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ID badges Millennium 560 Technical & Service Manual

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  • Page 2: Trademark Acknowledgments

    Notices The information in this document is subject to change without notice. NO WARRANTIES OF ANY KIND ARE MADE WITH REGARD TO THIS MATERIAL, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. The manufacturer shall not be liable for errors contained herein or for incidental damages in connection with the furnishing, performance, or use of this material.

  • Page 3: Table Of Contents

    Table of Contents SECTION 1: INTRODUCTION SECTION 1: INTRODUCTION 1.01 Scope Of This Manual..................... 1 1.02 Description Of MILLENNIUM Series Printers............1 1.03 Regulatory Compliances....................3 1.04 Technical Specifications....................4 SECTION 2: DIAGNOSTICS AND CALIBRATION SECTION 2: DIAGNOSTICS AND CALIBRATION 2.01 Running A Self Test......................
  • Page 4 3.18 Assembly – Ribbon Sensor Lower................36 3.19 Assembly – Card sensor Replacement................ 37 3.20 Roller – Card Feed Replacement ................. 37 3.21 Assembly – Card Feed Drive Replacement..............38 3.22 Assembly – Stepper Motor Replacement ..............39 3.23 Roller – Card Feed Prn Replacement ................39 3.24 Card Feed Mag Replacement..................

  • Page 5: Section 1: Introduction

    1.01 Scope Of This Manual This manual is intended for use by service and maintenance personnel who desire more technical information than is contained in the MILLENNIUM 560/575x User’s Manual. The information included relates to diagnostics, calibration and parts replacement procedures for MILLENNIUM Series printers.
  • Page 6 color to vary in hue, thus blending one color smoothly into the next and producing photo-realistic images. Resin Thermal Transfer is the process used to print sharp black text and crisp bar codes which can be read by both infra-red and visible-light bar code scanners. It is also the process used to print ultra-fast, one-color ID cards.

  • Page 7: Regulatory Compliances

    1.03 Regulatory Compliances FCC: MILLENNIUM printers comply with the requirements in Part 15 of the FCC rules for a Class A digital device. These requirements are designed to provide reasonable protection against harmful interference in a residential installation. If, however, operation of this equipment in a residential area causes unacceptable interference to radio and TV reception, the operator is required to take whatever steps are necessary to correct the interference.
  • Page 8 Printing Area: Accepted Card Width: 1" to 2.63” W (25mm to 67mmW) 575X 2.15" x 2.63" 560 Accepted Card Length: 3” x 3.8" to 3.8 x 10"” L 575X (96.52mm to 254mmL) 3.0 x 3.38 560 Accepted Card Thickness: .010” to .060” (.254mm to .75mm) 560 and 575X Maximum Print Area: 2.14"...

  • Page 9: Section 2: Diagnostics And Calibration

    Diagnostics And Calibration 2.01 Running A Self Test A self test should be performed after initial setup of the printer, after a calibration procedure has been conducted or after a part has been replaced to check for proper operation of the printer. The procedure described below is an alternative method than is found in the User’s Manual.
  • Page 10 Standard self test Print In addition to the standard self test, there are several other test modes available by changing the DIP switch settings within the printer. Below is an illustration of the Main Circuit Board showing the location of the DIP switches and how to activate them. To remove the rear cover to expose the Main Circuit Board, refer to section 3.04.
  • Page 11 Figure 2.01-B: The DIP Switch NOTE: This illustration shows all 4 switches in the normal OFF position NOTE: This illustration shows switches 1,2 & 3 in the ON position (example shown for the Ribbon Sensor calibration without the need for a PC). Please refer to Table 2.01-A for additional diagnostic selections.
  • Page 12 Table 2.01-A: DIP Switch Settings (X indicates switch should be set to ON or DOWN) Diagnostic modes 5x3 Default self test (YMC) 15x3 Shade self test (YMC) All Gray self test, full bleed. Registration self test, pink with ½” black lines.

