Page 1 ® Datacard SD/CD Series Card Printers SD160™, SD260™, SD260L™, SD360™ and CD800™ Service Manual SD260L Serial Number Before D11000 SD360 Serial Number Before B17000 CD800 Serial Number Before C20000 November 2015 Part No. 539879-001, Rev. D...
Page 2: Trademark Acknowledgments
Notice 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. Trademark Acknowledgments Datacard is a registered trademark and service mark of Entrust Datacard Corporation in the United States and other countries. All other product names are the property of their respective owners. Proprietary Notice The design and information contained in these materials are protected by US and international copyright laws. All drawings and information herein are the property of Entrust Datacard Corporation. All unauthorized use and reproduction is prohibited. Entrust Datacard 1187 Park Place Shakopee, MN 55379 Phone: 952‐933‐1223 Fax: 952‐933‐7971 www.entrustdatacard.com Copyright © 2015 Entrust Datacard Corporation. All rights reserved.
Page 3: Compliance Statements
Compliance Statements Liability The WARNING and CAUTION labels have been placed on the equipment for your safety. Please do not attempt to operate or repair this equipment without adequate training. Any use, operation, or repair in contravention of this document is at your own risk. Safety All Datacard® products are built to strict safety specifications in accordance with CSA/UL60950‐1 requirements and the Low Voltage Directive 2006/95/EC. 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. • Connect equipment to a grounded power source. Do not defeat or bypass the ground lead. • Place the equipment on a stable surface (table) and ensure floors in the work area are dry and non‐slip. • 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. ABC type extinguishers may be used on electrical fires. • Know local procedures for first aid and emergency assistance at the customer facility. • Use adequate lighting at the equipment location. • Maintain the recommended temperature and humidity range in the equipment area. Safe Human Interface • Use proper lifting techniques when moving or installing the equipment. • Use sandard electrostatic discharge (ESD) precautions when working on or near electrical circuits. • Do not defeat or disconnect safety interlocks on covers.
Page 5: Revision Log
Revision Log SD/CD Printer Service Manual Revision Date Description of Changes October 2010 First release of this document February 2011 Release of SD360 and of SD260 with smart card. February 2015 Addition of the SD160 printer. November 2015 Numerous printer manager updates.
Page 7: Table Of Contents
SD160/SD260 Simplex Print Engine (D1 Board) ....... . . 1-17...
Page 8 Status..............1-37 Printer Settings .
Page 9 Start Sentinel/End Sentinel ..........2-27 Longitudinal Redundancy Check (LRC).
Page 10 KPowerCalibration600DPI..........3-18 KPowerDuplex .
Page 11 FlipperHomeOffset ........... . 3-37 FlipperRegistrationOffset .
Page 12 Testing Smart Cards ............4-17 Identive Smart Card .
Page 13 153: Insert same card side 2 up ......... . 4-41 170: Insert new card side 1 up .
Page 14 Cleaning the Thermal Printhead (TPH) ........5-22 Using the Cleaning Card .
Page 15 Smart Card Options ............6-56 Smart Card Assembly, Simplex (SD160 or SD260)....... 6-56 Smart Card Assembly, Simplex (SD260L) .
Page 17: Chapter 1: Introduction
SD160/SD260 Simplex Print Engine (D1 Board) ....... . . 1-17...
Page 18 Ethernet Connection ..........1-34 USB Connection .
Page 19: About This Manual
About This Manual This manual gives general information about desktop printers and specific information about how these particular printers work, how to install them, and how to repair them. 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. Designates a procedure that involves electrostatic discharge sensitive ESD! components. ESD procedures must 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. SD/CD Service Manual...
Page 20: Precautions
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 front matter of this manual and “Avoiding Electrostatic Discharge” on page 5‐4. Introduction...
Page 21: Related Manuals
Related Manuals The following manuals provide information for the user of the SD/CD/CE series printer. Manuals named SDxxx, CDxxx or CExxx are available individually for either the SD260L, SD360, SD460, CD800, CD820, CE840 or CE870. Name of Manual Supplied SDxxx or CD800 Quick Installation Guide In paper with equipment and electronically on Owner’s Library Manuals on Owner’s Library CD SDxxx, CD800 User Guide SDxxx, CD800 Installation and Administrator's Guide XPS Card Printer Driver Guide SD or CD Series Printer Repackaging Manuals on Service Library CD SD/CD Printer Service Manual SD/CD Printer Illustrated Parts Manual SD/CD Service Manual...
Page 22: Introduction To Sd/Cd Series Printers
Introduction to SD/CD Series Printers The main features and options available for the printer are indicated in the following list: Front and back color and monochrome printing options  Single card hopper (standard)  Smart card reader/writer options  Magnetic stripe options (ISO and JIS)  Kensington® lock  Configuration Label The configuration code is printed on the serial number label. Options not listed here are not included in the configuration. When the code entry is “no entry”, skip that field in the configuration code. [Input hopper][Print][Magstripe][Duplex] Examples: H0M1 or H1M1D1S2 Input Hopper Option Option Code Entry Manual Feed 100 Card Printing Option Option Code Entry Color (no entry) No Print Introduction...
Page 23 Magnetic Stripe Option Option Code Entry No Magnetic Stripe (no entry) ISO and JIS Duplex Option Option Code Entry Simplex (no entry) Long Duplex Long Duplex Configured as Simplex SD/CD Service Manual...
Page 24 Smart Card Option Option Code Entry No Smart Card (no entry) Option Rear Cover (No Smart Card Assembly) Integrator Contactless SCM Dual HID PcProx Contactless iCLASS Read Contactless iCLASS Read/Write Contactless GEMPC USB/PcProx Dual Contact Station Identive PcProx Plus Dual Frequency Introduction...
Page 25: Sd Simplex Short Enclosure Printer
SD Simplex Short Enclosure Printer The figure below shows the main parts of the standard SD160 and SD260 card printer. 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  SD/CD Service Manual...
Page 26: Sd Simplex Short Enclosure Printer With Smart Card Option
SD Simplex Short Enclosure Printer with Smart Card Option The figure below show the main parts of the SD260 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  1-10 Introduction...
Page 27: Sd Simplex Long Enclosure Printer With Smart Card Option
SD Simplex Long Enclosure 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  SD/CD Service Manual 1-11...
Page 28: Sd Duplex Printer
SD Duplex Printer The figure below shows the main parts of the SD360 duplex card printer. The main features and options available for the printer are: Double side color and monochrome 200‐card input tray with card detection option   printing 100‐card input tray 100‐card output tray option   Output tray with 25‐card capacity and Kensington lock   reject tray Smart Card reader/writer Magnetic stripe options (ISO and JIS)   1-12 Introduction...
Page 29: Cd Simplex Short Enclosure
CD Simplex Short Enclosure The figure below shows the main parts of the CD800 card printer with the Smart Card option. The main features and options available for the printer are: Single side color and monochrome printing 200‐card input tray option   100‐card input tray or manual feed option 100‐card output tray option   Output tray with 25‐card capacity Kensington lock   Smart card reader/writer Magnetic stripe options (ISO and JIS)   Swingarm Lid Enclosure Flap Ribbon Cartridge with Lid Smart Card Enclosure Main Enclosure 100 Card Hopper Smart Card in Simplex Assembly Simplex Printer Print Engine Board (Main Control Board) Base Assembly SD/CD Service Manual 1-13...
Page 30: Cd Duplex Printer
CD Duplex Printer The figure below shows the main parts of the CD single hopper duplex card printers. The main features and options available for the printer are: 100‐card input tray Output tray with 25‐card capacity and reject   tray Double side color and monochrome printing 100‐card output tray option (N/A on CE units)   Magnetic stripe options (ISO and JIS) 200‐card input tray option   Smart Card reader/writer Kensington lock   Enclosure Flap Swingarm Lid Ribbon Cartridge with Lid Hood Enclosure Smart Card Enclosure Main Enclosure 100 Card Hopper Smart Card in Duplex Assembly Simplex Printer Print Engine Board (Main Control Board) Base Assembly 1-14 Introduction...
Page 31: Options Available
Options Available The SD/CD series printers have the following components as standard (S), optional (OP) or not available (NA). DP= Desktop Printer S= Standard OP= Option NA= Not Available Y= Yes N= No FK= Field Kit SD160 (D1) SD260 (D1) SD260 (D2) SD260L (D2) SD360 (D2 CD800 (D2) Sales Channel Standalone Printer Simplex Duplex Printing Rewritable Printing Magnetic Stripe OP/FK JIS Magnetic Stripe OP/FK JIS ISO (Dual) Mag Stripe Data Encryption View LCD Screen Touch Screen Trays and Hoppers Reject Tray Output Output Output Manual Feed Input Hopper (100) Input Hopper (200) MultiHopper (600)
Page 32 SD160 (D1) SD260 (D1) SD260 (D2) SD260L (D2) SD360 (D2) CD800 (D2) Locks and Alarms Tilt Alarm Lock Cable Locks Mechanical ‐ Printer Locks Mechanical ‐ Input Locks ‐ Reject Tray Software and Drivers Ethernet DPCL2 ‐ only D3 boards Activation XPS Driver CardWizard N OpenCard Y N N Smart Card ‐ Single Wire Duali (contact/contactless) Smart Card ‐ Loosely coupled Identive (contact/ OP/FK contactless) Duali (contact/contactless) 3rd party contactless only OP/FK 3rd party contact only OP/FK HID pcProx Plus OP/FK HID reader only (pcProx) OP/FK HID reader/writer (iCLASS)
Page 33: Functional Block Diagrams
Functional Block Diagrams SD160/SD260 Simplex Print Engine (D1 Board) SD/CD Service Manual 1-17...
Page 34: Sd260 Simplex Print Engine (D2 Board)
SD260 Simplex Print Engine (D2 Board) 1-18 Introduction...
Page 35: Sd260L With Smart Card Print Engine (D2 Board)
SD260L with Smart Card Print Engine (D2 Board) SD/CD Service Manual 1-19...
Page 36: Sd360 And Cd800 Duplex Print Engine (D2 Board)
SD360 and CD800 Duplex Print Engine (D2 Board) 1-20 Introduction...
Page 37: Iclass Or Pcprox Plus (Contactless) Smart Card
iCLASS or PcProx Plus (Contactless) Smart Card SD/CD Service Manual 1-21...
Page 38: Scm Or Identive (Contact/Contactless) Dual Smart Card
SCM or Identive (Contact/Contactless) Dual Smart Card 1-22 Introduction...
Page 39: Third-Party Integrator Basic Smart Card
Third-Party Integrator Basic Smart Card SD/CD Service Manual 1-23...
Page 40: Third-Party Contact Station
Third-Party Contact Station 1-24 Introduction...
Page 41: Duplex Module
Duplex Module SD/CD Service Manual 1-25...
Page 42: Printer Components
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. Refer to“Functional Block Diagrams” on page 1‐17 for connection information. Name Function Card Present This optional sensor on manual input printers detects when a card is present (Manual Feed) and ready to be picked. Card Present This sensor in the input hopper frame detects when the card input tray is (Hopper Empty) empty (SD360 printers only). 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. 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, and 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 when a card exits the exit rollers. MS Encoder This encoder monitors the rotation of the idler roller in the magnetic stripe ...
Page 43: Motors
Name Function Smart Card This sensor determines whether a card is present in the smart card module. Registration/ Position 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 1‐17 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 This 2‐phase (4‐wire), 24‐volt stepper motor turns the duplex drive rollers. Motor Duplex Flipper This 2‐phase (4‐wire), 24‐volt stepper motor rotates the entire flipper assembly. Motor TPH Fan The fan cools the thermal printhead (TPH). The airflow direction is toward the heat sink. SD/CD Service Manual 1-27...
Page 44: Circuit Boards
Circuit Boards The printer has several boards that are connected to the print engine drive board. See “Functional Block Diagrams” on page 1‐17 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 This circuit board controls the magnetic stripe head and provides an Daughter Board interface for the encoder. Ribbon Motion When the ribbon cartridge is installed in the printer the diametric magnet is Encoder Board 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 This circuit board provides a communication interface between the Board 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. 1-28 Introduction...
Page 45: Lcd Panel
LCD Panel The LCD panel, beneath the card input hopper in the printer, shows printer status information. It has menu options to run a cleaning card, view printer information, and configure the printer. Press 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  Printer firmware version  Ribbon part number  Ribbon Card Status Light Status Light Down Button User Button Power Button Up Button Enter Button 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. SD/CD Service Manual 1-29...
Page 46: Status Lights
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 Print ribbon is okay. Status Light Flashing amber Print ribbon is low if flashing slowly (every 2 seconds) or out if flashing quickly (every 1/2 second). Flashes green Print ribbon is out or broken. and amber In the SD160 printer with rewritable printing enabled, the ribbon light will flash green and amber if a print ribbon is in the printer. Card Status Cards are OK. Light Flashing amber There is a problem with the cards related to the printer component. The light flashes quickly (every 1/2 second). User Button System is powered off or suspended. and Light Green System is ready. Flashing green If the light flashes slowly (every 2 seconds), the system is busy. 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 ...
Page 47: Lcd Menu Options
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 Test Card Runs the test card. Exit Returns to the Main menu. Status Serial Number Displays the serial number of the card printer. FW Rev Displays the firmware revision number of the card printer. Network Status The following options are available: 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 Ribbon Type Displays the type of ribbon being used in the printer, if any.
