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DataCard SD260L Service Manual

Desktop card printer

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Installation and administrator's manual (130 pages)

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Service Guide

™

SD260L™, SD360

Desktop Card Printer

™

SD460

SLM Laminating System

™

™

CD800

, CD820

Desktop Card Printer

™

™

CE840

, CE870

Instant Issuance System

SD260L Serial Number D11000 and Later

SD360 Serial Number B17000 and Later

CD800 Serial Number C20000 and Later

August, 2019

527672-001, Rev. C

Table of Contents

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Summary of Contents for DataCard SD260L

Page 1 SLM Laminating System ™ ™ CD800 , CD820 Desktop Card Printer ™ ™ CE840 , CE870 Instant Issuance System SD260L Serial Number D11000 and Later SD360 Serial Number B17000 and Later CD800 Serial Number C20000 and Later August, 2019 527672-001, Rev. C...
Page 2: Trademark Acknowledgments
Trademark Acknowledgments Datacard is a registered trademark and service mark of Entrust Datacard Corporation in the United States and other countries. Entrust is a registered trademark and service mark in the United States and other countries.
Page 3: Compliance Statements
Safety All Entrust 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 Entrust Datacard equipment are primarily environmental and human interface.
Page 5: Revision Log
Revision Log Datacard Service Manual Revision Date Description of Changes November 2015 First release of this document that combines and updates elements of the previous SD and CD/CE Service Manuals for D3 firmware. February 2017 Added kiosk appendix for CD800k information and updated content to reflect firmware D3.17.1.
Page 7: Table Of Contents
Contents Chapter 1: Introduction........... . 1-1 About This Manual .
Page 8 Lock Option Components ........... . 1-43 Alarm Option Components .
Page 9 Identifying Regionalized Supplies ......... . . 3-16 98mm Ribbons .
Page 10 CardRegistrationCalibration ..........4-17 Color Management .
Page 11 MultiHopperXRight (Multi-Hopper Only) ........4-36 MultiHopperYHome (Multi-Hopper Only) ........4-36 MultiHopperYUp (Multi-Hopper Only) .
Page 12 Set Job Queue State ............4-59 Print Misadjustment.
Page 13 Testing the Thermal Printhead (TPH) Fan........5-16 Diagnosing the Ribbon RFID Antenna.
Page 14 Laminator Messages (177, 196 - 223)......... 5-50 Responding to Printer Messages (100-124, 149-173, 224) .
Page 15 Operator Procedures ............6-4 Clean the Printer .
Page 16 Single Card Tray ............8-14 100-Card Input Lid and Cover .
Page 17 Magnetic Stripe Optical Encoder and Mounting ......8-57 Magnetic Stripe Rocker Assembly and Read/Write Head ..... . . 8-58 Smart Card Options .
Page 18 Shuttle Vertical (Y) Motor and Belt ........9-22 Shuttle Card Transport Motor.
Page 19: Chapter 1: Introduction
Chapter 1: Introduction This chapter provides an introduction to the Datacard® SD/CD/CE series printer and its components. It includes information on the optional multi-hopper and Touch Screen. About This Manual............1-3 Intended Audience .
Page 20 Sensors..............1-35 Motors .
Page 21: About This Manual
About This Manual This chapter gives general information about the printer. Intended Audience This manual is for authorized representatives who are responsible for the maintenance, service, and repair of the card printer, card hoppers, and touch screen in the SD/CD/CE series printer. Service representatives must complete an authorized service training course and be certified prior to servicing the printer.
Page 22: 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, CDxxx or CExxx Quick Installation...
Page 23: Safety Precautions
Safety Precautions While working with the SD/CD/CE series printer, observe the following precautions: Remove power and disconnect the system when performing maintenance.  Remove watches, jewelry, and rings before servicing equipment.  Avoid wearing loose clothing when working around moving parts. ...
Page 24: Introduction To The Sd/Cd/Ce Series Printer
Introduction to the SD/CD/CE Series Printer The following figures show the main parts of the printer in the SD/CD/CE series printers. The first figure shows the basic SD/CD/CE series printer; the second shows the SD/CD/CE series printer with the multi-hopper option. The main features and options available for the printer are indicated in the following list: Front and back color and monochrome printing options ...
Page 25 Printing Option Option Code Entry Color (no entry) No Print 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 w/ Dual Magnetic Stripe Long Duplex Configured as Simplex SD/CD/CE Service Manual...
Page 26 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 Duali Standard Duali Single Wire Duali Single Wire Sony Felica GEMPC USB/PcProx Dual Contact Station Identive...
Page 27 Locking Option Option Code Entry No Locks (no entry) H1/H2 Locks H3/H4/H5 (Multi-Hopper) Locks - CE840/CE870 H1/H2 (Multi-Hopper) Locks - CE870 H3/H4/H5 (Multi-Hopper) Locks - CD800/CD820 H3/H4/H5 (Multi-Hopper) Locks Metal - CE870 H3/H4/H5 (Multi-Hopper) Locks Metal - CD800/CD820 Alarm Option Option Code Entry No Alarm...
Page 28: Sd Simplex Long Enclosure
SD Simplex Long Enclosure The figure below shows 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 ...
Page 29: Sd Duplex Printer
SD Duplex Printer The figure below shows the main parts of the SD360 and SD460 duplex card printers. The main features and options available for the printer are: Double side color and monochrome 200 card input tray option   printing 100 card input tray 100 card output tray option (N/A on SD460)
Page 30: 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 ...
Page 31: Cd/Ce Single Hopper Duplex Printer
CD/CE Single Hopper Duplex Printer The figure below shows the main parts of the CD and CE 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 ...
Page 32: Cd/Ce Multi-Hopper Duplex Printer
CD/CE Multi-Hopper Duplex Printer The figure below shows the main parts of the CD and CE multi-hopper duplex card printers. The main features and options available for the printer are: Five 100 card input trays and exception Output tray with 25 card capacity and ...
Page 33: Printer Optional Components
Printer Optional Components There are numerous options that can be factory installed or attached to the basic printer configuration. Multi-Hopper Option CD800, CD820 and CE870 printers include a multi-hopper option that has six hoppers that can contain 100 cards each. The multi-hopper may be configured to have five of the hoppers containing 100 cards each and the extra hopper (Hopper 2) excluded for exception and printer cleaning cards.
Page 34: Embosser
Embosser The CE870 and CE840 Instant Issuance systems include a CEM embosser (with indent and topper) unit. The CE series system is for financial card issuance. A card is drawn in from the appropriate hopper tray, run through printer functions such as magnetic stripe and smart card encoding, and transferred to the embosser component under the printer.
Page 35: Laminator
Laminator The SD460 system comes standard with a SLM laminator. The CD800 printer adds an optional CLM laminator as an upgrade. The laminator can apply overlays and topcoats to the card to improve durability. An optional impresser is also available for the laminator. Field upgrades for the laminator include impresser, impresser die, second laminator and bar code scanner.
Page 36: Options Available
DP= Desktop Printer, FII- Financal Instance Issuance, S= Standard, OP= Option, NA= Not Available, Y= Yes, N= No, FK= Field Kit, 1 = SDK Available for Printer Only * = Cannot use Touchscreen or Smart Card with USB Connection SD260L SD360 SD460...
Page 37 SD260L SD360 SD460 CD800 CD820 CE840 CE870 Trays and Hoppers Reject Tray Manual Feed Input Hopper (100) Input Hopper (200) MultiHopper (600) Output (25) Output (100) FK - single FK - single Output Cover (secure) Locks and Alarms Tilt Alarm...
Page 38 SD260L SD360 SD460 CD800 CD820 CE840 CE870 Smart Card - Single Wire Duali (contact/ contactless) - only D3 boards Smart Card - Loosely coupled SCM (contact/ contactless) Duali (contact/ contactless) Third-party contactless only Third-party contact only HID pcProx HID reader only...
Page 39: Functional Block Diagrams
Functional Block Diagrams The following diagrams detail the electrical connections of the printer. Print Engine SD/CD/CE Service Manual 1-21...
Page 40: Print Engine (Options)
Print Engine (Options) 1-22 Introduction...
Page 41: Iclass Or Pcprox Plus (Contactless) Smart Card
iCLASS or PcProx Plus (Contactless) Smart Card SD/CD/CE Service Manual 1-23...
Page 42: Scm Or Identive (Contact/Contactless) Dual Smart Card
SCM or Identive (Contact/Contactless) Dual Smart Card 1-24 Introduction...
Page 43: Omnikey (Contactless)
OMNIKEY (Contactless) SD/CD/CE Service Manual 1-25...
Page 44: Omnikey Single-Wire (Contactless)
OMNIKEY Single-Wire (Contactless) 1-26 Introduction...
Page 45: Duali Single-Wire (Contact/Contactless) Smart Card
Duali Single-Wire (Contact/Contactless) Smart Card SD/CD/CE Service Manual 1-27...
Page 46: Third-Party Integrator Basic Smart Card
Third-Party Integrator Basic Smart Card 1-28 Introduction...
Page 47: Third-Party Contact Station
Third-Party Contact Station SD/CD/CE Service Manual 1-29...
Page 48: Card Transfer (Duplex) Module
Card Transfer (Duplex) Module 1-30 Introduction...
Page 49: Electronic Lock Option
Electronic Lock Option SD/CD/CE Service Manual 1-31...
Page 50: Printer Components
Printer Components This section describes the sensors, motors, and circuit boards in the SD/CD/CE series printer. Sensors The sensors that may be in a card printer with multi-hopper are listed in the following table. Name Function Card Input This wide-slot photocell detects the presence of a card entering the print engine from an input hopper.
Page 51: Motors
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. Name Function Pick Motor This DC motor drives the card picking mechanism. Transport Motor This stepper motor drives the card through the printer.
Page 52: Circuit Boards
Circuit Boards The printer has several boards that are connected to the print engine drive board. 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...
Page 53: Multi-Hopper Components
Multi-Hopper Components This section describes the sensors, motors, and circuit boards in the multi-hopper option. Sensors The sensors in a multi-hopper are listed in the following table. Refer to the following figure for locations of the sensors. Refer to “Circuit Boards” page 1-34 for connection information.
Page 54 Back of Multi-Hopper Shuttle Up Shuttle Home Vertical Shuttle Card Entry Shuttle Shuttle Home Horizontal Shuttle Right Front of Multi-Hopper Shuttle Card Exit Near Hopper 6 Card Present Hopper # Hopper Door 1-36 Introduction...
Page 55: Motors
Motors The multi-hopper has a DC motor in each hopper. The other motors are stepper motors. Refer to the following figure for motor locations. Refer to “Circuit Boards” page 1-34 for connection information. Name Function Hopper # Pick Each of the six trays has a DC motor that drives a gear to move a card into the shuttle.
Page 56: Circuit Boards
Circuit Boards The multi-hopper has several boards. Refer to the following sections for connection information. Name Function Multi-Hopper Main Controls components in the unit and interfaces to the main printer board Board (at J32) via a 50-pin connector. Elevator Board (Aux 1) Controls horizontal movement of the shuttle.
Page 57: Diagram Of Boards
Diagram of Boards The main board for the multi-hopper is located under the unit and faces down. The elevator daughter board is in the base and faces up. The shuttle daughter board is on the bottom of the shuttle and faces down. Refer to the following figure for locations of jumpers and connections to the boards.
Page 58: Jumper Connections On Multi-Hopper Main Board