  • Page 13: Calibration Procedures

    2.02 Calibration Procedures MILLENNIUM printers are designed for ease of setup and operation. Almost all the necessary calibration procedures have been documented in the 560/575x User’s Manual and can be conducted through the use of the printers software driver from a computer.
  • Page 14 Figure 2.02-A: Lower Portion of Ribbon Sensor LED portion of Ribbon Sensor Align the Clear or the Yellow panel over the LED portion of the Ribbon Sensor and close the Top Cover.

  • Page 15: Intensity Level Adjustment

    2.03 Intensity Level Adjustment If you have replaced a Printhead, or are unsatisfied with the color intensity being printed to your particular brand of cards, the intensity level of the Printhead can be altered. Before attempting the procedure described below, please refer to the User’s Manual, Section 5F, the Picture Controls topic.
  • Page 16 Figure 2.03-A: Self Test Output Samples The output is too light, the last gray fill box does not appear. Use the Internal Printer Settings of the LCD Display to increase the darkness level. The output is too dark. Use the Internal Printer Settings of the LCD Display to reduce...

  • Page 18: Card Offset Adjustment

    2.04 Card Offset Adjustment When the printer is calibrated at the factory the green edge of the oversize (.060") card is slightly offset from the leading edge of the card. There should be a small space of white to indicate this. of your ribbon, or a card jam just as the card is being presented to the Printhead, the card offset may require adjustment.

  • Page 19: Magnetic Card Offset

    2.05 Magnetic Card Offset As a card is fed into the encoding module during the encoding process (see figure 2.05-A), the trailing edge of the card is read by a sensor and continues to feed for a given length of a standard CR-80 sized card. Then, the direction of the stepper motor is reversed and the Mag SC Motor actuates, raising the magnetic head to press it against the magnetic stripe of the card.
  • Page 20 Instructions For Setting the Elevation Screw 1. Disconnect power to the printer. 2. Remove the Cover - Top from the imaging assembly to simplify access and visibility. Close the imaging assembly after cover has been removed. 3. To prepare for the adjustment, insert a phillips screw driver onto the head of the Elevation Screw and hold it in place.
  • Page 21 Figure 2.05-B: Magnetic Head engaged. (Screw driver illustrated for adjustment found in Section 2.05)

  • Page 22: Magnetic Intensity Adjustment

    Figure 2.05-C: Data being encoded to the magnetic stripe of a card 0.293 inches (nul characters) Start Sentinel Position Magnetic Head (3 Stationary Magnetic Tracks) Direction of Card Travel while being Magnetically Encoded To accurately calibrate the magnetic offset, the use of magnetic developer spray , or a magnetic stripe viewer is required for measuring the location of the start sentinel on an encoded card.
  • Page 23 Instructions For Calibrating Magnetic Intensity, RP1 1. Before attempting to calibrate the RP1 potentiometer, the magnetic encoder head must be plugged into the J2 connector. 2. A digital DC volt meter is also required. Set the meter to read in a range of 0-10 volts, DC.

  • Page 24: Parallel Interface Information

    2.07 Parallel Interface Information MILLENNIUM Series printers are equipped with a standard 8-bit Centronics-type parallel data communications port. The printer's parallel interface connector is a standard 36- pin Amp type with two metal-wire retaining clips. It mates with a standard PC to printer parallel cable.
  • Page 25 Table 2.07-B: Centronics Parallel Pin Assignments Pin No. Signal Direction Description ______ A LOW pulse greater than 1 µs causes the Strobe printer to read one byte of data. Data 0 Data bit 0 Data 1 Data bit 1 Data 2 Data bit 2 Data 3 Data bit 3...
  • Page 26 Diagram 2.07-C: Printer Timing Diagram The timing diagram below illustrates the data and handshake lines during transfer of one data byte to the computer. DATA VALID Data 0 - Data 7 Strobe Tdsu Tstr Busy Tack Acknlg Printer Timing Interval Description Minimum Typical Value...

