from printer.
3. Slide the platen roller assembly (4) out through the hole.
Replacement
1. If needed, lubricate; see “Lubricating the Grease Points” on page 5-12.
2. Place the leading end of the platen roller through the hole and into place, and
push down on the end with the gear to click into place (4).
3. Replace the platen roller plate by inserting the tabs into the slots and
snapping the other side into place.
Clearance is tight, but the parts will flex slightly to permit the platen roller
assembly to get past the flanged drive pulley.
6-25
Card Guide/Spring and Registration Drive Assembly
Removal
1. Place one hand over the card guide and spring (1a) while lifting the pulley of
the registration backup roller (1b) to release.
2. Remove the card guide and card guide spring (2) and separate the spring
from the shaft (3).
3. Pull the registration drive assembly (4) out through the cutout.
6-26
Replacement
2. Place the registration drive assembly into the printer through the cutout,
insert the leading edge into the hole, and push down on the end with the gear
to click into place.
3. Place the spring on the card guide and snap the card guide into place. Position
the spring against the printer.
See “Ribbon Index Sensor, Ribbon Bridge” on page 6-41 for ribbon bridge
removal or “Magnetic Stripe Rocker Assembly and Read/Write” on page
6-57.
6-27
Drive Pulleys and Idler Pulleys
1. Remove the timing belt, see“Timing Belt” on page 6-23 and “Belt Plate” on
page 6-24.
2. Remove the idler pulleys by pulling them from their shafts (1).
3. To remove the drive pulleys (2) use a needle-nosed pliers to squeeze together
the tabs (3) at the end of the shaft and slip off.
Replacement
1. The idler pulleys can be placed on their shafts from either side.
2. Slip the drive pulleys (2) onto their shafts with the large flange toward the
printer and rotate so that the square key (4) slips into the square keyway.
3. Replace belt and belt plate.
Print several test cards to ensure there are no transport problems.
6-28
Backup Roller, Registration Backup and Top Cleaning Rollers
1. Remove the ribbon bridge (see “Ribbon Index Sensor, Ribbon
Bridge” on page 6-41) before pulling out backup roller.
2. Push top of the spring to the side (1) and pull from the shaft (2).
3. Push brackets from the inside of the printer (3a) while pulling up and over the
locking ramp (3b); there is a hard snap as it goes over the ramp.
4. Pull the bracket out of the cutout (4).
5. Tip the rollers (5) and lift out of the printer.
Replacement
1. Insert leading end into holes (7), be sure to replace the capstan roller sleeve (6)
on the registration backup roller before installing.
2. Place the brackets into the cutouts and slide down locking into place.
3. Place springs onto the shafts of the brackets and slide into position.
6-29
Backup Roller Springs and Brackets, Capstan Roller Sleeve
See previous page for remove and replace procedure.
6-30
Belt Tensioner and Spring, Idler Pulleys
1. If engaged, lift up on the release tab to release the tensioner.
2. Line up the belt tensioner (1) with the cutouts in the printer and lift out (2) of
the printer.
3. Remove the belt tensioner spring.
4. The idler pulleys (4) come right off.
Replacement
1. Place the spring onto the belt tensioner.
2. Insert the tensioner into the cutouts in the printer and slide upward until it
clicks into place.
3. Slide idler pulleys onto their shafts.
6-31
Cam Slide
1. Use “Other Troubleshooting Procedures” on page 4-14 to rotate the cam (1)
into position so the tangs (2) match the cutout of the cam slide (3). Or you can
physically move the cam with a flat head screwdriver.
2. Lift the cam slide to remove (4).
Replacement
1. Rotate the cam into position so that the tangs are in position and slip the cam
slide into place.
The tang and cutout positions for the belt side cam slide are at 3 and 6
o’clock on a clock face. The cam slide cutout on the cam motor side is in the
6 and 9 o’clock positions.