Jumper Connections on Multi-Hopper Main Board Jumper Connection Jumper Connection Hopper 6 Pick Motor Unused Hopper 5 Pick Motor Shuttle Home Horiz. (X) Sensor Hopper 4 Pick Motor Shuttle Right Sensor Unused To J32 of Printer Main Board Hopper 3 Pick Motor Card Present Hopper 6 Sensor Hopper 2 Pick Motor Card Present Hopper 5 Sensor...
Page 59: Jumper Connections On Elevator Board (Aux 1)
Jumper Connections on Elevator Board (Aux 1) The board that controls horizontal movement of the shuttle in the multi-hopper is located at the base of the elevator. (The board has the same part number as the shuttle board.) The following table indicates locations of jumpers and connections.
Page 60: Jumper Connections On Shuttle Board (Aux 2)
Jumper Connections on Shuttle Board (Aux 2) The board located on the side of the shuttle controls movement of the shuttle. (The board has the same part number as the elevator board.) Refer to the previous figure and the following table for locations of jumpers and connections.
Page 61: Lock Option Components
Lock Option Components The lock components are standard in the CE870 and optional in the CE840 and CD800 printers. The system has standard interlocks to protect against injury. The printer and embosser each have an interlock on the door cover. Systems with the multi-hopper have an additional interlock on the hopper door.
Page 62: Alarm Option Components
Alarm Option Components The following diagram shows the points for optional alarm connections. Touch Screen Option Components The optional touch screen at the top front of the printer has a circuit board to which a USB Ethernet cable and a power cable are connected. It also has a memory disk in the board. Touch Screen Circuit Board Connection to USB...
Page 63: Chapter 2: Menus
Chapter 2: Menus This chapter provides an introduction to the CD/CE series menus in the LCD panel and in the Printer Manager application. The LCD Panel ............. . . 2-2 Status Lights.
Page 64: The Lcd Panel
The LCD Panel The LCD panel (placed on the lower central card input hopper in the multi-hopper) shows printer, embosser and laminator status information. It has menu options to run a cleaning card, view printer information, and configure the printer. Pressing the down or up arrow while at the ready screen to access the quick menu.
Page 65: Status Lights
Status Lights The following table lists the LCD panel status light conditions and indicates what the lights mean. Light Light Condition Indication Ribbon Print ribbon and embosser or laminator supply is okay. Status Light Flashing Green Embosser or laminator supply is low if flashing slowly (every 2 seconds) or out if flashing quickly (every 1/2 second).
Page 66: Lcd Menu Options
LCD Menu Options An overview of the LCD panel menu for the card printers in the table below describes the items and options from the Main menu. When the option you want displays on the screen, touch the Enter button to select it. Main Menu Option Submenu Item Option...
Page 67 Main Menu Option Submenu Item Option Status Serial Number Displays the serial number of the card printer. Versions The following options are available: Firmware FPGA Embosser Smartcard Opencard Laminator Exit Network Status The following options are available: Address Mode IP Address Subnet Mask Gateway Address MAC Address...
Page 68 Main Menu Option Submenu Item Option Configuration Network IPv4 The following options are available: DHCP/Static IP Address Subnet Mask Gateway Address Apply Exit Network IPv6 The following options are available: IP Mode DHCPv6 SLAAC Manual IP Manual Address Prefix Length Gateway Address Exit LCD Backlight...
Page 69: Printer Manager
Printer Manager Printer Manager is a web interface that contains card printer settings, options, and diagnostics. The menus are used to find printer status, make adjustments, make test cards 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.
Page 70: Logging In To Printer Manager
Open a browser window and enter the IP address of the printer into the address bar (example: “https://xxx.xx.xxx.xx”). (Note the s on https.) Click Continue to this website. The Printer Manager login displays. 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.
Page 71: Printer Manager Passwords
Printer Manager Passwords For full service access open Printer Manager, select a language, select WebService as your access level, and enter the service password (926918). WebService access can change the passwords for WebService, WebAdmin, and WebUser. WebAdmin can change the passwords only for WebAdmin and WebUser. Changing the service password from the default value is not recommended.
Page 72: Status
Status The options on the Status menu display information about the printer; they cannot be changed here. Menu Option Purpose Display vital product data (VPD), including the manufacturer, model, options, and software/firmware version information. This information may be needed for service providers.
Page 73: Printer Settings
Printer Settings The options on the Printer Setting menu display printer settings and emboss offsets for adjustments. Menu Option Description Purpose Communication CloudMQTTBrokerURI Displays the default and current values of the communication method CloudMQTTKeepAlive (DHCP or static) and address CloudMQTTPort information.
Page 74 Menu Option Description Purpose Activity Log ExternalLog Allow you to enable or disable both internal and external logs and ExternalLogServer designate the external log server IP FilterCardActions address. You can set activity log filters FilterConfigChanges to notify at different levels or turn FilterJobStates them off.
Page 75 Menu Option Description Purpose VitalProduct AgencyModelName Display the default and current printer Data (VPD) information. Change the current serial Manufacturer number (for a board change) or ModelName restore default values. PartNumber SerialNumber SettingsVersion FrontPanel BacklightBrightness Display the default, current values, and allowed ranges for the front panel KeySenseLevel options.
Page 76 Menu Option Description Purpose Print CableCompMaxStrobe For printers with a printhead installed, displays the default, current values, CardRegistration and allowed ranges for the print CardRegistrationCalibration options. Change the current ColorManagement information or restore the default ColorMatchB[0-10] values. Refer to descriptions of these ColorMatchB[1] items in “Print”...
Page 77 Menu Option Description Purpose Print (Cont.) KCustom1Power KCustom1Power1200DPI KCustom1Power600DPI KFineText KPower KPower1200DPI KPower600DPI KPowerCalibration KPowerCalibration1200DPI KPowerCalibration600DPI KPowerDuplex KWhiteShade LeadTrim PowerCalibrationK98mm Offset PowerCalibrationK98mm Offset1200 PowerCalibrationK98mm Offset600 PowerCalibrationT98mm Offset PowerCalibrationYMC98mm Offset PowerCalibrationYMC98mm Offset600 RibbonOffset RibbonStripeOffset SettingsGroupPurpose TPower TPowerCalibration TPowerDuplex TrailTrim TWhiteShade VerticalOffset YMCMinShade YMCPower YMCPower600...
Page 78 Menu Option Description Purpose Pick Standard Printer: Display the default, current values, and allowed ranges for the pick MotorPWM offsets. Change the current PickAutoTimeout information or restore the default PickCardOffset values. PickManualTimeout PickReversePwm PickReverseTime Multi-Hopper Printer: CardsIntoShuttle MotorPWM MultiHopperCenterLeftOffset MultiHopperCenterRightOffset MultiHopperXHome MultiHopperXRight MultiHopperYHome...
Page 79 Menu Option Description Purpose Flipper (Duplex/ BarcodeLocation Display the default, current values, Transfer) and limits for the transfer assembly BarcodeParkOffset (duplex/flipper) that delivers cards to EmbossCardOut the embosser. Change the current FlipperBarcodeBackAngle information or restore the default FlipperBarcodeFrontAngle values. FlipperEmbossAngle FlipperFlippedAngle FlipperHomeOffset FlipperLaminatorAngle...
Page 80 Menu Option Description Purpose MagStripeGeneral Attempts Display the default, current values, and limits for general magnetic stripe AutoCoercivity options. Change the current Coercivity information or restore the default DataFormat1 values. DataFormat2 Coercivity can be HICO, LOCO, NTT1, DataFormat3 NTT2, or NTT3. NoDataDisableTrack Data Formats can be: IATA, ABA, TTS, ReadTrack1...
Page 81 Menu Option Description Purpose MagStripeMS2General MS2Attempts Display the default, current values, (Dual Magnetic Stripe and limits for general magnetic stripe MS2Coercivity Units Only) options for the dual JIS magnetic strip MS2DataFormat1 encoder (if present). Change the MS2JitterBitToBitJIS current information or restore the MS2JitterCheck default values.
Page 82 Menu Option Description Purpose Emboss EmbCompress7CPI The motors in the embosser, check the audit and reset logs, unlock the FlipperEntryPos emboss cover, or adjust the emboss FlipperFlipPos wheel characters. Refer to the FlipperHomeOffset embosser Service Manual for details IndentEngageOffset on these items. IndentMultiColor IndentPanel0 IndentPanel1...
Page 83 Menu Option Description Purpose Emboss (Cont.) Wheel1Offset Wheel1XEmboss Corner Wheel1YEmbossCorner Wheel2CardBow Wheel2Emboss07CPIForce Wheel2Emboss10CPIForce Wheel2EmbossForce Wheel2EmbossLowerOffset Wheel2EmbossUpperOffset Wheel2Offset Wheel2XEmbossCorner Wheel2YEmbossCorner Options DTCSmartCardContactless Indicate if smartcard, embossing/ indent, topping, kiosk and laminator EmbossModuleEmboss options are to be used. EmbossModuleExpected EmbossModuleIndent EmbossModuleKioskExtReader EmbossModuleKioskRollers Park EmbossModuleKioskSupport EmbossModuleTop...
Page 84 Menu Option Description Purpose Laminator CardExitOffset Display the default, current values, and limits for the laminator CardExitSpeed component operation. CardExitSpeedWithImpress CardExitWithImpressOffset CardInputPosition CardRejectOffset CardRejectSpeed DebowBottomHomeOffset DebowDelay DebowHomeOffset DebowRegOffset DebowSpeed ExceptionCardDebow Direction ExceptionCardDebow DistanceDown ExceptionCardDebow DistanceUp ExceptionCardDebow DwellMs ExceptionCardImpressDepth ExceptionCardImpressDwell Time ExceptionCardImpress PositionOffset1 ExceptionCardImpress...
Page 85 Menu Option Description Purpose Laminator (Cont.) FlipperVerticalAngle HeaterMinutesToPower Save Hopper1CardDebow Direction Hopper1CardDebow DistanceDown Hopper1CardDebow DistanceUp Hopper1CardDebowDwellMs Hopper1CardImpressDepth Hopper1CardImpress DwellTime Hopper1CardImpress PositionOffset1 Hopper1CardImpress PositionOffset2 Hopper1CardImpress PositionOffset3 Hopper1CardImpress Temperature Hopper1CardNumberOf Impresses ImpresserHomeOffset ImpresserRegisterSpeed ImpresserSpeed InterstageSpeed L1CoolingTime L1OverlayFinalStripStop Distance L1ThresholdTemperature L1ThresholdTemperature Reduction L2CoolingTime L2OverlayFinalStripStop Distance L2TemperatureReduction...
Page 86 Menu Option Description Purpose Laminator (Cont.) MfgImpressDepth MfgImpressPositionOffset MfgOverlayRegOffsetL1 MfgOverlayRegOffsetL2 PatchDriftAdjustment RollerL1CustomSpeedOffset RollerL1CustomTempOffset RollerL1RubberSpeed Offset RollerL1RubberTempOffset RollerL2CustomSpeedOffset RollerL2CustomTempOffset RollerL2RubberSpeedOffset RollerL2RubberTempOffset RollerTypeInstalledL1 RollerTypeInstalledL2 ScanBarCodeRetries ScanBarCodeVerifications ScanSpeedOffset SerialNumber 2-24 Menus...
Page 87 Menu Option Description Purpose Laminate Type CardPatchLength Display the default, current values, and limits to control the overlay and CardRegOffsetL1 topcoat application to the card. CardRegOffsetL2 CardStripDistance DatabaseVersion ExclusiveOverlayInL1 ExclusiveOverlayInL2 OverlayDisplayed Name OverlayInitialStripLength OverlayLoadedInL1 Name OverlayLoadedInL2 Name OverlayPartNumber OverlayRegOffsetL1 OverlayRegOffsetL2 OverlaySpeed OverlaySpeed AdjustmentL1 OverlaySpeed AdjustmentL2...
Page 88: Troubleshooting