  • Page 27: Macintosh Interface Information

    2.08 Macintosh Interface Information MILLENNIUM printers can be equipped with an optional Macintosh interface at the factory or in the field with a few simple alterations. Please refer to drawing 810606 for an illustration regarding the replacement of the Assembly - Board Parallel Cheetah and follow the instructions below.
  • Page 28 Figure 2.08-A: Pin out of the mini 8-pin serial port connector and view of Plate - Mac Interface Table 2.08-B: Signal assignments for the mini 8-pin serial port connector Pin Number Signal Name Signal Description HSKo Handshake output. Driven inverted from SCC’s /DTR. Voh=3.6V;...
  • Page 29 The transmit-data and receive-data lines of the Macintosh serial interface conform to the EIA standard RS-422, which differs from the more commonly used RS-232-C standard in that, whereas an RS-232-C transmitter modulates a signal with respect to a common ground, an RS-422 transmitter modulates that signal against an inverted copy of that same signal (to generate a differential signal).

  • Page 30: Introduction

    Parts Replacement 3.01 Introduction This section deals with field replacement of key components on the printer. A complete description of disassembly and part replacement will be given, while it is assumed the repairer will reverse the given steps for reassembly. The Mean Time To Repair (MTTR) is under 18 minutes.
  • Page 31 Table 3.01-A: Replacement Parts (continued) Part Number Description Quantity Time to Repair in Minutes 810621 Assembly - Slotted Sensor Mount 820593 Assembly - Board Ribbon ID Sensor 820855 Assembly - Ribbon Drive 830126 Assembly - Ribbon Sensor Lower * 810619 Assembly - Card Sensor * 810647-XX Roller - Card Feed...
  • Page 32 Table 3.01-B: Drawing Index Description Drawing Number 1. Assembly - Covers 810605 2. Assembly - Backplate / Electronics 810606 3. Assembly - Headlift Attachment 810604 4. Assembly - Printhead Mount 810616 5. Assembly - Upper Headlift 810613 6. Assembly - Ribbon Feed 810601 7.

  • Page 33: Cover - Top Removal

    Refer To Drawing 810605 For Procedures 3.02 Through 3.04 NOTE: For many of the replacement procedures explained throughout Section 3, it may be necessary to remove the Top, Front or Rear Cover. Procedures 3.02 through 3.04 outline the steps for removing these printer covers. 3.02 Cover - Top Removal, (810672) TTR: 5 minutes 1.

  • Page 34: Cover - Rear Removal

    3.04 Cover - Rear Removal, (810671) TTR: 5 minutes 1. Open the Top Cover Assembly, and allow it to swing up and open. 2. Loosen, but do not remove, the 2 (130971) Screws which fasten the Rear Cover to either side of the Assembly - Mechanism. 3.

  • Page 35: Assembly - Board Parallel Replacement

    Refer to Drawing 810606 For Procedures 3.05 through 3.07 NOTE: Please observe all established Electro-Static Discharge (ESD) procedures while handling cables on or near the Circuit Board and Printhead Assemblies. Removal of the Assembly - Backplate /Electronics from the Base Plate will be necessary. 3.05 Assembly - Board Parallel Replacement, (140191) TTR: 10 minutes 1.

  • Page 36: Assembly - Sensor Headlift Replacement

    Refer To Drawing 810604 For Procedures 3.08 Through 3.12 3.08 Assembly - Sensor Headlift Replacement, (760806) TTR: 10 minutes NOTE: Remove the Assembly - Front Cover according to the steps in Section 3.03. 1. From the front of the printer, remove the (130972) Screw which fastens the Assembly - Sensor Headlift to the Bracket - Head Switch.

  • Page 37: Assembly - Headlift Replacement

    810613) slightly and begin rotating the Printhead Assembly upwards. Release the Spring - Head and complete rotating the Printhead Assembly upwards. 4. Disconnect the two Printhead Cables connected to the Assembly - Printhead by simply working them loose and unplugging them from the Printhead connections. 5.

  • Page 38: Spring - Head Replacement

    Refer To Drawing 810613 For Replacements 3.13 Through 3.14 NOTE: All repairs in this section are done with the Cover - Top removed (see Section 3.02). Please observe all established Electro-Static Discharge (ESD) procedures while handling cables on or near the Circuit Board and Printhead Assemblies. 3.13 Spring - Head Replacement, (810214) TTR: 20 minutes 1.