Page 48 Main Menu Option Submenu Item Option Configuration LCD Backlight Sets the LCD backlight intensity. Range: 0 to 100% Default: 100% Network The following options are available: DHCP/Static IP IP Address Subnet Mask Gateway Address Apply/Restart Exit K Power ‐100 to 100 Mag Stripe The following options are available: Coercivity (High, Low, NTT1, NTT2, NTT3, Apply, Exit) Exit Menu Style: Modern Style: Legacy Exit Language Select, reset, and apply a language Exit Exit Exit to Main menu. 1-32 Introduction...
Page 49: Printer Manager
Printer Manager Printer Manager is a web based 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 network using an Ethernet cable. You can access Printer Manager via a current web browser such as Internet Explorer, Chrome or Firefox. 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. 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. The printer can connect to Printer Manager from the printer driver as well from Printer Status page by clicking on Configure Printer. SD/CD Service Manual 1-33...
Page 50: Ethernet Connection
Ethernet Connection Follow the steps below to connect to Printer Manager using a browser and Ethernet connection. Make sure that the printer is configured for DHCP (Dynamic Host Configuration Protocol) as described in “LCD Menu Options” on page 1‐31. Connect the card printer to the network using an Ethernet cable and turn the printer on. Use the LCD panel to determine the IP address of the printer. At the Ready status touch the User button once. At the Suspended Menu Available status touch Enter once. Touch the Down Arrow once to change the selection from Maintenance to Status. Touch Enter once. Use the Down Arrow to scroll to Network Status and touch the Enter button. Use the Down Arrow button to scroll to IP Address and touch Enter. Write down the IP address. Exit the Status Menu by touching User until Ready again displays. Open a browser window and enter the IP address of the printer into the address bar (example: “http://xxx.xxx.xxx.xxx”) The Printer Manager login displays 1-34 Introduction...
Page 51: Usb Connection
USB Connection Follow the steps below to connect to Printer Manager using a browser and a USB connection. Connect the card printer to the USB port and turn the printer on. Use the LCD panel to confirm the Serial Number. At the Ready status touch the User button once. At the Suspended Menu Available status touch Enter once. Touch the Down Arrow once to change the selection from Maintenance to Status and then touch Enter to select it. Use the Down Arrow to scroll to Serial Number and then touch Enter to select it. The Serial Number will be displayed. Open a browser window and enter the Serial Number of the printer into the address bar (example: “http://xxxxxx.local”). The Printer Manager login displays. SD/CD Service Manual 1-35...
Page 52: Logging In To Printer Manager
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. If a passwords has been set by the administrator, the password 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. This 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). 1-36 Introduction...
Page 53: Printer Manager Menu Options
WebService access can change the passwords for WebService, WebAdmin, and WebUser. WebAdmin can change only the passwords for WebAdmin and WebUser. Changing the service password from the default value is not recommended. Guard the password from unauthorized users. A lost password will require a main board replacement to restore the password to a known value. 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 “Status” on page 3‐4 and “Troubleshooting” on page 4‐1 for more information about 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 Displays vital product data (VPD) including the manufacturer, model, options, and software/firmware version information. This information may be needed for service providers. Printer Status Displays printer status information including the current state, time in seconds system has been on, and any current conditions. Supplies Displays 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 Displays 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 Displays information about the Printer Manager firmware version and copyright.
Page 54: Printer Settings
Printer Settings The options on the Printer Setting menu display printer settings for adjustments. Menu Option Description Purpose Communication EthAddressMethod Displays the default and current values of 1. the communication method (DHCP or static) EthGatewayAddress 2. and address information. Changes the EthIpAddress 3. current information or restores the default EthMacAddress 4. values. EthSubnetMask 5. UsbDeviceMacAddres 6. UsbHostMacAddress 7. Activity Log ExternalLog Allows you to enable or disable both 1. internal and external logs and designate the ExternalLogServer 2. external log server IP address. You can set FilterCardActions 3. activity log filters to notify at different levels FilterConfigChanges 4. or turn them off. Change the current values FilterJobStates 5. ...
Page 55 Menu Option Description Purpose FrontPanel BacklightBrightness Displays the default, current values, and 1. allowed ranges for the front panel options. KeySenseLevel 2. Change the current information or restore LcdConfigMenu 3. the default values. LedCardsPickedToCleaning 4. LedPrintheadCyclesTo 5. Cleaning LedRibbonLow 6. Speaker Enabled 7. Print CableCompMaxStrobe For printers with a printhead installed, 1. displays the default, current values, and CardRegistration 2. allowed ranges for the print options. CardRegistrationCalibration 3. Change the current information or restore ColorManagement 4. the default values. See descriptions of these ColorMatchB_0 5. items in “Print” on page 3‐11. Some items ...
Page 56 Menu Option Description Purpose Print (Cont.) ColorMatchR_6 34. ColorMatchR_7 35. ColorMatchR_8 36. ColorMatchR_9 37. ColorMatchR_10 38. FPower 39. FPowerCalibration 40. FPowerDuplex 41. FanTempOn 42. KFineText 43. KPower 44. KPower1200DPI 45. KPower600DPI 46. KPowerCalibration 47. KPowerCalibration1200DPI 48. KPowerCalibration600DPI 49. KPowerDuplex 50. KWhiteShade 51. LeadTrim 52. ...
Page 57 Menu Option Description Purpose Print (Cont.) YMCPowerCalibration600 73. YMCPowerDuplex 74. YMCPowerNosRGB 75. YMCWhiteShade 76. Pick MotorPWM Displays the default, current values, and 1. allowed ranges for the pick offsets. Change PickAutoTimeout 2. the current information or restore the PickCardOffset 3. default values. PickManualTimeout 4. PickReversePwm 5. PickReverseTime 6. Transport EjectHopperSpeed Displays the transport speed options. 1. Change the current information or restore FinalEjectSpeedExtended 2. the default values. FinalEjectSpeed 3. StandardHopper SmartContactOffset 4. ...
Page 58 Menu Option Description Purpose MagStripeGeneral Attempts Displays the default, current values, and 1. limits for general magnetic stripe options. AutoCoercivity 2. Change the current information or restore Coercivity 3. the default values. DataFormat1 4. Coercivity can be HICO, LOCO, NTT1, NTT2, DataFormat2 5. or NTT3. DataFormat3 6. Data Formats can be: IATA, ABA, TTS, JIS, NoDataDisableTrack 7. AAMVA, AAMVA‐ECC, VING, SAFLOK, ReadTrack1 8. TIMELOX, ONITY, CUSTOM, BINARY75, ReadTrack2 9. BINARY210, or None. ReadTrack3 10. SSA# values can be ‐4 to 4. SSA1 11. SSA2 12. SSA3 13. ...
Page 59: Troubleshooting
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 Purpose Sensors Printer/Hopper Sensors: Displays the current and historical value along with the jumper number and type for each sensor Card Present  in the system. Magstripe Register  Includes options to start an update and to reset Card Input  the sensor history. Reset restores the current Ribbon Motion settings. The Continuous Update Interval can be  adjusted from this display. Ribbon Index  Photocell sensors change status between 0 and 1; Head Latch (swingarm)  encoders are always indicated with an X. Cam Home  Card Exit  MS Encoder  Flipper Home  Smart Card Reg  Smart Card Contact ...
Page 60 Menu Option Description Purpose Test Transport Direction Displays the default, current values, and limits for 1. the transport stepper motor. Test the motor, make Speed 2. changes to the current values, and restore the Steps 3. default values. Test Pick Direction Displays the default, current values, and limits for 1. the pick motor. Test the motor, make changes to 2. the current values, and restore the default values. Time 3. Higher PWMs increase speed but decrease torque. Test Cam Direction Displays the default, current values, and limits for 1. the cam motor. Test the motor, make changes to Speed 2. the current values, and restore the default values. Steps 3. Test Ribbon PWM Value Displays the default, current values, and limits for 1. the ribbon motor. Test the motor, make changes to Time 2. ...
Page 61: Maintenance
Menu Option Description Purpose 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. 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 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. SD/CD Service Manual 1-45...
Page 62 1-46 Introduction...
Page 63: Chapter 2: Theory Of Operation
Chapter 2: Theory of Operation This chapter provides the theory of operation for the card printers. Sequence of Operation ............2-3 Power-On Initialization .
Page 64 Parity Check ............. 2-26 Data String .
Page 65: Sequence Of Operation
Sequence of Operation The printer uses the following sequence of operation. Power-On Initialization When the power button on the front of the printer is pressed, the printer begins its initialization routine. 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. The display backlight turns off briefly to show that the board is beginning to be initialized. The display backlight turns on again and Initializing displays on line 1 on the LCD and asterisk symbols scroll from left to right on line 2. The card status lights, ribbon status lights, and the user button on the front panel of the printer cycle between green and amber several times. amber several times. 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. While the control board examines and initializes external components, the user light flashes green. The cam motor cycles and homes. The transport is initialized and then operated for sufficient time to ensure that the card track is clear. The ribbon type is identified. This may result in the ribbon motor being energized for a short time to detect a ribbon encoder change. The duplex (if applicable) is placed in the flipper reject angle. 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. When the power button on the front of the printer is depressed for about two seconds, the printer begins its power down routine. The display shows Shutting Down and the user button glows steady amber. SD/CD Service Manual...
Page 66: Default Card Production Sequence
The backlight turns off and the display still indicates Shutting Down as the user button still glows steady amber. The message disappears and the user button goes dark. 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 After the card data has been sent to the printer, it begins the card personalization process. The card is picked and passes through the cleaning rollers. 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. The card is then sent toward the entrance of the printing area where it is sent to the magnetic stripe module first, if applicable. The leading edge of the card is registered by the magnetic stripe sensor. The optical encoder measures the distance the card is traveling during the encoding process. All tracks on the card are written simultaneously. The card data is verified on the return pass. The card is returned to the input sensor and registered for graphics printing. When the leading edge of the card reaches the platen roller, the cam engages and lowers the printhead onto the card. The ribbon motor is engaged. The motor is over‐driven, and the spindle clutch slips as needed to match the speed of the card. After a panel is printed, the printhead is raised and the card is returned to the input sensor. The ribbon motor advances to the next panel by examining the ribbon encoder. The process is repeated for the remaining panels. After printing, the card is moved into the output tray. Theory of Operation...
Page 67: Duplex Sequence
Duplex Sequence 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: The flipper home flag passes through the flipper home sensor and moves the distance defined by the Flipper Home Offset. 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. 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. 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. The four flipper positions are: Home: the flipper is close to horizontal.  Reject: the flipper is positioned here after initialization. This 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 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. SD/CD Service Manual...
Page 68: Smart Card Sequence
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. The identive Dual Smart Card Reader option or a contactless only option (such as the iCLASS Read/Write or PcProx Plus) may be installed. When the Identive Dual Reader is installed, it includes a contact block board with the smart card contact switch. When the printer detects the identive option, the firmware calls a routine that uses the switch as follows: The card is parked in the smart card module. The printer driver sends a park command to the firmware. As the card enters the module, the leading edge is detected by the smart card registration sensor. The card continues to move the distance defined by the SmartInOffset (contactless smart card only). The card continues to move the distance defined by the SmartContactOffset (simplex contactless smart card only). iii. 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.) 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. 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. A contactless‐only reader may be installed as part of a third‐party integrator, iCLASS reader/ writer or the PcProx Plus 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. The printer driver sends a park command to the firmware. As the card enters the module, the leading edge is detected by the smart card registration sensor. 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. Theory of Operation...
Page 69: Power Down Sequence
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 for transport out of the printer. Power Down Sequence The printer requires a proper shutdown. Do not interrupt power from the printer until it completes the shutdown. A sudden shutdown can damage the printer’s operating system, similar to a computer. When the power button on the front of the printer is depressed for about two seconds, the printer begins its power down routine. The display shows “Shutting Down” and the user button glows steady amber. The backlight turns off and the display continues to indicate “Shutting Down” as the user button continues to glow steady amber. The message closes and the user button goes dark. If the printer has the power removed with going through the correct power down sequence, an “Improper Shutdown” message will display on the lcd panel when the printer is powered on. SD/CD Service Manual...
Page 70: Card Feed
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. With 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 “Testing the Ribbon and Pick Motors” on page 4‐15. 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. Theory of Operation...
Page 71: Card Transport
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 sensors. 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” on page 3‐34 and “Troubleshooting” on page 4‐1. SD/CD Service Manual...
Page 72: Card Printing
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” 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 forth pass uses the K panel for black, and the last pass is for the topcoat. 2-10 Theory of Operation...
Page 73 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. SD/CD Service Manual 2-11...
Page 74: Monochrome Printing Sequence
Monochrome Printing Sequence When preparing to print a monochrome card 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. The figure below shows the process the printer uses to print a monochrome card. 2-12 Theory of Operation...
Page 75: Ribbon Advance
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 SD160 printer does not support tagless monochrome ribbon. 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 SD/CD Service Manual 2-13...
Page 76: Regionalized Print Ribbons
the chip on the encoder board. This generates 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” on page 3‐11 and “Testing the Ribbon and Pick Motors” on page 4‐15. Regionalized Print Ribbons Firmware version D2.15.1 and later added support for regionalized ribbons to ensure customers are purchasing ribbon from their partners in their region. Once the firmware in the printer has been upgraded, the printer cannot be  downgraded to an earlier version. Once the printer has been regionalized, only regionalized ribbon can be used.  Non‐regionalized ribbon can still be used in printers that have the upgraded firmware  provided a regionalized ribbon has not been installed in the printer. The following ribbons are now regionalized. YMCKT, 250 yeild  YMCKT, 500 yeild  ymcKT, 650 yeild  YMCKT‐KT, 350 yeild  The following ribbons are not affected by regonalization. Monochrome ribbons  Any other ribbon not listed (YMCKT‐K)  2-14 Theory of Operation...