Troubleshooting The options on the Troubleshooting menu enable testing motors, sensors, and the fan. Menu Option Description Description Purpose Sensors Standard Printer: Laminator Sensors (Cont): Displays the current and historical value Card Present Lam L1 Film Index along with the Card Register Lam L1 Film Motion jumper number and...
Page 89 Menu Option Description Purpose Testcard Test Card Print Options Select from a number of test card options and parameters. Refer to the Input Hopper Number Troubleshooting chapter in the printer Emboss Service Manual for instructions to use Magnetic Stripe and descriptions of cards and Color patterns.
Page 90 Menu Option Description Purpose Test Fan Time Display the default, current value, and limits for the time to run the fan in milliseconds. Test the fan, make changes to the current value, and restore the default value. Test Flipper Direction Display the default, current value, and range for the flipper motor in Speed...
Page 91: Personalization Tools
Menu Option Description Purpose Test Multi- Select from these motors to test: Test any of the motors in the multi- Hopper hopper assembly. Set the direction, Pick 1 through Pick 6 speed, and steps or time to run the Trans X motor (multi-hopper printer only) Trans Y Trans Card...
Page 92: Embosser
Embosser Refer to full instructions for using these embosser parameters in the embosser Service Manual. Menu Item Description Motor Test Select a motor and run it in either direction for a certain number of steps. Motors include: Emb Wheel 1/2 ...
Page 93: Maintenance
Maintenance For more information on card printer maintenance, refer to page 6-1. Menu Item Description Cleaning Use this option to run a cleaning card through the printer. Insert the card and click Run. Updates This option allows you to browse to a settings file and upload it to the printer. Download Settings This option allows you to export settings from the printer and save it to a settings file.
Page 94: Firmware Updates
PartnerPage. The firmware file can be run alone as a stand alone executable. Secure Encryption The printer encrypts all data and sends it to the Datacard Personalization Manager (DPM), which decrypts it for the various components. Access the following options for controlling encryption from the Printer Manager by selecting Printer Settings >...
Page 95: Chapter 3: Theory Of Operation
Chapter 3: Theory of Operation This chapter provides the theory of operation and sequence of operation for the SD/CD/CE series printer. Sequence of Operation ............3-3 Power-On Initialization .
Page 96 Multiple Record Format (SDS) ..........3-26 JIS X 6302 (Type I and Type II Cards) .
Page 97: Sequence Of Operation
Sequence of Operation This section describes the order of events in printer operation. Power-On Initialization When the power button on the front of the printer is pressed, the SD/CD/CE series system begins its initialization routine for various components. Multi-Hopper Initialization Sequence The unit checks the shuttle sensor state and clears any cards from the shuttle.
Page 98: Multi-Hopper Card Pick Sequence
The duplex (if applicable) is placed in the appropriate angle. When the printer finishes its initialization procedure and is ready to process cards, the status light turns green. Multi-Hopper Card Pick Sequence User sends select hopper command. The selected hopper is checked to see if a card is present. When a card is verified by the printer as present, the shuttle moves to the selected hopper.
Page 99: Default Card Production Sequence
Default Card Production Sequence After the card data has been sent to the printer, the printer begins the card personalization process. The card is picked from the hopper and passes through the cleaning rollers. The leading edge of the card passes through the cleaning rollers, and then the card is detected by the input sensor.
Page 100: Duplex/Transfer Sequence
Duplex/Transfer Sequence The duplex assembly can flip the card and send it back for printing on the back of the card or forward the card directly to the embosser. Before the card enters the transfer module, the flipper rotates to the home position to receive the card.
Page 101: 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.
Page 102: Power Off Sequence
been reached, the card is centered in the flipper assembly for transport out of the printer. Power Off 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.
Page 103: Card Feed
Card Feed When the card is fed into the printer from a card hopper, the pick motor powers the pick roller that draws the card into the printer and toward the cleaning rollers. The pick gate assembly makes sure that only one card at a time may be fed to the roller. The pick block assembly pushes a single card into the pick roller assembly.
Page 104: Card Transport In Printer
Card Transport in Printer The transport motor powers the rollers that move the card through the printer as the card is processed. Each roller pair in the printer has a bracket and spring on each side that provide tension to enable the rollers to grip a card. Three sensors are used during card transport: the card input, card exit, and cam home sensor.
Page 105: 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 600 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).
Page 106: Monochrome Printing Sequence
return the pick block assembly to its home position. The feed error check is also terminated unless 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.
Page 107 The figure below shows the process the printer uses to print a monochrome card. SD/CD/CE Service Manual 3-13...
Page 108: 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. All other ribbons are identified as black monochrome. The ribbon motor advances the ribbon until the ribbon index is seen by the ribbon index sensor and then moves the ribbon an additional amount as specified by the ribbon offset.
Page 109: Regionalized Print Ribbons
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. The ribbon motion sensor monitors the movement of the ribbon. 98mm ribbons do not have a separate index mark and use the K panels to initialize. Cover and uncover to make sure that they change state.
Page 110: 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.
Page 111: 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. The ribbons are susceptible to breaking if the print head goes beyond the trailing edge of the card. Regionalization Error Messages The following error messages displays on the front panel LCD when there is an error with regionalization.
Page 112: Magnetic Stripe Encoding
Magnetic Stripe Encoding Magnetic stripe write operations are performed while the card is moving from the card input sensor toward the card exit sensor. Read operations are performed while the card is moving from the card exit sensor back toward the card input sensor. The card input and card exit sensors monitor the card position.
Page 113: Magnetic Stripe Write Operation
Magnetic Stripe Write Operation The menu options in the following text are found in the Printer Manager. Refer to “Enabling the Proprietary Magnetic Stripe Option” page 4-75 for settings information. When the leading edge of the card reaches the card input sensor, it continues to move the number of steps defined by the StripeWriteFwdEntryOffset, and then data is written on the magnetic stripe.
Page 114: Magnetic Stripe Read Operation
Magnetic Stripe Read Operation The menu options in the following text are found in the Printer Manager. Refer to “Enabling the Proprietary Magnetic Stripe Option” page 4-75 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.
Page 115: Color Management
Color Management Overview Color management is a process for enhancing color, that 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.
Page 116 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, but also for many kinds of devices. As a result, color consistency is achieved through trial and error.
Page 117: Other Color Variation Factors
Other Color Variation Factors There are several 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 ...
Page 118: Monitor Calibration
For exact color matching, a monitor calibration solution is available for purchase. Entrust Datacard offers a ICC color calibration kit, (part number 523525-001). Recommended reading on color management: Adobe Technical Guide: http://dba.med.sc.edu/price/irf/Adobe_tg/manage/cmsdef.html...
Page 119: Magnetic Stripe Primary Data Standards
Magnetic Stripe Primary Data Standards 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) ISO/IEC 7811 is the primary standard for recording that most other formats and standards are based on.
Page 120: Multiple Record Format (Sds)
Multiple Record Format (SDS) Multiple Record Format (SDS) is a format 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.
Page 121: 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). Under the ISO and JIS standards, even if only one of the three tracks is used, the minimum track size follows this specification.
Page 122: 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 previously discussed standards, except a JIS Type II card. 3-28 Theory of Operation...
Page 123: 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...
Page 124: Character Encoding
Character Encoding 7-bit Alphanumeric Character Set as Defined by ISO/IEC 7811 Binary Binary Parit Parit Note Char Note Char Space “ & ‘ 3-30 Theory of Operation...
Page 125: 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...
Page 126: Smart Card Technology
Smart Card Technology The information presented in this section is not required for servicing the printers, but is provided for your information. A smart card has a chip embedded inside a plastic card. The chip may be microprocessor based or a simple memory device.
Page 127: 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. 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.
Page 128: Contactless Smart Cards
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 following: The format of the communication ...
Page 129: Communication
Communication Communication with contactless smart cards is more complex because there is no physical connection between the interface and the card. The card reader sends out a radio frequency broadcast, which provides power to the card and establishes communication. This is called inductive coupling.
Page 130 Amplitude Modulation: The magnitude (height) of the carrier signal is varied according to the height of the data signal. This is what is used in AM radio. Note: The blue data signal is shown here for clarity. It is not actually present in the actual modulated signal.
Page 131: Reader-To-Card Communication
Reader-to-Card Communication The reader communicates with the card by sending an amplitude modulated signal at 13.56 MHz. The modulation variant depends on the class of card. Type-A cards use 100% Amplitude Shift Keying (ASK100%). Type-B cards use ASK10% modulation. These two variants are shown in the previous graphics.
Page 132 Type-A Card Modulation The type of return modulation from the card to the reader differs with the two classes of cards (Type-A and Type-B). Type-A cards use a simple On-Off-Keying modulation (OOK). This is the binary equivalent of amplitude modulation. The card switches the resistance seen by the card reader at a frequency of 1/16th the frequency of the carrier signal.
Page 133: Chapter 4: Adjustments
Chapter 4: Adjustments This chapter includes navigation and use of the Printer Manager application to view and make adjustments to the SD/CD/CE series printer and optional multi-hopper. Refer to the CEM Embosser or the SLM/CLM Laminator Service Manuals for their respective adjustments. Factory and Power-On Settings .
Page 134 PickReversePWM Adjustment..........4-74 PickReverseTime Adjustment .
Page 135: Factory And Power-On Settings
Factory and Power-On Settings The card printer is shipped with default factory settings, but settings can be changed as needed to customize how the printer operates. Settings in Printer Manager contain changeable values with 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.