  • Page 39: Assembly - Slotted Sensor Mount Replacement

    Refer To Drawing 810601 For Procedures 3.15 Through 3.18 NOTE: All repairs in this section (unless otherwise specified) are done with the Rear Cover removed, see Section 3.04. 3.15 Assembly - Slotted Sensor Mount Replacement, (810621) TTR: 10 minutes NOTE: It will be necessary to use an off set #1 Phillips Screw Driver to remove the screws fastening these sensors to the side plate.

  • Page 40: Assembly - Ribbon Drive Replacement

    3.17 Assembly - Ribbon Drive Replacement, (820855) TTR: 10 minutes 1. Remove the Assembly - Ribbon Drive by removing the 3 (130971) Screws. 2. Follow the Assembly - Ribbon Drive Cable to its connection on the Main Board 4250(J25) and disconnect. When reassembling, place a small amount of grease on the end of the Shaft - Ribbon Right (760291).

  • Page 41: Assembly - Card Sensor Replacement

    Refer To Drawing 810602 For Replacements 3.19 Through 3.21 NOTE: All repairs in this section are done with the Top Cover Assembly open and with the Assembly - Front Cover and Cover - Rear removed, unless otherwise specified (see Sections 3.03 through 3.04 for cover removal instructions). 3.19 Assembly - Card Sensor Replacement, (810619) * TTR: 15 minutes NOTE: Removing this sensor will require some manual dexterity to guide the sensor...

  • Page 42: Assembly - Card Feed Drive Replacement

    5. Remove the Bearing - Drive Roller (760343) from the Card Feed Roller shaft. 6. Remove the Card Feed Roller from the printer. When reinstalling, be sure to insert the Card Feed Roller so the two notches on the shaft located near the rubber roller are oriented toward the front of the printer.

  • Page 43: Assembly - Stepper Motor Replacement

    Refer To Drawing 810603 For Replacements 3.22 Through 3.25 NOTE: Both the Front and Rear covers will need to be removed. It will also be necessary to remove the Assembly - Backplate /Electronics for these procedures. 3.22 Assembly - Stepper Motor Replacement, (810113) TTR: 10 minutes 1.

  • Page 44: Card Feed Mag Replacement

    3.24 Roller - Card Feed Mag Replacement, (810647-01) TTR: 15 minutes NOTE: On the right-hand side of the printer, the Retaining Clip and Bearing located on the Circuit Board side of the chassis is obscured by the Assembly - Card Feed, (820160 on drawing 810602).
  • Page 45 7. When removing, note the side of the gear with the notched opening must be oriented toward the rear of the printer. Remember this when reinstalling. 8. Remove the Platen Roller from the printer. When reinstalling, be sure to insert the Platen Roller so that the end of the shaft with the shorter, flat area is oriented toward the rear of the printer.

  • Page 46: Conn-Smart Card, Amphenol C702-2 Replacement

    Refer To Drawing 810607 For Procedures 3.26 Through 3.30 3.26 Conn-Smart Card, Amphenol C702-2 Replacement, (810687) TTR: 20 minutes 1. Remove the 2 (130988) Screws fastening the Conn - Smart Card to the Bracket - Smart Card Contact Mount (810663). 2.

  • Page 47: Assembly - Mag Head High Co. Replacement

    3.29 Assembly - Mag Head High Co. Replacement, (810687) * TTR: 20 minutes 1. From the front of the printer, remove the Assembly - Mag SC Motor (see Section 3.28). 2. Carefully remove the Gear - Headlift (760330) from the Shaft - Mag - SC by prying it off with your fingers.

  • Page 48: Main Board 4250 Cable Connector Locations

    Refer to the 4250.PCB Main Board Drawing For Section 3.31 NOTE: The connections listed below are shown in order from left to right as they appear when viewing the Main Circuit Board from the back of the printer. 3.31 Main Board Cable Connector Locations Cable Connector Location 1.
  • Page 49 13. Assembly - Board Ribbon Sensor (4250)* ........J14, pins 3-4 Refer to the Cable Assembly - Head Harness (820563) on Drawing 810613 14. Assembly - Cable LCD Control / Part # 24000311........J1 Drawing 810605 15. Assembly - Board Ribbon ID Sensor / Part # 820593 .........J33 Drawing 810602 16.

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Millennium 575x

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