Page 77: Identifying A Regionalized Printer
Identifying a Regionalized Printer The Ready screen on the front panel LCD can be used to quickly identity if the printer has been regionalized and the region code used for ribbon supplies. Non‐Regional Printer Front Panel LCD Regional Printer Front Panel LCD and Region Code A regionalized ribbon needs to be used to set the region on the printer. The printer will then take on the region that is assigned to the first regional supply that is loaded into the printer. Once the printer has taken on a region, the printer will be regionalized and only work with the supplies with the same region code. The part number of the ribbon can be displayed from the LCD display. Use the quick menu, by pressing the down arrow until the information is displayed. Identifying Regionalized Supplies The supply price pages will provide your detailed regional part numbers. You can identify the regionalized part numbers, as they end with R00X. There will be an insert in each box that includes stickers that have the part number for your region and can be placed on the printer to help with future orders. SD/CD Service Manual 2-15...
Page 78: 98Mm Ribbons
98mm Ribbons The regionalized ribbons are 98mm for each panel length rather than 101mm. There are no index marks between each panel set. The ribbon requires less power to print an image. and is more susceptible to breaking if the print head goes beyond the trailing edge of the card. Regionalization Error Messages The following error messages will display on the front panel LCD when there is an error with regionalization. Once the firmware in the printer has been upgraded, the printer cannot be  downgraded to an earlier version. Once the printer has been regionalized, only regionalized ribbon can be used.  Non regionalized ribbon can still be used in printers that have the upgraded firmware  provided a regionalized ribbon has not been installed in the printer. Message 119 will display If a regionalized ribbon is installed in the printer before the  firmware has been updated. Message 224 will display if a ribbon is installed in the printer with the wrong region code  after it has been regionalized. 2-16 Theory of Operation...
Page 79: Rewritable Graphics
Rewritable Graphics Rewritable cards used in the SD160 printer use a form of thermochromic printing, for which a color change is dependent on temperature. The cards contain a coating of a temperature‐ dependant leuco dye and a developer. A leuco dye is a material that changes color depending on the temperature applied to it. The card can also be erased using a different temperature and used numerous times. Separately, the leuco dye and developer are colorless. The dye is an electron donor and the developer is an electron acceptor. When they combine, the chemical reaction causes the dye to become colored. As with all leuco dyes, there is a specific temperature at which the dye and developer combine, and below this temperature, they separate. This temperature is in the same region as the melting point of the two components, so melting the mixture causes it to become colorized. If the mixture is allowed to cool slowly, the dye and developer will separate before the mixture solidifies and recrystallizes into its native state (non‐amorphous crystal). Most leuco dyes are immediately reversible in that they will revert back to their base color as soon as the heat is removed and the temperature returns to ambient. The difference with the leuco dye and developer used in rewritable cards is that the color change can be locked into the colored state by rapidly cooling and solidifying the film and preventing the dye and developer from separating at their normal separation temperature. SD/CD Service Manual 2-17...
Page 80: Magnetic Stripe Encoding
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. 2-18 Theory of Operation...
Page 81: Magnetic Stripe Write Operation
Magnetic Stripe Write Operation 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. SD/CD Service Manual 2-19...
Page 82: Magnetic Stripe Read 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 3‐45 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 Magnetic Stripe Read Operation. For information about tools, troubleshooting methods, and remove and replace procedures for magnetic stripe encoding, see page 5‐3 and Chapter 4, Troubleshooting. 2-20 Theory of Operation...
Page 83: Color Management
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 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. SD/CD Service Manual 2-21...
Page 84 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. 2-22 Theory of Operation...
Page 85: Other Color Variation Factors
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. 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 SD/CD Service Manual 2-23...
Page 86 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: Adobe Technical Guide: http://dba.med.sc.edu/price/irf/Adobe_tg/manage/cmsdef.html Overview Of Color Management: http://www.cambridgeincolour.com/tutorials/color‐management1.htm 2-24 Theory of Operation...
Page 87: Magnetic Stripe Encoding Format
Magnetic Stripe Encoding Format The data on a magnetic stripe is nothing more than a series of binary 1 and 0. 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 for the character code. Once the number of bits per word has been specified, all characters in the 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. SD/CD Service Manual 2-25...
Page 88: Parity Check
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. Binary Char Code Parity Bit Sum Char 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 Start Specific Data End Longitudinal Trailing Clock Pulses Sentinel Sentinel Redundancy Check 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.) 2-26 Theory of Operation...
Page 89: Specific Data
Specific Data This is the actual data that personalizes the card. This data can represent a person’s name, birth date, account number, and so on. 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.) Binary Char Code Parity Name Bit SumChar Start Sentinel Sample Data Sample Data Field Separator Sample Data Sample Data End Sentinel Pre‐LRC Sum ...
Page 90: Magnetic Stripe Primary Data Standards
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 Full Name Abbreviated Name Former Designation ISO/IEC 7811 part 2 or 6 Track 1 ISO‐1 IATA ISO/IEC 7811 part 2 or 6 Track 2 ISO‐2 ISO/IEC 7811 part 2 or 6 Track 3 ISO‐3 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 ...
Page 91: Multiple Record Format (Sds)
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, non‐recorded 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 ...
Page 92: Magnetic Media Locations
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 3‐ track 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.) 2-30 Theory of Operation...
Page 93: Data Track Locations
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. SD/CD Service Manual 2-31...
Page 94: Summary Of Specifications
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 JIS Type II Parameter Track 1 Track 2 Track 3 Single Track Bit Density Total Length Record Length Data Type 7‐bit A/N 5‐bit N 5‐bit N 7‐bit A/N Start Sentinel End Sentinel Field Separator Word Parity EVEN LRC Parity EVEN EVEN N = Numeric character set A/N = Alphanumeric character set 2-32 Theory of Operation...
Page 95: Character Encoding
Character Encoding 7-bit Alphanumeric Character Set as Defined by ISO/IEC 7811 Binary Binary Parit Parit Note Char Note Char Space “ & ‘ ‐ SD/CD Service Manual 2-33...
Page 96: 5-Bit Numeric Character Set As Defined By Iso/Iec 7811
< > Code Description 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. Additional reserved characters. S,E,F Reserved characters for Start Sentinel, End Sentinel, and Field Separator 5-bit Numeric Character Set as Defined by ISO/IEC 7811 Binary Note Char Parity < > Code Description 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 2-34 Theory of Operation...
Page 97: Smart Card Technology
Smart Card Technology In smart card enabled cards, a chip is embedded inside of the 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). SD/CD Service Manual 2-35...
Page 98: Contact Smart Cards
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. Name Purpose Name Purpose Supply voltage (3 or 5 V) Ground Resets the processor Variable voltage for programming Provides the timing (clock) Data line signal Reserved for future use 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). 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). The reset line (C2) is held low. (The active‐low reset forces the card to remain in the reset state until released.) 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.  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.
Page 99: Contactless Smart Cards
The I/O line is held in the receive mode (high impedance). If the card is a Type‐A card, the programming voltage (VPP) is placed in the pause value, which is equal to VCC. The clock signal is activated. The reader releases the reset by bringing it to a high voltage. 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  With communication parameters known, the interface can begin to communicate with the card. Serial communication across the I/O line commences. 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 2‐35 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. ® The FeliCa card format was developed by the Sony Corporation and is similar to the standard ...
Page 100: Communication
® 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. 2-38 Theory of Operation...
Page 101: Chapter 3: Adjustments
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. Printer Manager Factory and Power-On Settings........3-4 Status .
Page 102 RewritableWritePower ..........3-21 RewritableWritePowerCalibration .
Page 103 MagStripeCustomTrack........... . 3-43 Magnetic Stripe Settings.
Page 104: Printer Manager Factory And Power-On Settings
Printer Manager 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.  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 Manager 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 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 1‐37 to see what information is available from the Status submenus. Adjustments...
Page 105: Printer Setting
Printer Setting 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 This is the 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. UsbDeviceMacAddress This is the MAC address for the USB device on the USB network. UsbHostMacAddress This is the MAC address for the USB host on the USB network, SD/CD Service Manual...
Page 106: Activitylog
ActivityLog 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. FilterCardActions 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 Information similar to Syslog severities. 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 Information similar to Syslog severities. 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. Adjustments...
Page 107 Activity Log Example Following is an example of an external activity log using an application to monitor the system log. In Printer Manager select Printer Setting > Activity Log. In this example: The ExternalLog option has been enabled  The ExternalLogServer IP address has been entered  The FilterSOAPMsgs option has been set to filter for SOAP messages at the Notice 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 from their website. SD/CD Service Manual...
Page 108 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. 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. Adjustments...
Page 109: Behavior
Behavior These options control the printer operation and magnetic stripe encoding. See “Enabling the Proprietary Magnetic Stripe Option” on page 3‐45 for information about using proprietary magnetic stripe encoding. Option Description FactoryMode Enable or disable the factory mode. MSAamvaEncoding Enable or disable encoding the AAMVA magstripe data format. MSSaflokEncoding Enable or disable encoding the Saflok magstripe data format. MSTimeloxEncoding Enable or disable encoding the Timelox magstripe data format. MSVingEncoding Enable or disable encoding the Ving magstripe data format. RedefaultTrailTrimDone True enables or false disables restoring the TrailTrim setting to the pre‐firmware modified default value. This is an indication that the TrailingTrim has been redefaulted to 1.47 from 1.27 as deemed necessary by engineering, particularly for new ribbons Reject Hopper Put rejected cards in the reject hopper (otherwise front hopper). RibbonInitialize Enable or disable initialization of the ribbon at power on. Web Server Secure Allows access to the web server. VitalProductData 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 SerialNumber The serial number setting may need to be reset if replacing the print ...
Page 110: Frontpanel
FrontPanel This option has settings for the LCD panel, buttons, and the indicator lights. See “LCD Panel” on page 1‐29 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 1,000,000 cards Default: 1500 cards 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 Example: When the printer is using a five panel ribbon (YMCKT), there are five printhead cycles per card. You would set the LedPrintheadCyclesToCleaning setting to five 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 Use the speaker to provide sound indicators along with text and ...
Page 111: Print
Print The print options that control the quality of the printing are listed below. The print density is the overall lightness or darkness of the printing and is a result of a combination of CableCompMaxStrobe, YMCPowerCalibration, and YMCPower. CableCompMaxStrobe and YMCPowerCalibration are factory adjustments. 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 Increase to increase density in most areas.  Decrease to reduce unexpected lightness in smaller areas.  SD/CD Service Manual 3-11...
Page 112: Cardregistration
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) 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. Because 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...
Page 113: Cardregistrationcalibration
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: Set the CardRegistration to its default value of zero. Print Test Card Pattern 5 using the K panel. 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. SD/CD Service Manual 3-13...
Page 114: Color Management
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. Because 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 2‐21. ColorMatchB[0-10], ColorMatchG[0-10], ColorMatchR[0-10] The ColorMatch settings for Blue(B), Green(G), and Red (R), are used by the printer to make sure that the print color output for all ribbon types is consistent. Each value has been calibrated so that the colors that print on a card are the same for every ribbon type. We recommend that you do not change these settings except under the guidance of your service provider. To restore the color match settings to their default values, set the ColorMatchR[10] value to 0 and click Set Current. Power off the printer, and then power it on again. This restores all 33 of the color match settings to their default values. 3-14 Adjustments...
Page 115: Colormatchmode
ColorMatchMode Enables or disables the ColorMatchB/G/R values for SD160 printers only. Enable tells the printer to use the ColorMatch settings for all ribbon types. Disable uses the color settings that were in effect with the previous version of the SD160 firmware. If you have upgraded your SD160 printer firmware from a version prior to D.2.15.xx, select Disable to keep your card production consistent with the cards printed earlier. Options: Enabled or Disabled Default: Disabled FPower Increase or decrease the print intensity for the F panel of a UV ribbon. Increase to make UV printing more defined on the card. Decrease to reduce the UV intensity or if the ribbon breaks when printing the F panel. Range: ‐100 to 100 special units Default: 0 special units FPowerCalibration Range: ‐100 to 100 special units Default: 0 special units FPowerDuplex Increase or decrease the print intensity for the backside F panel of a UV ribbon. Increase to make UV printing more defined on the card. Decrease to reduce the UV intensity or if the ribbon breaks when printing the F panel. Range: ‐100 to 100 special units Default: 0 special units 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. SD/CD Service Manual 3-15...
Page 116: Kfinetext
KFineText Sharpens fine K text printing such as using 3 point fonts. Enable or disable fine text printing using the K panel. Options: Disabled or Enabled Default: Disabled 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 Default: 0 special units 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 rinting 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. 3-16 Adjustments...
Page 117: Kpower1200Dpi
KPower1200DPI This customer setting increases or decreases print intensity for K panel or K ribbon printed at 1200 dpi. Range: ‐100 to 100 special units Default: 0 special units Symptoms: Increase to make printing more intense (thicker).  Decrease to reduce intensity, for crisp bar codes, or to prevent ribbon breaks while printing.  KPower600DPI This customer setting increases or decreases print intensity for K panel or K ribbon printed at 600 dpi. Range: ‐100 to 100 special units Default: 0 special units Increase the value to make printing more intense (thicker).  Decrease the value to reduce intensity, for crisp bar codes, or to prevent ribbon breaks while  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. Range: ‐100 to 100 special units Default: 0 special units Note: This is a factory setting. SD/CD Service Manual 3-17...