Page 136: Printer Settings
Printer Settings The printer settings can be changed in printer manager in the following menus. Communication The following settings on the communication menu can be adjusted. Option Description CloudMQTTBrokerURI The server to connect to for MQTT broker usage. CloudMQTTKeepAlive Specifies the maximum time (in seconds) for no communication between the cloud client (printer) and cloud broker.
Page 137 Option Description 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.
Page 138 Option Description UsbAddressMethod Sets the method used to obtain the IP address on the USB network. UsbDeviceMacAddress Displays and sets the MAC address for the USB device on the USB network. UsbHostMacAddress Displays and sets the MAC address for the USB host on the USB network.
Page 139: Activity Log
Activity Log Enable or disable an internal or external activity log using this menu option. It lists the activities that can be included in the logs and allows you to set the severity level for when the activity should be written to the log. Severity levels include: off, critical, error, warning, notice, information, and debug.
Page 140: Activity Log Example
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 external log server IP address has been entered. ...
Page 141 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 kept minimized, messages at the bottom right appear above the Task Bar.
Page 142: Behavior
Behavior The behavior options control printer operation as well as magnetic stripe and smart card encoding. Refer to “Enabling the Proprietary Magnetic Stripe Option” page 4-75 information about using proprietary magnetic stripe encoding. Option Description ActivityLogExternal Enables or disables the external and/or internal activity logs. ActivityLogInternal AutoPPS When enabled (default) this setting allows the chip to negotiate...
Page 143 This setting does not apply if you use a key to unlock the printer. DPCL DPCL is Datacard Printer Control Language. These settings disable DPCL (port 9100) or disable DPCL Secure (port 9111) DPCL2 communications.
Page 144 Caution: Do not disable the web server. If the web server is disabled, you cannot launch Printer Manager and configuration changes cannot be made. To reverse this action, you must contact Datacard. To reverse this action, you must write a DPCL application. To restrict access for the WebAdmin access level, select Printer Setting >...
Page 145: Vital Product Data
Vital Product Data This option displays the default and current values of vital product data (VPD). Option Description AgencyModelName Agency model Manufacturer Name of printer manufacturer ModelName Printer model name, assigned by the manufacturer or dealer PartNumber Displays the part number of the printer or the FRU board, if any. SerialNumber The serial number setting needs to be reset if you replace the print engine board.
Page 146: Front Panel
Front Panel This menu has settings for the LCD panel, the keys, and the indicator lights. Option Description BacklightBrightness Sets the LCD backlight intensity. Range: 0 to 100% Default: 100 KeySenseLevel Sets sensitivity of front panel keys. Range: 0 (high) to 6 (low) Default: 5 LcdConfigMenu Hide the front panel LCD Configuration menu.
Page 147: Print
Print The options that control the quality of the printing are listed in the following table. The Print density is the overall lightness or darkness of the printing and is a result of a combination of the CableCompMaxStrobe, the YMCPowerCalibration, and the YMCPower. The first two, CableCompMaxStrobe and YMCPowerCalibration, are factory adjustments.
Page 148: 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) Symptoms: Increasing the CardRegistration adjustment adds to the total card movement.
Page 149: 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.
Page 150: 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.
Page 151: Colormatchb[0-10], Colormatchg[0-10], Colormatchr[0-10]
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.
Page 152: Fpowerduplex
FPowerDuplex Modify the print intensity for the back side F panel of UV ribbon. Range: -100 to 100 special units Default: 0 special units HalfPanelStartOffset This setting defines the point on the card (moving left to right) where color printing can begin. The remaining image is looked at, and actual printing begins with the first color data that lies beyond (to the right) of the setting point.
Page 153: Kcustom1Power
KCustom1Power This customer setting increases or decreases print intensity for custom k panel ribbon such as STKT or GTKT ribbon. Increase the value to make single-color printing thicker. Decrease the value for crisp bar codes or if the ribbon breaks when printing the K panel. This adjustment controls the overall lightness or darkness of the K panel.
Page 154: Kcustom1Power1200Dpi
KCustom1Power1200DPI This customer setting increases or decreases print intensity for custom k panel ribbon such as STKT or GTKT ribbon printed at 1200 dpi. Increase it to make printing thicker. Decrease for crisp bar codes or if the ribbon breaks when printing the K panel. This adjustment controls the overall lightness or darkness of the K panel.
Page 155: Kpower
KPower Modify the print intensity for K (single-color) panel or K (single-color) ribbon. Range: -100 to 100 special units Default: 0 special units Symptoms: Increase the value to make single-color printing thicker and more defined on the card.  Decrease the value for crisp bar codes or to prevent frequent ribbon breaks when printing ...
Page 156: Kpowercalibration1200
KpowerCalibration1200 Change intensity of printing for the K ribbon or panel at 1200 dpi. Increase the power used to print the K panel and make printing thicker. Decrease for crisp bar 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.
Page 157: Kwhiteshade
KWhiteShade KWhiteShade is power applied to the printhead to reduce ribbon friction without transferring the backcoating. 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.
Page 158: Powercalibration[K,T,Ymc]98Mmoffset[600,1200]
PowerCalibration[K,T,YMC]98mmOffset[600,1200] The PowerCalibration98mmOffset settings for Black(K), Topcoat(T), and Yellow, Magenta and Cyan(YMC), are used by the printer to make sure that the print color output for 98mm ribbon types is consistent with legacy 101mm ribbons. We recommend that you do not change these settings except under the guidance of your service provider.
Page 159: Ribbonoffset
RibbonOffset The RibbonOffset value is the d istance 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.
Page 160: Ribbonstripoffset
RibbonStripOffset 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.
Page 161: Tpower
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 Settings: Increase the value to make printed topcoat thicker or more uniform. ...
Page 162: 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: 1.27 mm (0.05 inch) Explanation: The TrailTrim setting affects the right edge of the card when viewed in the landscape mode as...
Page 163: 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:...
Page 164: 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: If a white shirt in a photo does not print, increase this value. ...
Page 165: 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 Settings:...
Page 166: Ymcpowernosrgb
YMCPowerNosRGB Modify the intensity when you are printing without the sRGB color mode. Range: -100 to 100 shades Default: 0 shades Settings: Increase the value to make the non-RGB color darker.  Decrease the value if using non-RGB color mode to prevent overly dark printing or ribbon ...
Page 167: Pick
Pick The printer pick settings control the pick motors and offsets for picking cards. These adjustments are all related to feeding a card into the printer. The adjustments described here are only for the default single hopper. Additional adjustment information specifically for the multi-hopper are described in “Multi-Hopper Adjustments”...
Page 168: Multihoppercenterrightoffset (Multi-Hopper Only)
MultiHopperCenterRightOffset (Multi-Hopper Only) This is the distance to continue moving left to position the shuttle in center from the X right center. Range: 0 - 1500 steps Default: 543 steps MultiHopperXHome (Multi-Hopper Only) This is the distance to continue moving left to home the shuttle in the X direction. Range: 0 - 150 steps Default: 4 steps MultiHopperXRight (Multi-Hopper Only)
Page 169: Pickautotimeout
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 Default: 4000 ms Symptoms:...
Page 170: Pickcardoffset (1-6, Multi-Hopper Only)
PickCardOffset (1-6, Multi-Hopper Only) This is the distance to move the card using the multi-hopper pick motor, after the input sensor event. The unit is a millimeter (1 mm is 0.040 inch) and the value is a floating point decimal with up to three significant digits, such as 0.812.
Page 171: Pickreversetime
PickReverseTime Milliseconds to run the pick motor in reverse after picking a card to prevent picking of two cards. Range: 100 to 1200 ms Default: 250 ms Symptoms: If the value is set too high, picking errors occur, especially for thin cards. ...
Page 172: Transport Settings
Transport Settings The transport motor moves the cards through the printer. BoostedTransportSpeed This is the transport speed when using the boost circuit. Range: 800 - 4000 steps per second Default: 3250 steps per second EjectHopperSpeed Optimize card eject speed determined by hopper type (standard or extended). Options: ehs_Standard or ehs_Extended Default: ehs_Standard FinalEjectSpeedStandardHopper...
Page 173: 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 the printer Flipped – returns flipped card to the printer Smart Card – sends the card to and from the smart card assembly Reject –...
Page 174: Barcodelocation
BarcodeLocation This setting controls the placement of the printed barcode, either on the front or the back of the card. Options: CardBack, CardFront Default: CardBack BarcodeParkOffset Range: 0 to 68 Default: 63.5 EmbossCardOut This offset advances the card until the trailing edge leaves the flipper and the leading edge enters the Embosser interstage drive rollers.
Page 175: Flipperembossangle
FlipperEmbossAngle This offset adjustment positions the flipper card track for alignment with the card track of the embosser interstage station. Engineering recommends you do not increase this setting. Range: 1 to 500 steps Default: 139 Symptom: Card jams Procedure: Defeat the interlocks and remove the ribbon cartridge. Be ready to open the swingarm. Send a test card to the system.
Page 176: 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 Default: Typical is 250 Symptom: Card jams FlipperHomeOffset This offset sets the number of motor steps to execute, after the home sensor is covered during the flipper homing operation.
Page 177: Flipperlaminatorangle
FlipperLaminatorAngle This offset adjustment positions the flipper card track for alignment with the card track of the laminator. Engineering recommends you do not increase this setting. Range: 1 to 500 steps Default: 392 Symptom: Card jams FlipperRegistrationOffset This is the offset from the Exit sensor to load the flipper. Engineering recommends that this not be adjusted.
Page 178: Flipperrotationspeed
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 Default: Typical is 700 Symptoms: If set too high, excessive noise is generated. ...
Page 179: Smartinoffset
SmartInOffset Offset into the smart card module from the leading edge. Range: 1 to 300 Default: Typical is 83 Symptom: Card jams SmartInStepsPastSwitch Range: 1 to 6 steps Default: 2 steps SmartOutOffset (Engineering recommends that this not be adjusted.) Offset out of the smart card module from the trailing edge.
Page 180: 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...