6-32
Cam, Cam Shaft, Cam Gear, Cam Idler Gear
1. On the belt side of the printer, use the edge of a roller to pry downward on the
retainer portion of the cam (1) until it is clear of the groove in the cam shaft (2)
and push cam shaft through cam.
2. On the motor side of the printer pull the cam gear and shaft (3) out of the
printer.
3. Remove the cam idler gear (4).
Replacement
2. Replace cam idler and push cam onto shaft and into the retainer.
3. Align the cam on each side when reinstalling.
6-33
Swingarm Components
Ferrite Bead
1. Clip the tie wrap (1) that surrounds the ferrite bead (2) and the printhead
cable (3).
2. Open the ferrite bead to release the fan and ribbon advance cables.
3. Disconnect the cables from the main board.
Replacement
1. Reconnect the cables to the board.
2. Place the ferrite bead around the fan and ribbon advance cables (2).
3. Place a cable tie (1) around the ferrite bead and the printhead cable (3).
See “Cable Routing” on page 6-5 for connection information.
6-34
Thermal Printhead (TPH)
1. Hold the printhead (1) while pressing one of the swingarm knuckle release
tabs (2a), and then tip the printhead (2b).
2. Disconnect the printhead cable.
3. Pull the printhead (3) from the swingarm assembly.
Replacement
1. Reconnect the printhead cable.
2. Press and hold one of the swingarm knuckle release tabs and insert the
printhead into the knuckle.
3. Raise the printhead and release the tab.
6-35
Fan
Observe cable routing and fan orientation. The fan blows air in the direction of
the printhead.
1. Pull up on the retaining tab (1) and slide the fan out of the frame (2).
Replacement
1. Orient the fan as shown in the figure below.
2. Slide the fan down into the frame, placing the cables through the notch in the
corner.
A tiny arrow on the front side of the fan indicates the airflow direction.
Look for arrow
pointing down.
6-36
Swingarm, Torsion Spring, Damper
1. Relieve the torsion spring tension (1) by lifting the spring up and
out of the boss.
2. Rotate the damper counterclockwise (2) to remove.
Note the orientation of the torsion spring (4).
3. Separate and lift slightly on each side of the swingarm (3, 5) to disengage the
swingarm from the hinge pins.
4. Move the swingarm back toward the rear of the printer and then up to
remove (6).
6-37
Replacement
1. Place the torsion spring on the printer (4) and then guide the spring into the
cutout in the swingarm as you install the swingarm.
2. With the swingarm nearly vertical, partially engage each side of the
swingarm onto the hinge pins.
6-38
3. With both sides partially engaged, bring the swingarm forward on both sides
simultaneously to fully engage both sides.
4. Lift the torsion spring into the boss.
5. Push on and rotate clockwise to replace the damper.
Always relieve the torsion spring tension when the damper has been removed.
6-39
Print Engine Sensors
Head Latch Sensor
Disconnect cable from J22 on print engine board and pull on sensor (1) to remove.
Replacement
1. Press sensor into the hole in the printer.
2. Reroute cable as indicated in “Cable Routing” on page 6-5, and reconnect
cable.
6-40
Ribbon Index Sensor, Ribbon Bridge
1. Note routing of the ribbon index sensor cable (1), disconnect it from the print
engine board (J21), and pull through the hole in printer.
2. Push to release the retaining clips (2) on either side of the ribbon bridge and
lift bridge (3) from the printer.
3. Pull on the ribbon index sensor to remove from the ribbon bridge.
Replacement
1. Push the sensor into place until fully seated and reroute the cable in the
bridge.
2. Feed the ribbon index sensor cable through the hole, reroute, and reconnect to
the board.
3. Place the ribbon bridge into the printer and into the retaining clips.
See “Transport Cables” on page 6-5 for routing information.
6-41
Card Input Sensor
1. Remove cam slide and bracket. See “Backup Roller Springs and Brackets,
Capstan Roller Sleeve” on page 6-30 and “Belt Tensioner and Spring, Idler
Pulleys” on page 6-31.