Page 118: Kpowercalibration1200Dpi
KPowerCalibration1200DPI 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 codes or if the ribbon breaks while printing the K panel. Range: ‐100 to 100 special units Default: 0 special units Note: This is a factory setting. KPowerCalibration600DPI Change intensity of printing for the K ribbon or panel at 600 dpi. Range: ‐100 to 100 special units Default: 0 special units Note: This is a factory setting. Increase the power used to print the K panel and make printing thicker.  Decrease for crisp bar codes or if the ribbon breaks while printing the K panel.  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: 100 special units Increase the value to make printing thicker.  Decrease the value for crisp bar codes or if the ribbon breaks when printing the K panel.  KPowerDuplex Increase or decrease the print intensity for the backside F panel of a color ribbon. Increase to make K printing more defined on the card. Decrease to reduce the K intensity or if the ribbon breaks when printing the F panel. Range: ‐100 to 100 special units Default: 0 special units 3-18 Adjustments...
Page 119: Kwhiteshade
KWhiteShade KWhiteShade is power applied to the printhead to reduce ribbon friction without transferring K panel white shade. 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 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) Default: 0.254 mm (0.01 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. SD/CD Service Manual 3-19...
Page 120: Rewritablecardenable
RewritableCardEnable Disable or enable rewritable card printing. Options: Disabled or Enabled Default: Disabled RewritableCardType Select the type of rewritable card being used. Options: MitsubishiBlue30mm or RicohBlack30mm. Default: MitsubishiBlue30mm RewritableErasePasses The number of erase passes to make on a rewritable card before reprinting. Range: 1 to 4 Default: 1 RewritableErasePower Increase or decrease the erase intensity for a rewritable card. Increase to apply more power to the erase action. Decrease to apply less power to the erase action. Range: ‐100 to 100 Default: 0 RewritableErasePowerCalibration Calibrates the power for the erasing to rewritable cards. Range: ‐100 to 100 Default: 0 3-20 Adjustments...
Page 121: Rewritablewritepower
RewritableWritePower Increase or decrease the write intensity for a rewritable card. Range: ‐100 to 100 Default: 0 Increase to make the printed information darker. Decrease to make the printed information lighter. RewritableWritePowerCalibration Calibrates the power for the writing to rewritable cards. Range: ‐100 to 100 Default: 0 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. SD/CD Service Manual 3-21...
Page 122: Ribbonstripoffset
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) Default: 20.32 mm (0.8 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.  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) Default: 7.62 mm (0.3 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.  3-22 Adjustments...
Page 123: Settingsgrouppurpose
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. TPower The TPower is a customer setting to modify the intensity of printing for the T ribbon panel. Range: ‐100 to 100 special units Default: 0 special units Increase the value to make printed topcoat thicker or more uniform.  Decrease the value to prevent ribbon breaks while printing topcoat.  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. Range: ‐100 to 100 special units Default: 0 special units Note: This is a factory setting. 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.  SD/CD Service Manual 3-23...
Page 124: Tpowerduplex
TPowerDuplex This customer adjustment is for increasing or decreasing the print intensity for the back side T ribbon panel. Range: ‐100 special units Default: 100 special units Increase the value to make topcoat thicker and more uniform.  Decrease the value if the ribbon breaks when printing the topcoat.  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. Range: ‐100 to 100 shades Default: 0 shades Setting: Reduce this value if extra material transfers to the card. 3-24 Adjustments...
Page 125: Trailtrim
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) Default: 1.47 mm (0.057 inch) with 98 mm ribbons, 1.27 mm (0.05 inch) with 101 mm ribbons 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. SD/CD Service Manual 3-25...
Page 126: Verticaloffset
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. 3-26 Adjustments...
Page 127: Ymcminshade
YMCMinShade This is the minimum shade value at which YMC color begins to transfer from the ribbon to the card. Range: ‐100 to 100 shades Default: 0 shades Settings: Increase the value if a white shirt in a photo does not print.  Decrease the value if highlights are washed out (grayish).  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. Range: ‐100 to 100 special units Default: 0 special units Settings: Increase the value to make color printing more intense.  Decrease the value to reduce intensity or to prevent ribbon breaks while 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. Range: ‐100 to 100 special units Default: 0 special units Increase the value to make color printing more intense.  Decrease the value to reduce intensity or to prevent ribbon breaks while printing colors.  SD/CD Service Manual 3-27...
Page 128: Ymcpowercalibration
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. Range: ‐100 to 100 special units Default: 0 special units Increase the value to make colors stronger.  Decrease the value 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. 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, set the field adjustment of YMCPower600 to zero. Range: ‐100 to 100 special units Default: 0 special units Increase the power used to print the color panels to make colors stronger.  Decrease the power to reduce intensity or prevent ribbon breaks while printing color panels.  YMCPowerDuplex This is a customer setting to modify the printing of the backside Y, M, and C ribbon 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, set the field adjustment, YMCPower, to zero. Range: ‐100 to 100 special units Default: 0 special units Increase the power to print stronger color panels.  Decrease the power to reduce intensity or prevent ribbon breaks while printing color panels.  3-28 Adjustments...
Page 129: Ymcpowernosrgb
YMCPowerNosRGB Range: ‐100 to 100 special units Default: 48 special units 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. Range: ‐100 to 100 shades Default: 0 shades 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. SD/CD Service Manual 3-29...
Page 130: Print Misadjustment
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 advance it slightly. First ensure that the horizontal print margin is correct. Then adjust the trim settings. 3-30 Adjustments...
Page 131: Pick
Pick 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. MotorPWM This offset sets a pick motor speed to a percentage. Use this adjustment to match the pick motor speed to the transport motor speed. 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, the motor can stall.  PickAutoTimeout 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 card‐not‐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: 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. Explanation: 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. SD/CD Service Manual 3-31...
Page 132: Pickcardoffset
PickCardOffset 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 85.725 mm (0.1 to 15.75 inches) Default: 20.32 mm (0.8 inch) 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. PickManualTimeout This is the number of seconds to attempt to pick a card (when 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. 3-32 Adjustments...
Page 133: Pickreversepwm
PickReversePwm PWM (pulse‐width modulation) at which the pick motor will run in reverse. Range: 0 to 100% Default: 50% PickReverseTime Milliseconds to run the Pick motor in reverse after picking a card to prevent picking of two cards. Range: 100 to 3000 ms 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. SD/CD Service Manual 3-33...
Page 134: Transport
Transport The transport motor moves the cards through the printer. EjectHopperSpeed Optimize eject speed based on hopper type (standard or extended). Options: Standard, Extended Default: Standard FinalEjectSpeedExtended This is the speed at which cards are ejected into the extended hopper. Range: 1000 to 3600 steps per second Default: 1800 steps per second FinalEjectSpeedStandardHopper This is the speed at which cards are ejected into the standard hopper. Range: 1000 to 3600 steps per second Default: 3000 steps per second SmartContactOffset The number of steps the card is transported into the smart card contact position. This offset is available only on simplex printers with a contacted smart card reader. Range: 0 to 500 steps Default: 6 steps TransMedSpeed Speed at which to run transport motor when clearing errors. Range: 300 to 1800 steps per second Default: 800 steps per second 3-34 Adjustments...
Page 135: Transportspeed
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. Range: 300 to 1800 steps per second Default: 1800 steps per second 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 because they have a boost circuit to achieve this. SD/CD Service Manual 3-35...
Page 136: Flipper
Flipper 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 Flip–returns flipped card to printer Smart Card–sends card to and from the smart card assembly Reject–sends card to reject bin 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. 3-36 Adjustments...
Page 137: Flipperflippedangle
FlipperFlippedAngle 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 steps Default: 249 steps FlipperHomeOffset 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 flipper at home position. Range: 1 to 100 steps Default: 23 steps Symptom: Card jams Procedure: Defeat the interlocks and remove the ribbon cartridge. Be ready to open the swingarm as you send a test card to the system. 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. SD/CD Service Manual 3-37...
Page 138: Flipperregistrationoffset
FlipperRegistrationOffset This is the offset from the Exit sensor to load the flipper. Engineering recommends that this not be adjusted. Range: 1 to 80 Default: 40 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. FlipperRejectAngle 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 deflects off the bottom of the flipper into the reject tray. Range: 1 to 500 steps Default: Typical is 461 Symptom: Card jams FlipperRotationSpeed 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 steps Default: 700 Symptoms: If set too high, excessive noise is generated.  If set too low, motor can stall.  3-38 Adjustments...
Page 139: Flippersmartangle
FlipperSmartAngle 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 499 steps Default: 49 Symptom: If set too high, may cause excessive noise.  If set too low, motor stalling can occur.  Setting FlipperSmartAngle either too high or too low could set an angle where the card will bump into the assembly rather than go into the smart card module. FlipperTransRampDownRegSpeed (Engineering recommends that this not be adjusted.) Range: 1 to 1200 steps Default: 200 SmartInOffset Offset into the smart card module from the leading edge. Range: 1 to 300 steps Default: 83 SmartOutOffset (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 steps Default: 14 steps Symptom: Card jams Testing can be done only by producing a test card. SD/CD Service Manual 3-39...
Page 140: Magstripegeneral
MagStripeGeneral 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 the number of retries and can affect how quickly cards are processed. 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 DataFormat 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 3-40 Adjustments...
Page 141 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) Note: ReadTrack does not disable reading of the card after the card has been encoded in order to verify the data has been written correctly. This is only used for cards that are pre‐encoded. SaflokBitOrder Selections: LSB, MSB Default: MSB SSA x Start sentinel adjustment for track 1, 2, or 3. The value is determined by the SSA test. (x=1, 2, or 3) Range: ‐4 to 4 mm (‐0.157 to 0.0157 inch) Default: 0 mm (0 inches) 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. Note: Engineering does not recommend changing this setting. Range: 1 to 1500 steps Default: 1150 steps StripeReadSpeed Transport motor speed when reading or verifying magnetic stripe data. Note: Engineering does not recommend changing this setting. Range: 500 to 2400 steps per second Default: 1600 steps per second StripeWriteEventOffset Number of steps to move the card during the write magnetic stripe ...
Page 142 Option Description 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. Range: 0 to 500 steps 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. Note: Engineering does not recommend changing this setting. Range: 1 to 500 steps Default: 420 steps StripeWriteSpeed Transport motor speed while writing the magnetic stripe. Note: Engineering does not recommend changing this setting. Range: 500 to 2400 steps per second Default: 1000 steps per second WriteTrack x Allows magnetic stripe write actions to write to track 1, 2, or 3. (x=1, 2, or 3) 3-42 Adjustments...
Page 143: Magstripecustomtrack
MagStripeCustomTrack All of the MagStripeCustom track adjustments are either user‐ or administrator‐access 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 the track. Range: 1 to 255 Default: 95 CustomCharLength#(1‐3) The number of bits to represent one byte of data on the 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 the track. Range: 1 to 255 Default: 32 CustomCharMask#(1‐3) Encoding mask for the 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 the track, also called bits per inch or bpi. Allowed values are 75 bpi or 210 bpi. Range: 75 to 255 bits per inch Default: 210 bits per inch CustomEndSentinel#(1‐3) The last character encoded, which identifies the end of the encoded data for track.
Page 144 Option Description CustomLrc#(1‐3) Cumulative parity bit for the 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. 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. 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. 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 3-44 Adjustments...
Page 145: Magnetic Stripe Settings
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. Download 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. Log on to www.PartnerPage.com. Hover over Services & Support on the top menu and click Desktop Card Printers. Select the printer model. Select Enable Options. Under How to Enable Proprietary Magstripe Options Click on Click Here to Continue. 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. SD/CD Service Manual 3-45...
Page 146: Update Settings
Click the link to download the file. Save the file to the hard disk on your PC and proceed to the next section. Update Settings This procedure is required to send the magnetic stripe file to the printer. Log on to Printer Manager with service level access. Select Maintenance > Updates. Click Browse and locate the settings file. 3-46 Adjustments...
Page 147 Select the settings file and click Open. Click Upload File. the user status light on printer LCD panel will flash green as the settings file is being sent to the printer. The LCD panel will display BUSY. When completed a message in Printer Manager will display "File Upload Complete". SD/CD Service Manual 3-47...
Page 148: Verifying Proprietary Magnetic Stripe Option
Verifying Proprietary Magnetic Stripe Option This procedure is required after a proprietary magnetic stripe option has been enabled. In printer manager, select Printer Setting > Behavior. Verify that the appropriate magnetic stripe option has a current value of Enabled. 3-48 Adjustments...
Page 149: Magnetic Stripe Track Height Test
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.  SD/CD Service Manual 3-49...
Page 150 Test Procedure Print a magnetic stripe test card in Printer Manager by selecting Troubleshooting > Testcard. Check the vertical track alignment (track height) with an alignment gauge. Wipe the card with a clean, lint‐free cloth. Apply developer to the card. Using the alignment gauge, check the vertical track alignment. Refer to specifications in “Start Sentinel Position Adjustment” on page 3‐51. 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 “Start Sentinel Position Adjustment” on page 3‐51  3-50 Adjustments...
Page 151: Start Sentinel Position Adjustment
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 3‐49  Procedure Print a magnetic stripe test card in Printer Manager by selecting Troubleshooting > Testcard. Check the vertical track alignment (track height) with an alignment gauge. Wipe the card with a clean, lint‐free cloth. Apply developer to the card. Using the alignment gauge, check the vertical track alignment. Refer to specifications in “Magnetic Stripe Track Height Test” on page 3‐49. The first bit of each start sentinel should lie between the vertical etched lines on the alignment gauge. 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. 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. SD/CD Service Manual 3-51...