Page 181 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 is erased. ReadTrack x Allows magnetic stripe read actions to read from track 1, 2, or 3. Note: ReadTrack does not disable reading of the card after the card (x=1,2, or 3) has been encoded in order to verify the data has been written...
Page 182 Option Description StripeWriteEventOffset Number of steps to move the card during the write magnetic stripe operation. Note: Engineering does not recommend changing this setting. Range: 1 to 1500 steps Default: 1050 steps StripeWriteFwdEntryOffset Number of steps after the card moves past the card in sensor until magnetic stripe encoding begins.
Page 183: Magstripecustomtrack
MagStripeCustomTrack All of the Magnetic Stripe Custom 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.
Page 184 Option Description CustomLrc#(1-3) Cumulative parity bit for track. It is encoded after the end sentinel, provides simple error checking, and is also called Longitudinal Redundancy Check or LRC. Range: Allowed values are EVEN, ODD and NONE. Default: EVEN CustomParity#(1-3) Character-level parity bit for track. It is encoded after each character, provides simple error checking, and is also called Vertical Redundancy Check or VRC.
Page 185: Magstripems2General
MagStripeMS2General The magnetic stripe general settings for the optional secondary JIS encoder are described in the following table. Option Description MS2Attempts 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.
Page 186 Option Description MS2JitterStxJIS The +/- percentage variation from nominal of the position of the start sentinel allowed. A value of 0 disables this check. Range: 0 to 40 steps Default: 13 steps MS2JitterSubintervalJIS The +/- percentage variation from nominal of the individual length of subintervals (each half of a "1"...
Page 187: Magstripems2Customtrack
MagStripeMS2CustomTrack The magnetic stripe MS2 custom track settings for the optional secondary JIS encoder are described in the following table. Option Description MS2CustomCharHigh1 Numeric value of the highest ASCII character supported for input data on track. Range: 1 to 255 Default: 95 MS2CustomCharLength1 The number of bits to represent one byte of data on track, also...
Page 188 Option Description MS2CustomLrc1 Cumulative parity bit for track. It is encoded after the end sentinel, provides simple error checking, and is also called Longitudinal Redundancy Check or LRC. Range: Allowed values are EVEN, ODD and NONE. Default: EVEN MS2CustomParity1 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.
Page 189: Emboss
Emboss The CE series embosser module adjustments are on the Printer Setting menu in the Emboss submenu of Printer Manager. Refer to the Embosser Service Manual for detailed instructions on using the options. Options This menu can disable or enable available options of the printer including smart card, embossing, topping, kiosk delivery and lamination.
Page 190 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.
Page 191: Set Job Queue State
Set Job Queue State This option is used for setting passwords to be used for remote access to the printer. SD/CD/CE Service Manual 4-59...
Page 192: 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.
Page 193: Multi-Hopper Adjustments
Multi-Hopper Adjustments The following adjustments are for printers equipped with the multi-hopper. CardsIntoShuttle Adjustment The card that leaves the selected input hopper is received by the shuttle assembly. A pair of entry and exit rollers transport the card through the shuttle. When the leading edge of the incoming card covers the shuttle card exit sensor, the card continues to move the distance specified by the CardIntoShuttle offset before stopping.
Page 194: Motorpwm Adjustment
MotorPWM Adjustment The motor PWM offset helps match the speed of the hopper pick motor to the card speed of the shuttle card transport motor to yield a smooth card transfer. Shuttle Card Transport Motor Hopper # Pick Motor Procedure With the printer cover off and the interlocks defeated, make a test card using the Printer Manager Testcard utility.
Page 195: Multihoppercenterleft Adjustment
MultiHopperCenterLeft Adjustment When the shuttle is at the hopper 1 or 4 position, the flag on the vehicle covers the X-home sensor. To move to hopper position 3 or 6, the vehicle moves to the right. When the flag uncovers the X-home sensor, this offset is implemented.
Page 196 Evaluate the card transfer position for entering the shuttle. Cards must transfer smoothly. If adjustment is necessary, navigate to the Printer Settings tab and click the Pick menu. Select the CenterLeftOffset and adjust as necessary. The default is 550 steps. For all the shuttle horizontal positioning offsets, it may be easier to insert both cards upside down and compare alignment of the magnetic stripes rather than the curved edges of the front of a card.
Page 197: Multihoppercenterright Adjustment
MultiHopperCenterRight Adjustment When the shuttle is at hopper 3 or 6, the flag on the transport covers the X-right sensor. To move to hopper position 2 or 5, the transport moves to the left. When the flag uncovers the X-right sensor, the center right offset is implemented.
Page 198 Slide a card into the shuttle from the rear so its edge almost touches the card in step 4. Analyze the position of the two cards using the hopper card as a reference. If cards are not getting into the shuttle, adjust the center right offset. 4-66 Adjustments...
Page 199: Multihopperxhome Adjustment
MultiHopperXHome Adjustment When the shuttle is at position 2, 3, 5, or 6, it moves to the left. When the leading edge of the flag on the transport covers the shuttle horizontal home sensor, this offset dictates how many additional motor steps to run before stopping. This offset aligns the entrance of the shuttle with the output from hopper 1 or hopper 4.
Page 200: Multihopperxright Adjustment
MultiHopperXRight Adjustment When the shuttle is at position 1, 2, 4, or 5, it moves to the right. When the leading edge of the flag on the transport covers the shuttle right sensor, this offset dictates how many additional motor steps to run before stopping. This offset aligns the entrance of the shuttle with the card output from either hopper 3 or hopper Procedure Place a single card in hopper 6.
Page 201: Multihopperyhome Adjustment
MultiHopperYHome Adjustment When the shuttle is at position 4, 5, or 6, it moves downward. When the leading edge of the flag on the transport covers the Y-home sensor, this offset dictates how many additional motor steps to run before stopping. This offset aligns the entrance of the shuttle with the card output from hopper 1, 2, or 3.
Page 202 Procedure Place a single card in hopper 1. Access Printer Manager, display the Troubleshooting menu, and select Testcard. In the Testcard window, select hopper 1 and click Run. Hold onto the card in hopper 1 so that it cannot feed to cause an error but move the shuttle in position to accept a card. Manually force the card out of the hopper into close proximity with the shuttle entrance.
Page 203: Multihopperyup Adjustment
MultiHopperYUp Adjustment When the shuttle is at position 1, 2, or 3, it moves upward as shown. When the leading edge of the flag on the transport covers the shuttle home vertical sensor, this offset dictates how many additional motor steps to run before stopping. This offset aligns the entrance of the shuttle with the card output from hopper 4, 5, or 6.
Page 204 Procedure Place a single card in hopper 6. Access Printer Manager, display the Troubleshooting menu, and select Testcard. In the Testcard window, select hopper 6 and click Run. Hold onto the card in hopper 6 so that it cannot feed to cause an error but move the shuttle in position to accept a card. Manually force the card out of the hopper into close proximity to the shuttle entrance.
Page 205: Pickautotimeout Adjustment
PickAutoTimeout Adjustment The Pick Auto Timeout setting is usually left as it came from the factory. (Pick Manual Timeout is not applicable to some printers.) When a card is to be fed, the hopper # pick motor is energized and the pick auto timeout offset is triggered. If the offset times out and the leading edge of the card still has not reached the shuttle card entry sensor, the pick motor is turned off and a card pick retry is initiated.
Page 206: Pickreversepwm Adjustment
Symptoms If set too high, two cards are picked.  If set too low, the hopper transport motor can stall, wearing out pick rollers prematurely.  Procedure Run a test card from Printer Manager and evaluate the position of the card within the shuttle when the card pick motor reverses.
Page 207: Magnetic Stripe Settings
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 should be used to restore magnetic stripe settings. Downloading the Settings File Follow the steps below to download the settings update file from PartnerPage to use when you are enabling proprietary magnetic stripe options.
Page 208: Updating Settings
Click the link to download the file. Save the file to the hard disk on your PC and proceed to the next section. Updating Settings Apply the magnetic stripe option settings file that you downloaded. Then use the following procedure to verify that the option has been enabled. Log on to Printer Manager with service level access.
Page 209 Select the settings file and click Open. Click Upload File. The user status light on printer LCD panel flash green as the settings file is being sent to the printer. The LCD panel displays BUSY. When completed a message in Printer Manager displays "File Upload Complete".
Page 210: 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 > MagStripeGeneral. Click Data Format for track 1, 2 or 3. The proprietary magnetic stripe option displays as a selection.
Page 211: 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.
Page 212 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.
Page 213: Start Sentinel Position Adjustment
Start Sentinel Position Adjustment Refer to “For Magnetic Stripe Option” page 8-5 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 “MagStripeMS2General”...
Page 214: 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, and optional embosser or laminator are stored in a memory disk on the print engine drive board.
Page 215: 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 Printer Manager A restore of printer settings can be made using Printer Manager. Open Printer Manager.
Page 216 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. 4-84 Adjustments...
Page 217: Chapter 5: Troubleshooting
Chapter 5: Troubleshooting This chapter provides troubleshooting information for the SD/CD/CE series printer and the optional multi-hopper. General Troubleshooting Procedures ..........5-3 Non-Clearing Repetitive Messages.
Page 218 Lost or Jammed Cards ........... . 5-41 Driver Messages .
Page 219: 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.
Page 220: Testing Sensors
Testing Sensors The Sensors option on the Troubleshooting menu in Printer Manager shows a list of all sensors in the printer (and multi-hopper, if the option is present) 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.
Page 221 Function Associated Sensors Presence of Card in Hopper and Card Present Hopper # (# can be 1 through 6) Shuttle Card Shuttle Entry, Card Shuttle Exit Door Status Input Hopper Door Determine if Sensor Has Failed This procedure determines if a sensor has failed or if the control board is not seeing the sensor properly.
Page 222: Making Test Cards
Making Test Cards The Testcard option on the Printer Setting menu allows you to select from many Test Patterns and Test Card Options. You can select certain features and indicate whether to print in color, monochrome, or not print at all. To access the Testcard option, start Printer Manager as described in “Logging In to Printer Manager”...