2. Disconnect cable from J18 on print engine board.
3. Remove by pushing out of the printer from the inside.
Replacement
1. Push into place using two Torx drivers and even pressure until fully seated.
2. Reconnect cable.
See “Cable Routing” on page 6-5 for more information.
6-42
Card Exit Sensor
1. Rotate cam (1a) so that the cam slide (1b) is not in the way of the sensor, and
disconnect cable from J24 of print engine board.
2. Remove by pushing sensor (2) out of the printer from the inside.
Replacement
1. Push into place using two Torx drivers and even pressure until fully seated.
2. Reconnect the cable.
Refer to “Transport Cables” on page 6-5 for routing information.
6-43
Cam Home Sensor
1. Use a flat head driver to rotate the cam motor (1a) to move the cam slide (1b)
out of the way.
2. Disconnect cable from J23 of print engine board.
3. Insert the torsion spring, or a tool such as a small screwdriver, through the
hole in the sensor to aid in pulling (2) the sensor out.
Replacement
1. Push the sensor into place using even pressure until fully seated.
Refer to “Cable Routing” on page 6-5 for routing information.
Caution: Pulling on the top of the outside of the sensor can break it.
6-44
Print Engine Motors
Pick Motor and Pick Drive Gear
1. Align the pick drive gear with screws (1) as shown.
2. Disconnect the connector from J19 of print engine board.
3. Remove two T6 torx screws (2) and remove the pick motor (3).
Replacement
1. Align the pick drive gear, place the motor into the hopper frame, and replace
the screws.
6-45
Ribbon Motor, Ribbon Drive Gear
1. Align the drive gear (1) so the screws are visible through the cutout.
2. Disconnect the motor connector from J27 on print engine board.
3. Remove the two T6 Torx screws (2), and lift the motor (3) out of the swingarm
(3).
Replacement
1. Line up the flats on the gear and the ribbon motor shaft and slide the gear
onto the shaft.
2. Place the motor into the swingarm, align the drive gear, and replace the
screws.
The swingarm must be removed to access the ribbon motor. See “Swingarm,
Torsion Spring, Damper” on page 6-37.
6-46
Cam Drive Motor Assembly
1. Use a T10 Torx driver to loosen and remove the two screws (1).
2. Disconnect the motor connection from J12 on the print engine board.
3. Pull the motor from the printer.
Replacement
1. Replace motor and secure with the two screws.
The cam drive motor assembly cable is oriented toward the rear of the printer.
6-47
Transport Motor Assembly
1. Use a T10 Torx driver to loosen and remove the two screws (1).
2. Disconnect the cable from J11 on print engine board.
3. Pull the motor from the printer.
Replacement
1. Replace motor and secure with the two screws.
The transport motor assembly cable is oriented toward the front of the printer.
6-48
Circuit Board Components
See also “Smart Card Circuit Board” on page 6-60 and “Duplex
Circuit Board” on page 6-76.
Print Engine Drive Board
1. Remove enclosure as described in “Enclosures” on page 6-13“Enclosures” on
page 6-13, and disconnect cables from the board.
2. Push in on both tabs that hold the board in place at the front of the printer (1),
and then loosen the corners (2) of the board (3) to release it from the printer.
3. If the printer has the magnetic stripe option, those cable connections will
prevent you from moving the board more than a short distance from the
printer. Tip the printer to the side (timing belt side of printer) and disconnect
the cables. Then remove the magnetic stripe board and standoffs. See
“Magnetic Stripe Board ISO (IAT) and JIS (NTT)” on page 6-54 for more
information.
6-49
Replacement
1. If applicable, install the magnetic stripe board and connect the cables and
standoffs.
2. Insert the back end of the board into the printer, and then push to lock the
board under the front tabs (1).
3. Reconnect cables.
See “Cable Routing” on page 6-5.
4. See “Replacing the Print Engine Drive Board” on page 5-27 for instructions on
loading the new settings file.
Replacement
1. If applicable, install the USB host board and connect the cables and standoffs
for Duali single-wire smart card.