Page 152: Update Password
Update Password Use this procedure to change Printer Manager passwords for the site. Caution: Do not change the WebService password. Login to Printer Manager. 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 1‐36. Make sure to enter the Static IP address after http://. Example: http://172.17.1.113 Select WebService to log in to Printer Manager with service options. At the password prompt, enter the default service password of 926918. 3-52 Adjustments...
Page 153 Change WebUser and WebAdmin passwords to match customer access requirements. Select Printer Setting and Update Password. 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, A‐Z, 0‐9, +, and /. Enter the previous password for that login. Enter and reenter the same new password. iii. Click Update Password. SD/CD Service Manual 3-53...
Page 154: Replacing The Print Engine Drive Board
Replacing the Print Engine Drive Board Follow the procedure for removing and replacing the main control board (see “Print Engine Drive Board” on page 6‐48), 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. Log in to www.PartnerPage.com. Hover over Services & Support on the top menu. Choose Card Printers under Desktop ID Solutions. Click on the printer model to display its menu. 3-54 Adjustments...
Page 155 Click on Board Replacement. Click on Click Here to Continue. 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. Click on the link to download the file. Save the file on the hard disk of your PC. SD/CD Service Manual 3-55...
Page 156: Updating Printer Settings
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. Back Up Printer Settings The offsets for the printer are stored in a memory disk on the print engine drive board. If the site changes offsets, those 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. Back Up Using the DPCL Service Utility A back up file of printer settings can be made using the DPCL service utility (D1 board printers only). If you have not already done so, install the DPCL Service Utility from the Service Library CD or PartnerPage. It creates an icon on the Desktop. Connect a PC with the software program loaded to the Internet and set the IP Address to the printer’s address. Click the icon to start the DPCL Service Utility. Select Diag > Settings > Save All Settings. Browse to a location to save the file. 3-56 Adjustments...
Page 157: Back Up Using Printer Manager
Back Up Using Printer Manager A back up file of printer settings can be made using Printer Manager. Open Printer Manager. Log in as WebService. Select Maintenance > Download Settings. Click Download. Click Save to save the settings file. Browse to the desired save location and click Save. SD/CD Service Manual 3-57...
Page 158: Restore Printer Settings
Restore Printer Settings Use this procedure if you have changed the print engine drive board and need to restore the offsets to the as‐shipped settings or to settings you saved. Restore Using the DPCL Service Utility A restore of printer settings can be made using the DPCL service utility (D1 board printers only). If you have not already done so, install the DPCL Service Utility from the Service Library CD or PartnerPage. It creates an icon on the Desktop. Connect a PC with the software program loaded to the Internet and set the IP Address to the printer’s address. Click the icon to start the DPCL Service Utility. Select Diag > Settings > Restore All Settings. Browse to a location of the saved restore file. Restore Using Printer Manager A restore of printer settings can be made using Printer Manager. Open Printer Manager. Log in as WedAdmin or WebService. Select Maintenance > Updates. Click Browse to select the directory that contains the settings file. 3-58 Adjustments...
Page 159: Download A Settings File
Select the settings file and click Open. Click Upload File. The user status light flashes green as the file is being sent to the printer. When the process is completed, the LCD panel displays the message, File Upload Complete. Download a Settings File If the site has not backed up printer settings, download the as‐shipped settings for that printer from PartnerPage. Refer to “Downloading Settings File for Board” on page 3‐54 for details. SD/CD Service Manual 3-59...
Page 160 3-60 Adjustments...
Page 161: Chapter 4: Troubleshooting
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 _____________________________________________________ 4-13 Testing the Ribbon and Pick Motors _______________________________________ 4-15 Testing the Cam and Transport Motors ____________________________________ 4-15...
Page 162 102: Card not in position______________________________________________ 4-33 103: Printer problem __________________________________________________ 4-34 104: Critical problem _________________________________________________ 4-34 105: Magstripe data error ____________________________________________ 4-34 106: Magstripe data not found _______________________________________ 4-35 107: Magstripe read data error _______________________________________ 4-35 108: Magstripe read no data _________________________________________ 4-36 109: Print ribbon problem _____________________________________________ 4-36 110: Print ribbon out or missing ________________________________________ 4-36 111: Card not picked ________________________________________________ 4-37...
Page 163 511: Cannot lock or unlock the printer. Locks are not installed.__________ 4-45 512: Cannot lock or unlock the printer. The password is incorrect or invalid. 4- 513: Cannot lock or unlock the printer. The printer is busy. ______________ 4-45 514: Cannot lock or unlock the printer. The cover is open. ______________ 4-45 515: Failed to lock or unlock the printer.
Page 164: General Troubleshooting Procedures
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. Caution: 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 you 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. When the error message is displayed and the printer beeps, do not clear the error message from the computer screen. Instead, hold the Enter button for 3 seconds or until the User light turns green. The printer cancels its present job and enters suspend mode. Press the User button again to go back online. 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. Troubleshooting...
Page 165: Sensors
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 Using Printer Manager, navigate to TroubleShooting > Sensors. Click Run. The screen blinks while the card printer runs the sensor test. The Current and History columns are updated to reflect any changes detected during the test. Test the Sensors Using Continuous Update Using Printer Manager, navigate to TroubleShooting > Sensors. Enter the time interval in seconds and click Start Update. The sensors are sampled at the interval indicated until you click Stop Update. 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 SD/CD Service Manual...
Page 166: Determine If The Sensor Has Failed
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. 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. 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. If the replacement sensor functions, the original sensor is defective. Verify this by reconnecting the original sensor. If the replacement sensor is not 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.) Troubleshooting...
Page 167: Test Card
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. The TestPatternManufacturing test cards are used only in manufacturing setup. Option Description Test Cards Print Options Note: No values selected will reset the cam and act like a pick and eject test. Options: Magnetic Stripe, Color, Monochrome, Topcoat, Second Topcoat, Rewritable (Pre‐Erase), Rewritable Erase, Rewritable (Post‐ Erase) Default: Color Test Card Other Options TestPattern1 Full color test card. SD/CD Service Manual...
Page 168 Option Description TestPattern2 Halfcolor test card. TestPattern3 Dense blue test card. Troubleshooting...
Page 169 Option Description TestPattern4 Color step test card (RGBK/YMC) TestPattern5 Used to set up card registration. SD/CD Service Manual...
Page 170 Option Description TestPattern6 Full color test card. TestPatternRegistration Used to test card registration mechanically. Side/side or lead/trailing may indicate a chassis, card guide, or roller problem. 4-10 Troubleshooting...
Page 171 Option Description 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. SD/CD Service Manual 4-11...
Page 172 Option Description TestPatternGrid Full K panel test card. PaleBlue: RewritableTestCard Select this test pattern with the Rewritable Write Pre‐Erase and Rewritable Erase options to print a test card that shows the effect of the erase power settings. RewritableEraseWholeCard Erase the entire card. Use this test pattern with the Rewritable Erase option to erase a card with no rewrite. Copies Range: 1 to 10 copies Default: 1 4-12 Troubleshooting...
Page 173: Troubleshooting Motors
Option Description Park Smart Card Select to park the smart card. Smart Card Park Time Range: 0 to 300 seconds Default: 10 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 that sure you remove all cards from the card hopper. If you do not, you will feed several cards and jam the printer. You can control the Direction, Speed, and Steps. The cam motor can be set to an uninstall position, see “Other Troubleshooting Procedures” on page 4‐16. 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.) Use this test to run the printhead fan. You can control only Time ...
Page 174 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. 4-14 Troubleshooting...
Page 175: Testing The Ribbon And Pick Motors
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. 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. Swap motor connectors on the print engine board, J12 for the cam motor and J11 for the transport. In Printer Manager, test the motor. SD/CD Service Manual 4-15...
Page 176: Other Troubleshooting Procedures
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. In Printer Manager, select Troubleshooting > Test Cam. Set the Speed to 600 and the Steps to 310 and then 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. 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 ...
Page 177: Testing Smart Cards
Testing Smart Cards The following procedures are for testing types of smart cards. Identive Smart Card Use the Printer Manager to park test card. Open the Printer Manager and log on with WebService access. Select the Troubleshooting tab and select Testcard. Click to clear the check boxes for all Test Card Print Options to avoid printing on the smart card. Place a test card in the input hopper. Place each test card in the input hopper by itself and run the smart card test. Scroll down to Test Card Other Option and select Park Smart Card. Click Run. The card is picked and is moved into the smart card encoding area. SD/CD Service Manual 4-17...
Page 178: Troubleshooting
Verify that the smart card ATR can be read for reader type (contact or contactless). Open the PC/SC Diagnostic tool. 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.  4-18 Troubleshooting...
Page 179: Scm Dual Contact/Contactless
SCM Dual Contact/Contactless Smart PC/SC Diagnostics reads the ATR of the smart card. The diagnostics can be downloaded from SCM Microsystems at: http://support.identive‐group.com/download_scm/download_scm.php?lang=en Test Procedure Install the SCM diagnostics (SmartPCSCDiag V2.04 or higher) and the SCM driver. Connect the USB port on the rear of the printer to a USB port on the PC. Open SCM diagnostics as shown: Click Connected Readers. Click SCR331‐DI Smart Card Reader. SD/CD Service Manual 4-19...
Page 180 Open Printer Manager and display the Troubleshooting tab. Choose the Testcard test. Clear all Test Card Print Options check boxes to avoid printing on a smart card. Put a contact smart card into the input tray. Scroll down to Test Card Other Option. Select Park Smart Card. If desired, change Copies as well as Smart Card Park Time. 4-20 Troubleshooting...
Page 181 Click Run. The card is picked and enters the smart card module. The ATR of the card is read. Click SCR331‐DI USB Contactless Reader. SD/CD Service Manual 4-21...
Page 182 Put a contactless smart card into the input tray. Click Run. The card is picked and enters the smart card module. The ATR of the card is read. The test is complete. 4-22 Troubleshooting...
Page 183: Hid Iclass Reader/Writer
HID iCLASS Reader/Writer The AIRIDCardMgr.exe application reads the Filter Mask, Facility Code and ID Code from the HID https:// iCLASS card. The configuration utility can be downloaded from RFIDeas Inc at: www.rfideas.com/support/downloads Test Procedure Place a test card in the input hopper. Log on to the Printer Manager with WebService access, and select the Troubleshooting tab. Click Testcard. Clear all Test Card Print Options to avoid printing on the test cards. Scroll down to Test Card Other Option and select Park Smart Card. Click Run. The card is picked and is moved into the smart card area. SD/CD Service Manual 4-23...
Page 184 Open the Air ID Card Manager and check the test card data. In the Connect tab under Select Card Type, click iCLASS. Under AIR ID Writer Device, click Connect AIR ID Writer USB or RS232. Check for the test card data (ATR) in the Card Serial Number. 4-24 Troubleshooting...
Page 185: Pcprox Plus Contactless
PcProx Plus Contactless The PcProx configuration utility reads the Filter Mask, Facility Code and ID Code from the HID PcProx card. Place a test card in the input hopper. Log on to the Printer Manager with WebService access, and select the Troubleshooting tab. Click Testcard. Clear all Test Card Print Options to avoid printing on the test cards. Scroll down to Test Card Other Option and select Park Smart Card. Click Run. The card is picked and is moved into the smart card area. SD/CD Service Manual 4-25...
Page 186 Open the pcProx Configuration Utility and check the test card data. Click Connect and make sure that the PcProx device appears in the Connect tab under Device list. Under Output test area, click AutoGetID. Make sure that the test card data (ATR) displays in the Output test area. 4-26 Troubleshooting...
Page 187: Third-Party Basic Smart Card Integrator
Third-Party Basic Smart Card Integrator Use the diagnostics/smart card driver from the third‐party smart card manufacturer to read the ATR on the smart card. Use the configuration utility of the third‐party reader or reader/writer manufacturer to read the Filter Mask, Facility Code, and ID Code from the card. Test Procedure Install the third‐party diagnostics/smart card driver or configuration utility. Connect the USB port on the rear of the printer to a USB port on the PC. Open the third‐party diagnostics or configuration utility. Place the third‐party card into the input hopper. Open Print Manager and display the Troubleshooting tab. Select Testcard test. Clear all Test Card Print Options check boxes to avoid printing on the third‐party card. Scroll down to Test Card Other Option and select Park Smart Card. If desired, change Copies as well as Smart Card Park Time. Click Run. The card is picked and enters the smart card module. Verify the third‐party card can be read. SD/CD Service Manual 4-27...
Page 188: Performance Problems
Performance Problems Printer Initialization Errors Symptom Comments The printer initializes but reports a Check the operation of the card input sensor using the sensor  card stuck in the transport, and screen in printer diagnostics. If the sensor is always blocked, the transport runs more than it is either disconnected or not fully seated (obscured by part expected. 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.  The printer initializes but reports a Check the encoder on the ribbon cartridge for damage.  broken print ribbon. Make sure the encoder board is connected and functioning.  The printer initializes and the Remove the ribbon and close the cover. Check the sensor setting ribbon is advanced, but the printer in printer diagnostics. If the sensor is not active: reports that the index mark could Make sure that the reflective tape is present on the  not be found.
Page 189: Card Jams At Card Input
Card Jams at Card Input Symptom Comments A card is not picked from the input Clean the printer.  hopper. Use graphic quality cards.  Teach operators how to fan cards properly.  Inspect the pick roller for buildup or debris.  Test the pick motor using printer diagnostics.  Inspect the card gate to make sure that 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 Clean the printer.  cleaning rollers. Inspect the cleaning rollers for excessive debris.  Transport not working.  A card is picked and appears to be Clean the card input sensor.  properly positioned, but the error is Check the position of the card input sensor and make sure that  still reported. it is fully and firmly seated into the transport.