Page 223 Option Description Emboss Test Cards The drop-down list offers 10 test cards and two calibration cards for the CEM embosser only. Testcard 1: Embosses three 8’s on the card to check emboss positioning borders. Testcard 2: Embosses multiple full lines on the card using Emboss Wheel 1 and tops the characters to test the topper.
Page 224: Emboss Test Cards
Option Description Debow Select application of debow correction to the card. Used with the SLM/ CLM laminator only. Impress Select application of impresser stamp to the card. Used with the SLM/CLM laminator only. Copies Select a number other than 1 to print up to 10 test cards. Park Smart Card Check this to move a smart card into position under the encoder.
Page 225 Testcard 3: Emboss with Topping and Indent back of card Testcard 4: Wheel 1 Emboss and Topping to check all of the topping region Testcard 5 and 6: Indent (on front) and Emboss all characters on Emboss Wheel 1 (no topping) Testcard 7: Wheel 2 Emboss and Indent Back of Card Testcard 8: Indent Testcard to check all...
Page 226: Test Patterns For Printing
Testcard 9 and 10: Emboss all characters on Emboss Wheel 2 Calibrate Pick Do not use this testcard option. Refer to the Pick Y Position adjustment in the Embosser Service Manual. Calibrate Topper Do not use this testcard option. Refer to the Topper Offsets in the “adjustments”...
Page 227 Test Pattern Front of Card/Back of Card Test Pattern 3: Dense blue test Test Pattern 4: Color step test (RGB/K/ YMC) Test Pattern 5: Card registration SD/CD/CE Service Manual 5-11...
Page 228 Test Pattern Front of Card/Back of Card Test Pattern 6:Full color test Registration: Card registration mechanically Checkered: Card registration mechanically 5-12 Troubleshooting...
Page 229 Test Pattern Front of Card/Back of Card Short: Test short panel ymcKT Grid: Test full K panel PaleBlue: Improper side/side or lead/trailing printing may indicate a chassis, card guide, or roller problem. SD/CD/CE Service Manual 5-13...
Page 230: Troubleshooting Motors
Troubleshooting Motors Printer and Hopper Motors Each of the motors in the printer has a test 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.
Page 231: 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 drive board is faulty. Testing the Cam and Transport Motors The cam and transport motors are identical, so swapping the two motor connectors can isolate whether the motor or the print engine board is faulty.
Page 232: 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. Select the Test Cam option from the Troubleshooting menu in Printer Manager. Set the Speed to 600 and the Steps to 310 and click Run. Testing the Thermal Printhead (TPH) Fan The printhead fan begins to run when it reaches the correct temperature.
Page 233: 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.
Page 234: 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 ...
Page 235: 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.
Page 236 Open Print Manager and display the Troubleshooting tab. Select the Testcard test. Clear all Test Card Print Options check boxes to avoid printing on the card. Put a contact smart card into the input tray. Scroll down to Test Card Other Options. Select the Park Smart Card check box.
Page 237 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/CE Service Manual 5-21...
Page 238 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. 5-22 Troubleshooting...
Page 239: Hid Iclass Reader/Writer Contactless
HID iCLASS Reader/Writer Contactless The AIRIDCardMgr.exe application reads the Filter Mask, Facility Code and ID Code from the HID iCLASS card. The configuration utility can be downloaded from RFIDeas Inc at: https:// 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.
Page 240 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. 5-24 Troubleshooting...
Page 241: 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.
Page 242 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. 5-26 Troubleshooting...
Page 243: Omnikey Contactless
OMNIKEY Contactless Use the Printer Manager to park test card. Open the Printer Manager and log on with WebService access. Select the Troubleshooting tab and select Test Card. 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.
Page 244 Verify that the smart card ATR can be read for reader type (contactless). Open the PC/SC Diagnostic tool. From the Connected Readers entry in the left hand column, select the HID OMNIKEY 5127 CK 0. The ATR of the card is read and the results display in the PC/SC Attribute column of the PC/SC ...
Page 245: Omnikey Single Wire Contactless
OMNIKEY Single Wire Contactless Install the Dpcl2Test.exe configuration utility. Make sure that the printer is powered on and connected to the computer. Click the Dpcl2Test.exe icon to open the configuration utility. Enter the printer’s IP address and click Connect. SD/CD/CE Service Manual 5-29...
Page 246 Select the test smart card options. Hopper – Enter hopper number (1 for single input hopper).  Exception card – Prompts to insert card.  Contactless – Select for contactless cards.  Always eject – Deposits card into the hopper when done. ...
Page 247 The card is run and tested. Success and ATR and APDU data display when the test smart card procedure succeeds.  Error: Connect to card fail: displays when the test smart card procedure fails.  SD/CD/CE Service Manual 5-31...
Page 248: Duali Single-Wire Smart Card
Duali Single-Wire Smart Card Use the Dpcl2Test.exe configuration utility to test the Duali single-wire smart card. Install the Dpcl2Test.exe configuration utility. Make sure the printer is powered on and connected to the computer. Open the Dpcl2Test.exe configuration utility. Enter the printers IP address and click Connect. Pick the test smart card options.
Page 249 Enter 1 for hopper, select card type (contact or contactless) and always eject and click Run. The card is run and tested. Success and good ATR and APDU messages display when the test smart card procedure  succeeded. SD/CD/CE Service Manual 5-33...
Page 250 Error: Card is not present: and Get card status... displays when the test smart card  procedure failed. 5-34 Troubleshooting...
Page 251: 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.
Page 252: Performance Problems
Performance Problems Print Quality Symptom Comments Poor Print Quality (General) Produce a test card using the in Printer Manager. Click  Troubleshooting > Test Card > Run to run a test card and rule out customer card design as possible cause. Run 2-3 Isopropyl cleaning cards.
Page 253 Print Discoloration Along Short Produce four full edge to edge test cards. If the line of  Edge of Card discoloration reduces in size with each card printed and eventually disappears, no further action is required. Note: If a print ribbon is exchanged for another used print ribbon or the used print ribbon material is removed from the ribbon cartridge take up spool, the printer requires 4-5 cards in order to recalibrate the ribbon panel registration process...
Page 254: Printer Initialization Errors
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.
Page 255: Card Jams At Input
Card Jams at Input Symptom Comments A card is not picked from the multi- Clean the printer.  hopper. Use graphic quality cards.  Fan cards properly.  Inspect the pick roller for buildup or debris.  Test the pick motor using Diagnostics. ...
Page 256: 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. ...
Page 257: Driver And Sdk Messages And Conditions
Driver and SDK Messages and Conditions When an unexpected or undesired event occurs, the printer and/or software generates an error code and displays it on the monitor. Many times the error code instructs the operator to perform a required or routine task. Other times the error code is the result of a non-routine event that indicates a more serious problem with the system.
Page 258: Driver Messages
 Do not connect the PC to a network using VPN.  In device manager under network adapters, determine whether a Datacard Printer  High Speed USB Connection was installed. Check if printer is communicating. To check for this, you need to ping the USB printer.
Page 259 The card data is missing or is not usable The driver is set to encode magnetic stripe data only. USB communication issue An important driver component is not running. The card is canceled. 1. Restart the computer. The component starts automatically. 2.
Page 260: Responding To Driver Messages
Responding to Driver 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.
Page 261: 505: Usb Communication Issue
505: USB communication issue An important driver component is not running. The card is 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.
Page 262: Driver Sdk Messages
Driver SDK 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. Error Code Symptom Cause Cannot lock or unlock the printer...
Page 263: Lcd Messages And Conditions
LCD Messages and Conditions When the printer cannot process the card sent, it issues a condition. The LCD panel on the front panel shows these conditions. If you use the XPS Card Printer Driver, the printer driver also displays the condition as a message on the PC. In a shared printer environment, messages might differ slightly from the messages and conditions described in this section.
Page 264 LCD Message User Light Supply Light Card Light Sound Print ribbon out or missing Amber Flash Warning Card not picked Amber Flash Amber Flash Warning Card hopper empty Amber Flash Amber Flash Warning Close cover to continue Amber Flash Amber Flash Attention Cover opened during job Amber Flash...
Page 265: Embosser Messages (125 - 148)
Embosser Messages (125 - 148) Messages that indicate conditions of the embosser displays on the printer LCD panel. Refer to the CEM Embosser Service Manual for details on how to recover from conditions of embosser messages. LCD Message User Light Supply Light Card Light Sound...
Page 266: Laminator Messages (177, 196 - 223)
Topping foil support err. Amber Flash Green Flash Error Topping foil no tag found Amber Flash Green Flash Error Topping foil low Amber Flash Green Flash Warning Laminator Messages (177, 196 - 223) Messages that indicate conditions of the SLM of CLM laminator displays on the printer LCD panel. Refer to the SLM/CLM Laminator Service Manual for details on how to recover from conditions of laminator messages.
Page 267 Supply Laminator LCD Message User Light Light Card Light Light Sound L2 supply out or missing Amber Red Flash Error Flash L2 supply type problem Amber Red Flash Error Flash L2 supply not supported Amber Red Flash Error Flash L2 supply not identified Amber Red Flash Error...
Page 268: Responding To Printer Messages (100-124, 149-173, 224)
Responding to Printer Messages (100-124, 149-173, 224) Messages 100-124, 149-17 and 224 indicate a condition in the printer. Messages can display on the LCD of the front panel to identify various operational conditions and errors of card production on the printer. Important! Always discard damaged, rejected, or partially printed cards according to your organizations established procedures.
Page 269: 102: Card Not In Position
102: Card not in position The card is not positioned in the printer correctly. This error is issued when the card is expected at a card sensor and has not arrived in the allotted time or when the card is expected to clear a card sensor and has not cleared in the allotted time.
Page 270: 103: Printer Problem
103: Printer problem The printer had an error. The card is canceled. This error is most often a mechanical issue with the cam or printhead. A failure of the printer to register the RFID of the print ribbon can also cause this error.
Page 271: 104: Critical Problem
104: Critical problem The printer had a serious error. The card is canceled. Press the printer Power button to power off the printer. Request service. The system must remain powered off. Click OK in the message box to clear the message. &...
Page 272: 105: Magstripe Data Error
105: Magstripe data error The printer component could not verify the magnetic stripe data written on the card. To print the card again: 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.