2. Insert the USB host board into terminal J45 of the print engine drive board.
Insert the USB host board into the print engine drive board at and angle and
then press the host board down into the standoffs to secure installation.
6-50
3. Reconnect cables.
See “Cable Routing” on page 6-5.
4. See “Replacing the Print Engine Drive Board” on page 5-27 for instructions on
loading the new settings file.
Sensor Encoder Cable Assembly (RFID)
1. Note routing of cables for the RFID board (1), ribbon motor
(2), fan (3), and printhead (4) from main control board.
2. Lift the bottom left side of the RFID board (5) to lift from the standoff, and
then pull the board up (6) to remove.
6-51
Replacement
1. Slide the RFID board down into the printer and over the standoff.
2. Reroute and connect cables.
See the following procedures for more routing information. See “Ribbon
Cartridge” on page 6-9.
6-52
Ribbon Motion Magnetic Encoder Board
1. Disconnect cable.
2. Push up from the bottom of the encoder (1) and pull it out of
the printer.
Replacement
1. Push the encoder into place with even pressure until fully seated.
Refer to “Cable Routing” on page 6-5 for routing information.
6-53
Magnetic Stripe Option
Magnetic Stripe Board ISO (IAT) and JIS (NTT)
1. See “Print Engine Drive Board” on page 6-49 for how to remove the print
engine board. As you remove the board from the printer, the cable
connections can prevent you from moving the board more than a short
distance from the printer. Tip the printer to the side (timing belt side of
printer) and disconnect the magnetic stripe encoder (2) and head (1).
2. Remove board (3) and standoffs (4).
Replacement
1. Replace standoffs and board and reconnect cables.
6-54
Magnetic Stripe Optical Encoder and Mounting
1. Loosen setscrew on collar (1) with special four-flute spline
wrench. See “For Magnetic Stripe Option” on page 5-3.
2. Remove two phillips screws (2) and remove optical encoder (3).
3. Bend spring (4) forward and remove.
4. Remove Torx screw (5) and remove encoder mounting bracket (6).
Replacement
When replacing the optical encoder on the mounting bracket, be sure the two tabs
go into the slots on the encoder.
The encoder mounting bracket replaces the normal backup bracket on
machines with the magnetic stripe option.
6-55
1. Make sure encoder is in the opened position before sliding encoder over
rocker arm.
Opened
osition
2. Once installed, close the encoder by pushing "in" on the bottom piece.
3. Install encoder wire into encoder.
Caution: Make sure to install encoder wire exactly as shown with the 4 wires
on the left side. Incorrect wire installation will damage the magnetic stripe
encoder.
6-56
Magnetic Stripe Rocker Assembly and Read/Write
1. Disconnect the magnetic stripe head cable. See “Magnetic Stripe
Board ISO (IAT) and JIS (NTT)” on page 6-54.
2. Remove the magnetic stripe rocker assembly (1) by unsnapping from printer.
3. Pull back on retaining clip to release and then push head (2) up from bottom
to remove.
Replacement
1. Replace head and rocker assembly and reconnect cables.
2. Lubricate the assembly as described in “Lubricating the Magnetic Stripe
Assembly” on page 5-16.
6-57
Smart Card Options
Smart Card Assembly, Simplex
1. Remove the smart card circuit board as described on page 6-60.
2. Remove the smart card assembly by pulling tabs (1a) out on both sides while
pulling out the smart card assembly (1b).
6-58
Smart Card Assembly, Duplex
1. Remove the flipper assembly as described on page 6-78.
2. Remove the smart card assembly by pulling tabs (1a) out on both sides while
lifting out the smart card assembly (1b).
6-59
Smart Card Circuit Board
1. Disconnect USB (1) and power plugs (2).
2. Push tab (3a) down while lifting board (3b) out enough to
release.