Page 190: Card Jams In Printing Area
Card Jams in Printing Area Symptom Comments Card stops prior to reaching the Clean the rollers in the printer.  platen roller. Increase the card registration distance.  Card stops under the printhead. 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. Clean the rollers.  Check for bowed card stock.  Ribbon Break Errors Symptom Comments Ribbon did not break, but the error Clean the printhead. It may be preventing the ribbon from  is reported. 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 ...
Page 191: Messages And Conditions
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 can 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 Error Request not supported Amber Flash Error Job could not complete Amber Flash Error Card not in position Amber Flash Amber Flash Error...
Page 192 No. LCD Message User Light Supply Light Card Light Sound Card hopper empty Amber Flash Amber Flash Warning Close cover to continue Amber Flash Amber Flash Attention Cover opened during job Amber Flash Error Magstripe not available Amber Flash Error Reader not available Amber Flash Error Print ribbon type problem Amber Flash None Print ribbon not supported Amber Flash None User paused the printer Amber Flash Warning Print ribbon not identified Amber Flash None Magstripe format problem Amber Flash Error Insert new card side 1 up Amber Flash Amber Flash None Insert same card side 2 up...
Page 193: Printer Messages
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. The card will be canceled. Press the User button on the printer, or click OK in the message box to clear the message. 102: Card not in position The card is not positioned in the printer correctly. Open the printer and remove the ribbon cartridge. Turn the knob to remove the card. 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. SD/CD Service Manual 4-33...
Page 194: 103: Printer Problem
103: Printer problem The printer had an error. The card will be canceled. Press the printer Power button to power off the printer. 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. Press the printer Power button to power off the printer. Return the printer to Datacard service. The system must remain powered off. Click OK in the message box to clear the message. 105: Magstripe data error The printer failed to verify that the correct magnetic stripe data was written on the card. Make sure that you are using magnetic stripe cards that match the printer settings. Make sure that the cards are placed in the printer correctly. Press the User button on the printer. In the message box, click Retry, or click Cancel to cancel the card. 4-34 Troubleshooting...
Page 195: 106: Magstripe Data Not Found
106: Magstripe data not found The printer did not find magnetic stripe data on the card. Make sure that you are using magnetic stripe cards that match the printer settings. Make sure that the cards are placed in the printer correctly. Press the User button on the printer. In the message box, click Retry, or click Cancel to cancel the card. 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. Make sure that you are using magnetic stripe cards that match the printer settings. Make sure that the cards are placed in the printer correctly. Press the User button on the printer, or click OK in the message box to clear the message. Hints & Tips 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.  SD/CD Service Manual 4-35...
Page 196: 108: Magstripe Read No Data
108: Magstripe read no data The printer did not find any magnetic stripe data on card. The card will be canceled. Make sure that you are using magnetic stripe cards that match the printer settings. Make sure that the cards are placed in the printer correctly. Press the User button on the printer, or click OK in the message box to clear the 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. Open the printer and remove the ribbon cartridge. Reposition, repair, or replace the ribbon and advance the repaired area one full turn. 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. 110: Print ribbon out or missing The printer does not have usable ribbon. To complete the current card: Open the printer and remove the ribbon cartridge. Install a new ribbon and cleaning roller. 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. 4-36 Troubleshooting...
Page 197: 111: Card Not Picked
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. Press the User button on the printer. In the message box, click OK, or click Cancel to cancel the card. 112: Card hopper empty The printer did not detect cards in the input hopper. Add cards to the input hopper. Press the User button on the printer. In the message box, click OK, or click Cancel 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. Press the User button on the printer. In the message box, click OK, or click Cancel 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. Press the User button on the printer. In the message box, click Retry, or click Cancel to cancel the card. Hints & Tips Make sure that the ribbon cartridge is installed properly with the handle even with the edges of ...
Page 198: 116: Magstripe Not Available
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. Press the User button on the printer, or click OK in the message box to clear the 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 “Magnetic Stripe Formats” in your printer’s Installation and Administrator’s Guide. 117: Reader not available 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. 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. Press the User button on the printer, or click OK in the message box to clear the message. Hints & Tips Purchase ribbon from your dealer or authorized reseller.  Check the website for newer firmware that supports new ribbon types. ...
Page 199: 119: Print Ribbon Not Supported
119: Print ribbon not supported The printer cannot use the ribbon installed. The card will be canceled. Use ribbon designed for this printer. Press the User button on the printer, or click OK in the message box to clear the 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 User button on the printer. 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 The printer cannot use the ribbon installed. The card will be canceled. Use ribbon designed for this printer. Press the User button on the printer, or click OK in the message box to clear the message. Hints & Tips Purchase ribbon from 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 ...
Page 200: 123: Insert New Card Side 1 Up
123: Insert new card side 1 up Insert a new card in the printer with side 1 facing up. If the card is not immediately picked, press the User button on the printer or click OK. Click Cancel in the message box if you want to cancel the card. 124: Insert same card side 2 up Take the card from the printer. Turn the card over end to end so side 2 is facing up. Insert the card in the printer. If the card is not immediately picked, press the User button on the printer or click OK. Click Cancel in the message box if you want to cancel the card. 149: Option not installed 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. 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. Click OK in the message box to clear the message.
Page 201: 151: Failed To Lock
151: Failed to lock An attempt to lock the printer failed. Make sure that all access doors are closed securely. Try locking the printer again. Click OK in the message box to clear the message. 152: Insert new card side 2 up Turn a new card over end to end so side 2 is facing up. Insert the card in the printer. If the card is not immediately picked, press the User button on the printer or click OK. Click Cancel in the message box if you want to cancel the card. 153: Insert same card side 2 up Take the card from the printer and turn it over end to end so side 2 is facing up. Insert the card in the printer. If the card is not immediately picked, press the User button on the printer or click OK. Click Cancel in the message box if you want to cancel the card. 170: Insert new card side 1 up Insert a new card in the printer with side 1 facing up. If the card is not immediately picked, press the User button on the printer or click OK. Click Cancel in the message box if you want to cancel the card. 171: Insert same card side 1 up Take the card from the printer and turn it over end to end so side 1 is facing up.
Page 202: 173: Improper Shutdown
173: Improper shutdown Always use the power button to power off the printer. Click OK in the message box to clear the message. 224: Supply region not valid The printer cannot use the supply installed. The card will be canceled. Use a supply with the correct code for your region. 225: Rewrite config mismatch The rewritable card settings in the driver and Printer Manager do not match. The card will be canceled. Make sure that the following settings do not conflict: Printing Preferences > Print Mode tab: Print using rewritable cards  Printer Manager > Print menu: RewritableCardEnable  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: Make sure that the printer is powered on and in the Ready state. 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. ...
Page 203: 502: The Card Data Is Missing Or Is Not Usable
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. Click OK to clear the message. 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. Click OK to clear the message. 505: USB communication issue An important driver component is not running. The card will be canceled. Restart the computer. The component should start automatically. If this message is displayed after restarting, notify your printer support contact. Click OK to clear the message. 506: A card is currently processing The printer is busy processing an interactive job. The card will be canceled.
Page 204: 509: The Printer Is Offline Or Suspended
509: The printer is offline or suspended The printer must be online to print. To complete the current card press the User button on the printer until the printer returns to the Ready state. Click OK to clear the message, or click Cancel to cancel the card. 510: The printer is unlocked The printer must be locked to resume printing. Make sure that all access doors are closed securely and locked. Click OK to clear the message, or click Cancel to cancel the card. 4-44 Troubleshooting...
Page 205: Driver Sdk Messages
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.
Page 206 4-46 Troubleshooting...
Page 207: Chapter 5: Routine Maintenance
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 Schedule ___________________________________________ 5-6 Preventive Maintenance Procedures _________________________________________ 5-7 Mechanical Inspection ___________________________________________________ 5-7...
Page 208: Required Tools And Supplies
Required Tools and Supplies The following tools and supplies are needed for routine maintenance procedures. Description Part Number Compressed air (canned) TUL001‐018 General purpose, non‐abrasive cleaner 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 must not contain any abrasives, oils, fragrances, antibacterial agents, solvents, or isopropanol. Do not use soft‐scrubbing 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 Cable Ties 803190‐010 Enclosure Release Tool...
Page 209: For Magnetic Stripe Option
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 804267‐918 Wrench part number Miniature Hex Driver, 0.035” (9MM) Bit 804267‐920 KY Read® dip magnetic tape developer TUL001‐014 804267‐915 Kit, Glass Card Gauge, ISO ID‐1; or 560585‐001 Magnetic Stripe Alignment Gauge 513739‐001 Magnetic stripe cards (blank) HICO 803229‐034 LOCO 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 SD/CD Service Manual...
Page 210: Avoiding Electrostatic Discharge
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” at the beginning of this manual and “Precautions” on page 1‐4. 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 Wrist strap grounding cable   Mat‐grounding cable Grounding plug   Static‐grounding wrist strap  Procedure: Wear appropriate clothing. Avoid wool and synthetic fabrics. Remove movable carpet and rugs. 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. Connect one end of the grounding cable to the wrist strap. Using the grounding plug, connect the other end of the grounding cable to the earth ground of a facility AC outlet. 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. Always set unshielded static‐sensitive materials on the grounded antistatic mat. Whenever possible, place components into static‐shielded bags. When bringing two objects into contact (tool to circuit board or board to mat), first simultaneously touch both objects with fingers. Routine Maintenance...
Page 211: Screw Torque Specifications
Screw Torque Specifications Torque Screw Location (in‐lbs) +/‐ 10% Torx Bit Pick Motor Ribbon Motor Transport Motor Cam Motor TPH Heat Sink TPH Adjustment SD/CD Service Manual...
Page 212: Preventive Maintenance Schedule
Preventive Maintenance Schedule Frequency Task Procedure As needed Use a cleaning swab to clean the Use gentle pressure to move the cleaning printhead. swab back and forth along the edge of the printhead. Refer to “Cleaning the Thermal Printhead (TPH)” on page 5‐22. Every 500 cards or Run a cleaning card and change Refer to “Using the Cleaning Card” on after each used print the cleaning sleeve. page 5‐23. ribbon Note: The frequency of 500 cards may vary due to ribbon type. Every time service is Do mechanical inspection. Refer to “Mechanical Inspection” on performed page 5‐7. Clean the interior of the system. Clean photocell sensors. Inspect belts and gears. Whenever the grease points have accumulated dirt and debris, clean and lubricate the grease points. Lubricate the magnetic stripe assembly. Whenever debris accumulates on the rollers or when cards are not ...
Page 213: Preventive Maintenance Procedures
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 1‐4 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. Check the fixed cleaning rollers to make sure they are not nicked or gouged. Replace them if they are brittle. Check all other rollers for wear or damage. Check springs to verify they are in position and not damaged. Inspect the transport system: Inspect the timing belt for wear and missing teeth. Inspect the idler pulleys and make sure they are securely seated. Inspect the drive pulleys for wear and broken teeth. Inspect the platen roller gear and pulley for wear and broken teeth. SD/CD Service Manual...
Page 214 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. Routine Maintenance...
Page 215 Inspect the ribbon drive gear for wear and broken teeth. Make sure it is securely seated on the motor shaft. Inspect the ribbon cartridge. Inspect the spindle gear for wear and missing teeth. Check the spindles for proper movement and ensure that the clutch provides a slight drag. SD/CD Service Manual...
Page 216 Check to see that the cooling fan is running properly by running a test card. If applicable, inspect the duplex module drive and idler rollers for wear and damage. 5-10 Routine Maintenance...
Page 217 If applicable, inspect the smart card module. Inspect all the gears depicted in the following figure for wear and missing teeth. Verify smooth transition of cards through the module. SD/CD Service Manual 5-11...
Page 218: Cleaning The Interior Of The Printer
Cleaning the Interior of the Printer Turn the printer off if necessary. Unplug the printer. Remove the printer enclosures. Remove the chassis from the base enclosure. Using canned compressed air: Blow out any debris near the sensors Blow out any dust from the control board and other surfaces of the base. Blow out any dust and debris from the underside of the chassis. Lubricating the Grease Points Look to see if the grease points have accumulated dirt and debris. For each of the following points, wipe off the grease with a dry cloth, and re‐grease the surfaces with Molykote DX grease. Caution: Do not add more lubrication than necessary. 5-12 Routine Maintenance...
Page 219 Lubricate the platen roller. SD/CD Service Manual 5-13...
Page 220 Lubricate the registration roller. 5-14 Routine Maintenance...
Page 221 Lubricate the cam shaft. SD/CD Service Manual 5-15...
Page 222: Lubricating The Magnetic Stripe Assembly
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...
Page 223: Cleaning The Rollers
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.) 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). SD/CD Service Manual 5-17...
Page 224 Use the TestFlipperTrans 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...
Page 225: Maintaining The Smart Card Module
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 SD/CD Service Manual 5-19...
Page 226 Duplex Assembly 5-20 Routine Maintenance...
Page 227: Visual Inspection For Card Quality
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. Refer to “Magnetic Stripe Track Height Test” on  page 3‐49 for the procedure. Verify the start sentinel position. Refer to “Start Sentinel Position Adjustment” on page 3‐51  for the procedure. SD/CD Service Manual 5-21...
Page 228: Operator Maintenance
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) 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...