Page 273: 106: Magstripe Data Not Found
106: Magstripe data not found The printer could not find magnetic stripe-written 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.
Page 274: 109: Print Ribbon Problem
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.
Page 275: 110: Print Ribbon Out Or Missing
Open the swing arm and check if the ribbon is broken or is sticking to the card. If the ribbon is  broke or sticking, check the card registration in Printer Manager. Click Printer Settings > Print. Confirm that the CardRegistration setting is set at the default value of 0. Change this ...
Page 276: 112: Card Hopper Empty
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. &...
Page 277: 114: Cover Opened During Job
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. &...
Page 278: 116: Magstripe Not Available
116: Magstripe not available The printer does not have a magnetic stripe option. The card is 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. &...
Page 279: 119: Print Ribbon Not Supported
119: Print ribbon not supported The printer cannot use the ribbon installed. The card is 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. &...
Page 280: 122: Magstripe Format Problem
122: Magstripe format problem The magnetic stripe data sent does not match the format set in the printer. The card is canceled. Press the User button on the printer, or click OK in the message box to clear the message. 123: Insert new card side 1 up Insert a new card in the printer with side 1 facing up.
Page 281: 150: Print While Unlocked
150: Print while unlocked The printer is unlocked. The card is canceled. Make sure that all access doors are closed securely and locked. Click OK in the message box to clear the message. 151: Failed to lock An attempt to lock the printer failed. The card is canceled. Make sure that all access doors are closed securely.
Page 282: 171: Insert Same Card Side 1 Up
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. Insert the card in the printer. If the card is not immediately picked, press the printer’s User button or click OK. Click Cancel in the message box if you want to cancel the card.
Page 283: Return Shipment For Service
Proceed to exit from the menus and then power down the machine. If deactivation fails, contact Datacard Technical Phone Support at 1-800-328-3996. When the repaired machine is returned to the site, you need to enter the same activation code used during the original installation unless a substitute machine is sent.
Page 284 5-68 Troubleshooting...
Page 285: Chapter 6: Maintenance
Chapter 6: Maintenance This chapter provides card SD/CD/CE series printer and optional multi- hopper maintenance procedures for the service technician. Required Tools and Supplies ........... 6-2 Preventive Maintenance Schedule .
Page 286: Required Tools And Supplies
Required Tools and Supplies Refer to the list of tools and supplies needed for routine maintenance procedures from the option on the CD menu. Cleaners used on the printer’s exterior must not contain any abrasives, oils, fragrances, antibacterial agents or solvents. Do not use soft-scrubbing cleansers, products with petroleum, or products with mineral, pine, or lemon oil.
Page 287: 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. Every 500 cards or Run a cleaning card and change after each used print the cleaning sleeve.
Page 288: Operator Procedures
Operator Procedures These procedures are usually done by the operator and are included in this service manual for reference and in case operator training is required. Clean the Printer The operator uses the following procedures to keep the printer component of the system clean and in good operation.
Page 289: Run A Cleaning Card
Run a Cleaning Card The operator runs a cleaning card to clean debris from the inside of the printer system. The cleaning card can remove most contaminants from the print system. Run a cleaning card after every print ribbon used (typically 500 cards, varies by ribbon type). Single Hopper Prepare the printer for cleaning.
Page 290 Use the LCD menu system. Begin when the printer displays Ready and the User button shows steady green. Press the User button. Suspended displays on Line 1 of the LCD panel. Press the Enter key to enter the menu system. Maintenance displays on line 2 of the LCD panel.
Page 291 The printer moves the card through the printer several times and ejects it in the output hopper. Remove the used cleaning card. Wait a few minutes for the rollers to dry. Prepare the printer for use. Unlock the printer. Replace the cards in the input hopper. Remove the print ribbon cartridge.
Page 292: Optional Multi-Hopper
Optional Multi-Hopper Cleaning a printer equipped with the optional multi-hopper involves two steps: cleaning the printer and cleaning the hopper rollers. REPARE THE RINTER FOR LEANING Power on the printer. Unlock the printer and open the printer supplies access door. Open the printer cover and remove the print ribbon cartridge.
Page 293 Press the Enter key. Maintenance displays on line 2 of the LCD panel. Press the Enter key to enter the Maintenance menu. Cleaning Card displays on line 2 of the LCD panel. Press the Enter key to enter the Cleaning Card menu.
Page 294 LEAN THE OPPER OLLERS Access the LCD menu system and enter the Cleaning Card menu. Select the hoppers for cleaning. Press the down arrow key until Hopper displays on line 2 of the LCD panel. Press the ENTER key to enter the Hopper menu. Press the down arrow key and select All to clean hoppers H1, H3, H4, H5, and H6.
Page 295 REPARE THE RINTER FOR Unlock the printer and open the multi-hopper door. Remove the used cleaning cards from the hoppers. Replace the cards in the input hoppers. Open the printer supplies access door and the printer cover. Remove the print ribbon cartridge. Install a new cleaning sleeve on the ribbon cartridge and remove the protective cover.
Page 296: Cleaning The Thermal Printhead (Tph)
Cleaning the Thermal Printhead (TPH) On systems that print the cards the operator cleans the printhead using an isopropanol cleaning swab. (Refer to Service Tools and Supplies on the CD library for the part number to order.) Open the swingarm and use gentle pressure as you move the isopropanol tip of the swab back and forth along the edge of the printhead.
Page 297: Service Procedures
Service Procedures Perform preventive maintenance procedures each time the printer is serviced to extend the life of the printer. Caution: Static electricity can destroy components on a circuit board. Follow the precautions in the section titled “Safety Precautions” page 1-5 and the Avoiding ESD Discharge file from the CD menu, when handling the board, its components, or tools in contact with the board or its components.
Page 298 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. 6-14 Maintenance...
Page 299 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.
Page 300 Inspect the ribbon drive gear for wear and broken teeth. Make sure it is securely seated on the motor shaft. 6-16 Maintenance...
Page 301 Inspect the ribbon cartridge. Inspect the spindle gear for wear and missing teeth. Check the spindles for proper movement and make sure that the clutch provides a slight drag. Check to see that the cooling fan is running properly by running a test card. SD/CD/CE Service Manual 6-17...
Page 302 Inspect the duplex module drive and idler rollers for wear and damage. 6-18 Maintenance...
Page 303 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 module. SD/CD/CE Service Manual 6-19...
Page 304: Cleaning The Interior Of The Printer
Cleaning the Interior of the Printer Turn the printer off and disconnect it. 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.
Page 305: Lubricating The Grease Points
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 old grease with a dry cloth, and re-grease the surfaces with Molykote DX grease. Caution: Do not add more lubrication than is indicated. Lubricate the platen roller rod.
Page 306 Lubricate the ends of the registration roller. 6-22 Maintenance...
Page 307 Lubricate the cam shaft. SD/CD/CE Service Manual 6-23...
Page 308: Lubricating The Magnetic Stripe Assembly
Lubricating the Magnetic Stripe Assembly Apply Molykote grease (1) and rotate shaft (2) to spread grease on the magnetic stripe assembly. 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.
Page 309: 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.
Page 310 Use the Test Flipper Trans test to move the duplex drive and idler rollers.  Take care to remove any contamination from the drive rollers to prevent card slippage. This is particularly important if the card stock being used contains a signature panel.
Page 311: Maintaining The Smart Card Module
Maintaining the Smart Card Module Clean the smart card registration sensor.  Inspect and clean the rubber rollers.  Inspect all the gears.  Verify contact switch operation, if applicable.  Verify smooth operation.  Using Printer Manager, verify that a smart card enters the smart card module. ...
Page 312: Inspecting For Card Quality
Inspecting 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. Refer to “Making Test Cards” page 5-6 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”...
Page 313: Chapter 7: Removing Covers
Chapter 7: Removing Covers This chapter provides procedures for separating the embosser from the printer and removing covers and enclosures on the CD/CE series printer. Removing Single Hopper Covers and Enclosure ........7-2 Separating the Printer from the Laminator .
Page 314: Removing Single Hopper Covers And Enclosure
Removing Single Hopper Covers and Enclosure First remove the back enclosure cover and then the front one. A special tool (Part No. 571712- 001) is needed for these procedures. Loosen the back cover: From the back of the printer, push the chamfer edge of the tool (1) up under the cover and lift the opposite side of the tool.
Page 315 SD/CD/CE Service Manual...
Page 316 Remove the back cover by lifting and maneuvering it up and back several times (1). The printhead (2) may also need to be maneuvered while lifting the cover. Removing Covers...
Page 317 Loosen and remove the front cover: Using tool as shown, place it between the base and the front cover (1). Push the tool down (2) to free the cover from the base tabs. Repeat once on same side and twice on opposite side (see location detail A).
Page 318: Separating The Printer From The Laminator
Separating the Printer from the Laminator The printer must be removed from the laminator prior to many removal and replacement procedures. Separate the printer from the laminator as described in the following procedure. Power off the system. Disconnect the power cable to the printer. Disconnect the power cable to the laminator.
Page 319 Disconnect the network cable to the printer. Disconnect the interconnect cable from the laminator to the printer. Open the laminator access door and slide the printer locking lever in the laminator to the left position (unlocked). SD/CD/CE Service Manual...
Page 320 Lift the printer off of the laminator and place the printer in a secure position. Lock Unlock Removing Covers...
Page 321: Separating The Printer From The Embosser
Separating the Printer from the Embosser The printer must be removed from the embosser prior to many removal and replacement procedures. Separate the printer from the embosser as described in the following procedure. Caution: Before doing any service procedures, be sure to disarm the alarm system according to site procedures.
Page 322 Disconnect the network cable from the printer in the receptacle above the data cable. Use the embosser key to unlock the cover. Push in the key and move it counterclockwise to unlock (clockwise to lock). (The key can be removed only if in lock position.) Open the embosser cover, move the latching lever on the embosser to the left to free the printer, and lift the printer off the embosser.