3. Lift tab (4a) while lifting board (3b) again to release board.
4. Slide board (5) out from under tab (6) and remove board.
6-60
Smart Card Lid Assembly, Duplex
1. Remove the smart card assembly as described on page 6-58.
2. Push tabs (1a) on both sides to release catches (1b).
3. Lift smart card lid assembly (2) out.
6-61
Smart Card Contact Board
1. Disconnect the assembly by pushing the contact mount back and holding it
steady with left index finger (1) while pushing down and out at 2a and 2b
with your thumbs.
2. Separate from contact plug (3).
6-62
Smart Card Station Spring
Remove smart card lid assembly as described on page 6-60.
Unhook spring (1) and lift from smart card base assembly.
6-63
Smart Card Gate Roller
1. Push smart card guide (1a) back while pushing tab (1b) out and lifting contact
mount (1c) up to release.
2. Slide contact mount (2) back and out on the slots and pegs (3).
3. Remove plug (4) from contact guide.
4. Remove gate roller (5) from guide.
6-64
Smart Card Cable Connector
Maneuver plug (1) up through the opening in the smart card base lid (2) when it
is not necessary to remove the reader board (3).
6-65
Card Guide
Slide card guide (1) forward until it stops, and lift peg (2) from keyway slot.
6-66
Dual Reader Board (Contact/Contactless)
1. Squeeze the snap-tips (1) on the standoffs and lift the reader board (2) just
enough to clear the standoffs.
2. Place a flat screwdriver between the base (3) and reader board, and then
carefully twist the screwdriver to release the adhesive pad (4).
Always use all new adhesive pads when reassembling.
Simplex Installation
6-67
6-68
i-Class Read/Write or PC Prox Board
carefully twist the screwdriver to release adhesive pads (2).
2. Lift reader (3) off.
Be sure to use all new adhesive pads when reassembling. Place them near the
center of the board.
6-69
Duplex Installation
6-70
Duali Single Wire Smartcard
carefully twist the screwdriver to release adhesive pads (2).
2. Lift reader (3) off.
Be sure to use all new adhesive pads when reassembling. Place them near the
center of the board.
6-71
Duplex Installation
6-72
Duplex Components
Duplex Frame
1. Disconnect cables from tie downs at indicated on page 6-8.
2. Disconnect cables (1) at J13 and J29 on print engine board.
3. Pull out tabs (2a) on both sides while sliding the frame (2b) away from the
main frame.
4. Pull frame (3) away and up to remove.
6-73
Duplex Home Sensor
1. Disconnect sensor cable (J5) from duplex circuit board.
2. Push tab (1a) out while lifting duplex circuit board (1b) to clear tab.
3. Slide board (2) out from under tab (3) to remove.
4. Remove flipper home sensor (4).
6-74
Duplex Transport and Flipper Motors
1. Disconnect motor cable(s) from connector on duplex board: J7 for Transport
or J3 for Flipper.
2. Push tab (1a) in while rotating motor (1b) in direction shown.
3. Remove motor (2).
6-75
Duplex Circuit Board
1. Disconnect cables from duplex circuit board.
2. Feed cable through the frame as indicated in “Cable
Routing” on page 6-5.
3. Push tab (1a) out while lifting duplex circuit board (1b) to clear tab.
4. Slide board (2) out from under tab (3) to remove.
6-76
Duplex Backup Idler Roller, Springs
1. Push spring (1a) out from under tab (1b) to release spring.
2. Remove spring (2).
3. Repeat to remove other spring, and remove both backup idler rollers (3).
6-77
Flipper Assembly and Transport Gear
1. Hold flipper assembly (1a) firmly while separating it from frame (1b) until
mis-aligning the shaft (1c).
2. Lift flipper assembly (2) by maneuvering it up through the frame assembly.
3. If gear (3) did not fall out, remove it.
6-78
Duplex Drive Rollers and Body Gear
1. Remove flipper assembly as described on page 6-78.
2. Push drive roller (1) into larger hole until you hear a hard snap.
3. Remove drive roller (2) from frame (3).
4. Repeat for other drive roller.
6-79
6-80

Datacard® SD Series Card Printers

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