Page 229: Using The Cleaning Card
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. Remove the print ribbon and cleaning sleeve from the printer. Remove any cards from the printer. To clean the card printer use the procedure in either Printer Manager or the LCD Panel. Procedure 1 Run the cleaning card using Printer Manager: Select Maintenance > Cleaning. Click Run. At the Insert cleaning card prompt, remove the cleaning card from its wrapper and insert it into the card feeder. SD/CD Service Manual 5-23...
Page 230 Procedure 2 Run the cleaning card using the LCD panel: Ribbon Card Status Light Status Light Down Button User Button Power Button Up Button Enter Button Begin with the display showing Ready. Press the User button once. At the Suspended Menu available prompt touch Enter lightly. At the Main Menu > Maintenance prompt touch Enter. At the Maintenance > Cleaning Card prompt touch Enter. At the Cleaning Card > Start prompt touch Enter. At the Insert cleaning card prompt, remove the cleaning card from its wrapper and insert it into the card feeder. 5-24 Routine Maintenance...
Page 231: Chapter 6: Removal And Replacement
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 .
Page 232 Smart Card Options ............6-56 Smart Card Assembly, Simplex (SD160 or SD260)....... 6-56 Smart Card Assembly, Simplex (SD260L) .
Page 233 Duplex Circuit Board ............6-74 Duplex Backup Idler Roller, Springs .
Page 234: Introduction To This Chapter
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 printer power 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 5‐7. 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 Compliance Statements, “Precautions” on page 1‐4, and “Avoiding Electrostatic Discharge” on page 5‐4. Symbols The appearance and purpose of the symbols used in this chapter are presented below. 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.
Page 235: Printer Components
Printer Components See “Introduction to SD/CD Series Printers” on page 1‐6 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. SD/CD Service Manual...
Page 236: Smart Card And Duplex Cables
Smart Card and Duplex Cables Removal and Replacement...
Page 237: Swingarm Cable Routing
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 6‐45, “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.
Page 238: Freeing Cables From Clamps
Freeing Cables from Clamps Use this procedure to remove wires from cable clamps as needed. Group the wires in a line. Slide them out. Functional Block Diagrams See “Functional Block Diagrams” on page 1‐17 for diagrams of the boards and connections. Removal and Replacement...
Page 239: Exterior Components
Exterior Components Ribbon Cartridge Push button (1) to release the swingarm latch (2). LIft the ribbon cartridge out of the printer (3). Replacement With the swingarm open, place the ribbon cartridge in the printer. Push down the front edge of the swingarm until it latches. Lift the cartridge. SD/CD Service Manual...
Page 240: Ribbon Cartridge Lid
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 Removal and Replacement...
Page 241 Replacement Attach one tab and then the other by slightly spreading the sides. When installing the cartridge in the printer, place the diametric magnet next to the Ribbon Encoder Board. SD/CD Service Manual 6-11...
Page 242: Swingarm Lid And Enclosure Flap
Swingarm Lid and Enclosure Flap Remove the lid (1) by pushing in on the tabs on the side opposite the manual advance knob. 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 When reassembling, replace enclosure the flap before the swingarm lid. Place the flap around the pins (3) on one side and then the other. Replace the swingarm lid (4) by inserting the tabs into the side with the manual advance knob first. 6-12 Removal and Replacement...
Page 243: Enclosures
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. Cut a card in half lengthwise (1). Open the swingarm. 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). 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. 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. SD/CD Service Manual 6-13...
Page 244: Removal And Replacement
Replacement Open the swingarm and slide the enclosure down over it. Be careful to clear the manual advance knob (6). Snap the enclosure into the base in all four locations. 6-14 Removal and Replacement...
Page 245: Card Tray
Card Tray 100-Card Input Lid and Cover Lift the lid (1) and push in on the release tab (2). Lift the lid and cover up and off the tray. Remove the lid from the cover by lifting the arm from the hinge pin on one side and then the other. Replacement Place the arms of the lid (1) onto the pins. 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. SD/CD Service Manual 6-15...
Page 246: Tray Assembly And Manual Feed
Tray Assembly and Manual Feed Push both latches (1a, 1b) of the input tray frame (2) and lift it up and off the hooks (3). Carefully disconnect the cables from the main board (4). Replacement Reconnect the cables and close the display panel connector securely. Place the four openings in the tray over the hooks (3) on the printer and slide the tray 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 Removal and Replacement...
Page 247: Front Bezel, Lcd Interface Panel, And 25-Card Output
Front Bezel, LCD Interface Panel, and 25-Card Output Push out on both clips (1) and slide the bezel forward (2) to remove it from the input tray (3). The interface panel (4) sits in the front bezel. Slide out to remove. Lift the clips on either side (5) and slide the output tray forward (6). Replacement Slide the output tray (6) back into the slot until it clips into place. 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. SD/CD Service Manual 6-17...
Page 248: Lcd Interface Panel Routing
LCD Interface Panel Routing The flat ribbon cable goes through a flat ferrite bead on the chassis to conform to FCC emissions standards? 6-18 Removal and Replacement...
Page 249: Simplex Base
Simplex Base Simultaneously press the tabs (1a) and pull on the printer (1b). Lift and remove the printer frame from the base (2). Replacement Line up the four points. 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. SD/CD Service Manual 6-19...
Page 250: Tray
Tray Pick Gate and Pick Gate Spring Hold the spring (1a) while separating the tabs (1b) of the pick gate from the hinge pins on both sides. Hold the spring (2a), lift the pick gate (2b), and pull the pick gate out of the hopper frame. Separate the spring (3) from the pick gate. Replacement Place the spring on the pick gate. Hold the spring in place, push the pick gate into the hopper frame, and attach each side to the hinge pins. 6-20 Removal and Replacement...
Page 251: Pick Roller Assembly
Pick Roller Assembly Pull up on the pick roller assembly (1). Remove pick roller assembly (2) from the input hopper frame. Replacement Replace pick roller assembly and snap it into place. See also “Pick Motor and Pick Drive Gear” on page 6‐44 SD/CD Service Manual 6-21...
Page 252: Picker Crankshaft, Pick Block Assembly
Picker Crankshaft, Pick Block Assembly Push the picker crankshaft (1) forward into the larger slot (listen for a hard snap). Separate the picker crankshaft (2) from the pick block assembly (3) and slide the block out of the hopper frame; then slide the picker crankshaft (4) from the hopper frame. Separate the picker crankshaft (5) from the pick roller clutch and drive pick gear. Replacement Replace the pick roller clutch and drive pick gear on the crankshaft. Surfaces must be flush. Slide picker crankshaft into the hopper frame, reattach it to the pick block assembly, and then snap it back into place. See also “Pick Motor and Pick Drive Gear” on page 6‐44 6-22 Removal and Replacement...
Page 253: Transport Components
Transport Components Timing Belt Removal To remove the timing belt (1), push the belt tensioner (2) upward to lock it in place. This removes tension from the belt. Remove the belt from the three drive pulleys (3), the manual advance knob (4), and the five idler pulleys (5). Replacement Replace the belt with the routing shown below. Pull out on the tab (6) to unlock and lower the belt tensioner. Do not stretch or twist the belt. This can break the belt fibers and cause the belt to wear prematurely and can cause magnetic stripe errors. SD/CD Service Manual 6-23...
Page 254: Belt Plate
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 Removal and Replacement...
Page 255: Platen Roller Assembly
Platen Roller Assembly 1. Remove the ribbon bridge (refer to “Ribbon Index Sensor, Ribbon Bridge” on page 6‐40 for ribbon bridge removal). Push to loosen the tabs on the platen roller plate (1) while lifting the manual advance knob (2) and lift plate (3) from the printer. Slide the platen roller assembly (4) out through the hole. Replacement 1. If needed, lubricate; see “Lubricating the Grease Points” on page 5‐12. 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 it into place (4). 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. SD/CD Service Manual 6-25...
Page 256: Card Guide/Spring And Registration Drive Assembly
Card Guide/Spring and Registration Drive Assembly Removal Place one hand over the card guide and spring (1a) while lifting the pulley of the registration backup roller (1b) to release it. Remove the card guide and card guide spring (2) and separate the spring from the shaft (3). Pull the registration drive assembly (4) out through the cutout. 6-26 Removal and Replacement...
Page 257 Replacement 1. If needed, lubricate; see “Lubricating the Grease Points” on page 5‐12. 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. 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 6‐40 for ribbon bridge removal or “Magnetic Stripe Rocker Assembly and Read/Write” on page 6‐55. SD/CD Service Manual 6-27...
Page 258: Drive Pulleys And Idler Pulleys
Drive Pulleys and Idler Pulleys 1. Remove the timing belt, refer to“Timing Belt” on page 6‐23 and “Belt Plate” on page 6‐24. Remove the idler pulleys by pulling them from their shafts (1). 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 the pulley off. Replacement The idler pulleys can be placed on their shafts from either side. Slip the drive pulleys (2) onto their shafts with the large flange toward the printer and rotate the shaft so that the square key (4) slips into the square keyway. Replace the belt and belt plate. Print several test cards to ensure there are no transport problems. 6-28 Removal and Replacement...
Page 259: Backup Roller, Registration Backup, And Top Cleaning Rollers
Backup Roller, Registration Backup, and Top Cleaning Rollers Remove the ribbon bridge (see “Ribbon Index Sensor, Ribbon Bridge” on page 6‐40) before pulling out backup roller. Push top of the spring to the side (1) in the illustration on the next page and pull it from the shaft (2). Push the 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. Pull the bracket out of the cutout (4). Tip the rollers (5) and lift them out of the printer. Replacement Insert the leading end into the holes (7). Be sure to replace the capstan roller sleeve (6) on the registration backup roller before installing it. Place the brackets into the cutouts and slide down, locking them into place. Place springs onto the shafts of the brackets and slide the brackets into position. SD/CD Service Manual 6-29...
Page 260: Backup Roller Springs And Brackets, Capstan Roller Sleeve
Backup Roller Springs and Brackets, Capstan Roller Sleeve See previous page for remove and replace procedure. 6-30 Removal and Replacement...
Page 261: Belt Tensioner And Spring, Idler Pulleys
Belt Tensioner and Spring, Idler Pulleys If it is engaged, lift up on the release tab to release the tensioner. Line up the belt tensioner (1) with the cutouts in the printer and lift it out (2) of the printer. Remove the belt tensioner spring (3). The idler pulleys (4) come right off. Replacement Place the spring onto the belt tensioner. Insert the tensioner into the cutouts in the printer and slide upward until it clicks into place. Slide idler pulleys onto their shafts. SD/CD Service Manual 6-31...
Page 262: Cam Slide
Cam Slide 1. Use “Other Troubleshooting Procedures” on page 4‐16 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. Lift the cam slide to remove it (4). Replacement 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 on a clock face. The cam slide cutouts on the cam motor side are in the 6 and 9 o’clock positions. 6-32 Removal and Replacement...
Page 263: Cam, Cam Shaft, Cam Gear, And Cam Idler Gear
Cam, Cam Shaft, Cam Gear, and Cam Idler Gear 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 the cam. On the motor side of the printer pull the cam gear and shaft (3) out of the printer. Remove the cam idler gear (4). Replacement 1. If needed, lubricate; see “Lubricating the Grease Points” on page 5‐12. Replace the cam idler and push the cam onto the shaft and into the retainer. Align the cam on each side when reinstalling. SD/CD Service Manual 6-33...
Page 264: Swingarm Components
Swingarm Components Ferrite Bead Clip the tie wrap (1) that surrounds the ferrite bead (2) and the printhead cable (3). Open the ferrite bead to release the fan and ribbon advance cables. Disconnect the cables from the main board. Replacement Reconnect the cables to the board. Place the ferrite bead around the fan and ribbon advance cables (2). Place a cable tie (1) around the ferrite bead and the printhead cable (3). “Cable Routing” for connection information. on page 6‐5 6-34 Removal and Replacement...
Page 265: Thermal Printhead (Tph)
Thermal Printhead (TPH) Hold the printhead (1) while pressing one of the swingarm knuckle release tabs (2a), and then tip the printhead (2b). Disconnect the printhead cable. Pull the printhead (3) from the swingarm assembly. Replacement Reconnect the printhead cable. Press and hold one of the swingarm knuckle release tabs and insert the printhead into the knuckle. Raise the printhead and release the tab. SD/CD Service Manual 6-35...
Page 266: Fan
Observe cable routing and fan orientation. The fan blows air in the direction of the printhead. Pull up on the retaining tab (1) and slide the fan out of the frame (2). Replacement Orient the fan as shown in the figure below. 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 Removal and Replacement...
Page 267: Swingarm, Torsion Spring, Damper
Swingarm, Torsion Spring, Damper Relieve the torsion spring tension (1) by lifting the spring up and out of the boss. Rotate the damper counterclockwise (2) to remove. Note the orientation of the torsion spring (4). Separate and lift slightly on each side of the swingarm (3, 5) to disengage the swingarm from the hinge pins. Move the swingarm back toward the rear of the printer and then up to remove (6). SD/CD Service Manual 6-37...
Page 268 Replacement Place the torsion spring on the printer (4) and then guide the spring into the cutout in the swingarm as you install the swingarm. With the swingarm nearly vertical, partially engage each side of the swingarm onto the hinge pins. With both sides partially engaged, bring the swingarm forward on both sides simultaneously to fully engage both sides. Lift the torsion spring into the boss. Push on and rotate clockwise to replace the damper. Always relieve the torsion spring tension when the damper has been removed. 6-38 Removal and Replacement...
Page 269: Print Engine Sensors
Print Engine Sensors Head Latch Sensor Disconnect the cable from J22 on the print engine board and pull on the sensor (1) to remove it. Replacement Press the sensor into the hole in the printer. 2. Reroute cable as indicated in “Cable Routing” on page 6‐5, and reconnect the cable. SD/CD Service Manual 6-39...
Page 270: Ribbon Index Sensor, Ribbon Bridge
Ribbon Index Sensor, Ribbon Bridge Note routing of the ribbon index sensor cable (1), disconnect it from the print engine board (J21), and pull it through the hole in the printer. Push to release the retaining clips (2) on either side of the ribbon bridge and lift bridge (3) from the printer. Pull on the ribbon index sensor to remove from the ribbon bridge. Replacement Push the sensor into place until it is fully seated and then reroute the cable in the bridge. Feed the ribbon index sensor cable through the hole, reroute it, and reconnect it to the board. Place the ribbon bridge into the printer and into the retaining clips. Refer to“Transport Cables” for routing information. on page 6‐5 6-40 Removal and Replacement...
Page 271: Card Input Sensor
Card Input Sensor 1. Remove the cam slide and bracket. Refer to “Backup Roller Springs and Brackets, Capstan Roller Sleeve” on page 6‐30 and “Belt Tensioner and Spring, Idler Pulleys” on page 6‐31. Disconnect the cable from J18 on the print engine board. Remove the sensor by pushing it out of the printer from the inside. Replacement Push the sensor into place using two Torx drivers and even pressure until it is fully seated. Reconnect the cable. Refer to “Cable Routing” on page 6‐5 for more information. SD/CD Service Manual 6-41...
Page 272: Card Exit Sensor
Card Exit Sensor Rotate the cam (1a) so that the cam slide (1b) is not in the way of the sensor, and disconnect the cable from J24 of the print engine board. Remove the sensor (2) by pushing it out of the printer from the inside. Replacement Push it into place using two Torx drivers and even pressure until fully seated. Reconnect the cable. Refer to “Transport Cables” on page 6‐5 for routing information. 6-42 Removal and Replacement...
Page 273: Cam Home Sensor
Cam Home Sensor Use a flat head driver to rotate the cam motor (1a) until the cam slide (1b) is out of the way. Disconnect the cable from J23 of the print engine board. 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 Push the sensor into place using even pressure until it is fully seated. Reconnect the cable. 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. SD/CD Service Manual 6-43...
Page 274: Print Engine Motors
Print Engine Motors Pick Motor and Pick Drive Gear Align the pick drive gear with the two screws (1) as shown. Disconnect the connector from J19 of the print engine board. Remove the two T6 torx screws (2) and remove the pick motor (3). Replacement Align the pick drive gear, place the motor into the hopper frame, and replace the screws. 6-44 Removal and Replacement...
Page 275: Ribbon Motor, Ribbon Drive Gear
Ribbon Motor, Ribbon Drive Gear Align the drive gear (1) so the screws are visible through the cutout. Disconnect the motor connector from J27 on print engine board. Remove the two T6 Torx screws (2), and lift the motor (3) out of the swingarm (3). Replacement Line up the flats on the gear and the ribbon motor shaft and slide the gear onto the shaft. 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. SD/CD Service Manual 6-45...
Page 276: Cam Drive Motor Assembly
Cam Drive Motor Assembly Use a T10 Torx driver to loosen and remove the two screws (1). Disconnect the motor connection from J12 on the print engine board. Pull the motor from the printer. Replacement Replace the motor and secure it with the two screws. The cam drive motor assembly cable is oriented toward the rear of the printer. 6-46 Removal and Replacement...
Page 277: Transport Motor Assembly
Transport Motor Assembly Use a T10 Torx driver to loosen and remove the two screws (1). Disconnect the cable from J11 on the print engine board. Pull the motor from the printer. Replacement Replace the motor and secure it with the two screws. The transport motor assembly cable is oriented toward the front of the printer. SD/CD Service Manual 6-47...
Page 278: Circuit Board Components
Circuit Board Components See also “Smart Card Circuit Board” on page 6‐60 and “Duplex Circuit Board” on page 6‐74. Print Engine Drive Board 1. Remove enclosure as described in “Enclosures” on page 6‐13, and disconnect cables from the board. 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. 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. Refer to“Magnetic Stripe Board ISO (IAT) and JIS (NTT)” on page 6‐52 for more information. 6-48 Removal and Replacement...
Page 279 Replacement If applicable, install the magnetic stripe board and connect the cables and standoffs. Insert the back end of the board into the printer, and then push the board to lock it under the front tabs (1). Reconnect the cables. See “Cable Routing” on page 6‐5. 4. Refer to “” on page 5‐24 for instructions on loading the new settings file. SD/CD Service Manual 6-49...
Page 280: Sensor Encoder Cable Assembly (Rfid)
Sensor Encoder Cable Assembly (RFID) Note the routing of cables for the RFID board (1), ribbon motor (2), fan (3), and printhead (4) from the main control board. Lift the bottom left side of the RFID board (5) to lift it from the standoff, and then pull the board up (6) to remove it. Replacement Slide the RFID board down into the printer and over the standoff. Reroute and connect cables. Refer to the following procedures for more routing information. Refer “Ribbon Cartridge” on page 6‐9. 6-50 Removal and Replacement...
Page 281: Ribbon Motion Magnetic Encoder Board
Ribbon Motion Magnetic Encoder Board Disconnect the cable. Push up from the bottom of the encoder (1) and pull it out of the printer. Replacement Push the encoder into place with even pressure until it is fully seated. Reconnect the cable. Refer to “Cable Routing” on page 6‐5 for routing information. SD/CD Service Manual 6-51...
Page 282: Magnetic Stripe Option
Magnetic Stripe Option Magnetic Stripe Board ISO (IAT) and JIS (NTT) 1. Refer to “Print Engine Drive Board” on page 6‐48 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). Remove the magnetic stripe board (3) and standoffs (4). Replacement Replace the standoffs and board and reconnect the cables. 6-52 Removal and Replacement...
Page 283: Magnetic Stripe Optical Encoder And Mounting
Magnetic Stripe Optical Encoder and Mounting Loosen the setscrew on the collar (1) with the special four‐flute spline wrench. Refer “For Magnetic Stripe Option” on page 5‐3. Remove two Phillips screws (2) and the optical encoder (3). Bend spring (4) forward and remove it. Remove the Torx screw (5) and the 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. SD/CD Service Manual 6-53...
Page 284 Make sure the encoder is in the opened position before sliding it over the rocker arm. Opened Position After it is installed, close the encoder by pushing "in" on the bottom piece. Install the encoder wire into the encoder. Caution: Make sure to install the encoder wire exactly as shown with the four wires on the left side. Incorrect wire installation will damage the magnetic stripe encoder. 6-54 Removal and Replacement...
Page 285: Magnetic Stripe Rocker Assembly And Read/Write
Magnetic Stripe Rocker Assembly and Read/Write 1. Disconnect the magnetic stripe head cable. Refer “Magnetic Stripe Board ISO (IAT) and JIS (NTT)” on page 6‐52. Remove the magnetic stripe rocker assembly (1) by unsnapping it from the printer. Pull back on retaining clip to release and then push the head (2) up from the bottom to remove it. Replacement Replace the head and rocker assembly and reconnect the cables. Lubricate the assembly as described in “Lubricating the Magnetic Stripe Assembly” on page 5‐16. SD/CD Service Manual 6-55...
Page 286: Smart Card Options
Smart Card Options Smart Card Assembly, Simplex (SD160 or SD260) Remove the USB cable (1). Press down on the three tabs at the top of the rear enclosure extension (2a), and swing out the enclosure extension out from the top (2b). Push in on the two tabs at both sides of the simplex frame (3a) and pull back to remove the simplex frame (3b). 6-56 Removal and Replacement...
Page 287 Remove the contact station assembly by pulling the tabs (3a) out on both sides while pulling out the smart card assembly (3b). SD/CD Service Manual 6-57...
Page 288: Smart Card Assembly, Simplex (Sd260L)
Smart Card Assembly, Simplex (SD260L) Push in on the two tabs at both sides of the simplex frame (1a) and pull back to remove the simplex frame (1b). Remove the contact station assembly by pulling tabs (2a) out on both sides while pulling out the smart card assembly (2b). 6-58 Removal and Replacement...
Page 289: Smart Card Assembly, Duplex (Sd360)
Smart Card Assembly, Duplex (SD360) 1. Remove the flipper assembly as described on page 6‐76. Remove the smart card assembly by pulling tabs (1a) out on both sides while lifting out the smart card assembly (1b). SD/CD Service Manual 6-59...
Page 290: Smart Card Circuit Board
Smart Card Circuit Board Disconnect the USB (1) and power plugs (2). Push tab (3a) down while lifting the board (3b) out enough to release it. Lift tab (4a) while lifting the board (3b) again to release the board. Slide the board (5) out from under tab (6) and remove the board. 6-60 Removal and Replacement...
Page 291: Smart Card Lid Assembly, Duplex
Smart Card Lid Assembly, Duplex 1. Remove the smart card assembly as described on page 6‐58. Push tabs (1a) on both sides to release catches (1b). Lift smart card lid assembly (2) out. SD/CD Service Manual 6-61...
Page 292: Smart Card Contact Board
Smart Card Contact Board Disconnect the assembly by pushing the contact mount back and holding it steady with your left index finger (1) while pushing down and out at 2a and 2b with your thumbs. Separate the board from contact plug (3). 6-62 Removal and Replacement...
Page 293: Smart Card Station Spring
Smart Card Station Spring Remove the smart card lid assembly as described on page 6‐60. Unhook spring (1) and lift it from smart card base assembly. SD/CD Service Manual 6-63...
Page 294: Smart Card Gate Roller
Smart Card Gate Roller Push the smart card guide (1a) back while pushing tab (1b) out and lifting the contact mount (1c) up to release the guide. Slide the contact mount (2) back and out on the slots and pegs (3). Remove the plug (4) from the contact guide. Remove the gate roller (5) from the guide. 6-64 Removal and Replacement...
Page 295: Smart Card Cable Connector
Smart Card Cable Connector Maneuver the plug (1) up through the opening in the smart card base lid (2) when it is not necessary to remove the reader board (3). SD/CD Service Manual 6-65...
Page 296: Card Guide
Card Guide Slide the card guide (1) forward until it stops, and lift the peg (2) from the keyway slot. 6-66 Removal and Replacement...
Page 297: Identive Reader Board (Contact/Contactless)
Identive Reader Board (Contact/Contactless) Squeeze the snap‐tips (1) on the standoffs and lift the reader board (2) just enough to clear the standoffs. 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 new adhesive pads when reassembling. Simplex Installation SD/CD Service Manual 6-67...
Page 298 duplex Installation 6-68 Removal and Replacement...
Page 299: I-Class Read/Write Or Pc Prox Board
i-Class Read/Write or PC Prox Board Place a flat screwdriver between the base (1) and reader board, and then carefully twist the screwdriver to release adhesive pads (2). Lift the reader board(3) off. Be sure to use all new adhesive pads when reassembling. Place them near the center of the board. Simplex Installation SD/CD Service Manual 6-69...
Page 300 Duplex Installation 6-70 Removal and Replacement...
Page 301: Duplex Components
Duplex Components Duplex Frame 1. Disconnect cables from tie downs as indicated on page 6‐8. Disconnect cables (1) at J13 and J29 on the print engine board. Pull out tabs (2a) on both sides while sliding the frame (2b) away from the main frame. Pull the frame (3) away and up to remove it. SD/CD Service Manual 6-71...
Page 302: Duplex Home Sensor
Duplex Home Sensor Disconnect the sensor cable (J5) from the duplex circuit board. Push the tab (1a) out while lifting the duplex circuit board (1b) to clear the tab. Slide the board (2) out from under the tab (3) to remove it. Remove the flipper home sensor (4). 6-72 Removal and Replacement...
Page 303: Duplex Transport And Flipper Motors
Duplex Transport and Flipper Motors Disconnect the motor cable(s) from the connector on the duplex board: J7 for Transport or J3 for Flipper. Push tab (1a) in while rotating the motor (1b) in the direction shown. Remove the motor (2). SD/CD Service Manual 6-73...
Page 304: Duplex Circuit Board
Duplex Circuit Board Disconnect cables from the duplex circuit board. Feed the cable through the frame as indicated in “Cable Routing” on page 6‐5. Push tab (1a) out while lifting the duplex circuit board (1b) to clear the tab. Slide the board (2) out from under tab (3) to remove it. 6-74 Removal and Replacement...
Page 305: Duplex Backup Idler Roller, Springs
Duplex Backup Idler Roller, Springs Push spring (1a) out from under tab (1b) to release the spring. Remove the spring (2). Repeat to remove the other spring, and remove both backup idler rollers (3). SD/CD Service Manual 6-75...
Page 306: Flipper Assembly And Transport Gear
Flipper Assembly and Transport Gear Hold the flipper assembly (1a) firmly while separating it from the frame (1b) until mis‐ aligning the shaft (1c). Lift the flipper assembly (2) by maneuvering it up through the frame assembly. If the gear (3) did not fall out, remove it. 6-76 Removal and Replacement...
Page 307: Duplex Drive Rollers And Body Gear
Duplex Drive Rollers and Body Gear 1. Remove the flipper assembly as described on page 6‐76. Push the drive roller (1) into the larger hole until you hear a hard snap. Remove the drive roller (2) from the frame (3). Repeat for the other drive roller. SD/CD Service Manual 6-77...
Page 308 6-78 Removal and Replacement...

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