Page 323: Removing Multi-Hopper Covers And Enclosure
Removing Multi-Hopper Covers and Enclosure The multi-hopper printer has several covers and enclosures that may need to be removed for adjustment or replacement procedures. This section describes cover removal for the printer with the multi-hopper option. Caution: Always disarm the system before removing covers. It may be helpful to separate the printer from the embosser as described in “Separating the Printer from the Embosser”...
Page 324: Removing Multi-Hopper Front Door
Removing Multi-Hopper Front Door After shutting off alarms, use the following procedure to remove the front door from the multi- hopper. Power off the printer and remove the power cords from the outlet. Lower the door and remove cards from hoppers, if necessary. With the door halfway open to release tension on the spring at the right, disconnect the strap.
Page 325: Removing Hopper Enclosure
Removing Hopper Enclosure Four recessed screws hold the enclosure: two at the bottom to the base, and two at the top to the printer enclosure. Use the Torx driver to remove the four screws. Lift out from the hopper enclosure by rotating it out of the bottom tabs at the back (behind the touch screen, if applicable).
Page 326 Simultaneously press in on the tabs at the cover side to free the swingarm lid and remove it. (During replacement, thread in from lock side and then get tabs on inside before snapping in place.) Push the swingarm down and lift the flap over the pin on the other side of the swingarm to separate the swingarm from the flap on the enclosure.
Page 327: Removing Printer With Hopper From Base
Removing Printer with Hopper from Base Use a 7/16-inch wrench to remove the lock nut with washer on the mechanical lock assembly on the side of the printer opposite the door. Remove the lock pawl by rotating it out of the lock assembly until it is free. Pull out the (unused) reject tray from the right side of the printer.
Page 328 Disconnect the small white alarm connector from its board on the lock side of the printer near the hopper assembly. (The cable is part number 504467-001. You may need a needle- nose pliers to grip it without damaging the wires.) Use a flat blade driver to push straight down and depress the transport lock on one side of the transport while pulling toward the rear of the printer to free the side.
Page 329 Replacement Notes Place the hopper side into the base at a steep angle, lower the transport assembly, and lower back to connect all the tabs. Slide the assembly forward (toward the rear of the printer) until it snaps. SD/CD/CE Service Manual 7-17...
Page 330 7-18 Removing Covers...
Page 331: Chapter 8: Removal And Replacement
Chapter 8: Removal and Replacement This chapter provides procedures for removing and replacing components and assemblies in the SD/CE/CE series printer. The following chapter has the procedures for the optional components. Introduction to this Chapter ........... . 8-4 General Notes .
Page 332 Fan..............8-37 Swingarm, Torsion Spring, Damper .
Page 333 Lock Motor ............. . 8-80 Eccentric Gear, Swingarm Latch, and Springs .
Page 334: 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. Disconnect the printer and follow the instructions for removing the “Removing Multi-Hopper ...
Page 335: 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) 0.048-Inch, Four-Flute Spline Bristol Wrench S-048-4L ® dip magnetic tape developer KY Read TUL001-014 or equivalent such as TXC, Magna See 804267-915...
Page 336: Printer Components
Printer Components Refer to “Introduction to the SD/CD/CE Series Printer” page 1-6 for a diagram of the components in a printer. Cable Routing Transport Cables For more routing information, refer to “Swingarm Cable Routing” page 8-8 “LCD Interface Panel Routing, Single Hopper” page 8-17.
Page 337: Smart Card And Duplex Cable Routing
Smart Card and Duplex Cable Routing SD/CD/CE Service Manual...
Page 338: Swingarm Cable Routing
Swingarm Cable Routing Note routing of the cables for fan (1), printhead (2), and the ribbon motor (3). Refer to “Ribbon Motor, Ribbon Drive Gear” page 8-46 “Fan” page 8-37, and “Thermal Printhead (TPH)” page 8-35 for more information. Removal and Replacement...
Page 339: Freeing Cables From Clamps
Freeing Cables from Clamps Use this procedure to remove wires from cable clamps. Group the wires in a line. Slide them out. Functional Block Diagrams Refer to “” page 1-20 for diagrams of the boards and connections. SD/CD/CE Service Manual...
Page 340: Exterior Components
Exterior Components Most of these procedures show the standard CE series system printer without the multi-hopper option. Replacements for multi-hopper system that are different are provided in “Multi-Hopper Unit” page 9-2. Ribbon Cartridge Push button (1) to release the swingarm latch (2). LIft the ribbon cartridge out of the printer (3).
Page 341: 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). SD/CD/CE Service Manual 8-11...
Page 342 EPLACEMENT Attach one tab and then the other by slightly spreading the sides. When installing the cartridge back into the printer, place the diametric magnet next to the Ribbon Encoder Board. 8-12 Removal and Replacement...
Page 343: Swingarm Lid, Enclosure Flap
Swingarm Lid, 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 comes off. EPLACEMENT When reassembling, replace enclosure flap before the swingarm lid.
Page 344: Single Card Tray
Single 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.
Page 345: Tray Assembly
Tray Assembly 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). EPLACEMENT Reconnect cables and close the display panel connector securely after reconnecting. Place the four openings in the tray over the hooks (3) on the printer and slide down until it latches in place.
Page 346: Front Bezel, Lcd Interface Panel, Single Hopper, 25-Card Output
Front Bezel, LCD Interface Panel, Single Hopper, 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).
Page 347: Lcd Interface Panel Routing, Single Hopper
LCD Interface Panel Routing, Single Hopper Refer to “LCD Panel” page 9-15 for the removal procedure and cable routing in a system with a multi-hopper. SD/CD/CE Service Manual 8-17...
Page 348: Simplex Base
Simplex Base Simultaneously press the tabs (1a) and pull on the printer (1b). Lift and remove it from the base (2). EPLACEMENT 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).
Page 349: Tray
Tray Pick Gate and Pick Gate Spring Hold spring (1a) while separating the tabs (1b) of the pick gate from the hinge pins on both sides. Hold spring (2a) lift pick gate (2b) and pull out of hopper frame. Separate spring (3) from pick gate. EPLACEMENT Place spring on pick gate.
Page 350: Pick Roller Assembly
Pick Roller Assembly Pull up on pick roller assembly (1). Remove pick roller assembly (2) from input hopper frame. Replacement Replace pick roller assembly and snap into place. Refer to “Pick Motor and Pick Drive Gear” page 8-45 8-20 Removal and Replacement...
Page 351: Picker Crankshaft, Pick Block Assembly
Picker Crankshaft, Pick Block Assembly Push picker crankshaft (1) forward into larger slot (hard snap). Separate picker crankshaft (2) from pick block assembly (3) and slide block out of the hopper frame; then slide picker crankshaft (4) from hopper frame. Separate picker crankshaft (5) from pick roller clutch and drive pick gear.
Page 352: Transport Components
Transport Components Timing Belt EMOVAL 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).
Page 353: Belt Plate
Belt Plate Push the tab (1) on the inside of the rear of the printer to release the belt plate (2). EPLACEMENT Line up the holes with the pins and snap the tab into place. SD/CD/CE Service Manual 8-23...
Page 354: Platen Roller Assembly
Platen Roller Assembly Refer to “Ribbon Index Sensor, Ribbon Bridge” page 8-41 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 printer. Slide the platen roller assembly (4) out through the hole.
Page 355: Card Guide/Spring And Registration Drive Assembly
Card Guide/Spring and Registration Drive Assembly EMOVAL Place one hand over the card guide and spring (1a) while lifting the pulley of the registration backup roller (1b) to release. 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.
Page 356 Replacement If needed, lubricate; refer to “Lubricating the Grease Points” page 6-21. 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.
Page 357 Drive Pulleys and Idler Pulleys Remove the timing belt, refer to “Timing Belt” page 8-22 “Belt Plate” page 8-23. 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 off.
Page 358: Backup Roller, Registration Backup And Top Cleaning Rollers
Backup Roller, Registration Backup and Top Cleaning Rollers Remove the ribbon bridge (refer to “Ribbon Index Sensor, Ribbon Bridge” page 8-41) before pulling out backup roller. Push top of the spring to the side (1) and pull from the shaft (2). Push brackets from the inside of the printer (3a) while pulling up and over the locking ramp (3b);...
Page 359 EPLACEMENT Insert leading end into holes (7), make sure to replace the capstan roller sleeve (6) on the registration backup roller before installing. Place the brackets into the cutouts and slide down locking into place. Place springs onto the shafts of the brackets and slide into position. SD/CD/CE Service Manual 8-29...
Page 360: Backup Roller Springs And Brackets, Capstan Roller Sleeve
Backup Roller Springs and Brackets, Capstan Roller Sleeve Refer to the previous page for the remove and replace procedure. 8-30 Removal and Replacement...
Page 361: Belt Tensioner And Spring, Idler Pulleys
Belt Tensioner and Spring, Idler Pulleys If the release tab is engaged, lift up on it to release the tensioner. Line up the belt tensioner (1) with the cutouts in the printer, and lift out (2) of the printer. Remove the belt tensioner spring (3). The idler pulleys (4) come right off.
Page 362: Cam Slide
Cam Slide “Other Troubleshooting Procedures” page 5-16 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 (4). EPLACEMENT Rotate the cam into position so that the tangs are in position and slip the cam slide into place.
Page 363: Cam, Cam Shaft, Cam Gear, Cam Idler Gear
Cam, Cam Shaft, Cam Gear, 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 cam.
Page 364: 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. EPLACEMENT Reconnect the cables to the board.
Page 365: Thermal Printhead (Tph)
Thermal Printhead (TPH) Refer To “Cable Routing” page 8-6 for connection information. 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. SD/CD/CE Service Manual 8-35...
Page 366 EPLACEMENT 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. 8-36 Removal and Replacement...
Page 367: Fan
Observe cable routing and fan orientation. The fan blows air toward the printhead. Pull up on the retaining tab (1) and slide the fan out of the frame (2). EPLACEMENT 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.
Page 368: 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.
Page 369 EPLACEMENT 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.
Page 370: Print Engine Sensors
Print Engine Sensors Head Latch Sensor Disconnect cable from J22 on the print engine board and pull on sensor (1) to remove. EPLACEMENT Press sensor into the hole in the printer. Reroute cable as indicated in “Cable Routing” page 8-6, and reconnect cable. 8-40 Removal and Replacement...
Page 371: 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 through the hole in printer. Push to release the retaining clips (2) on either side of the ribbon bridge and lift bridge (3) from the printer.
Page 372: Card Input Sensor
Card Input Sensor Remove cam slide and bracket. Refer to “Backup Roller Springs and Brackets, Capstan Roller Sleeve” page 8-30 “Belt Tensioner and Spring, Idler Pulleys” page 8-31. Disconnect cable from J18 on print engine board. Remove by pushing out of the printer from the inside. EPLACEMENT Push into place using two Torx drivers and even pressure until fully seated.
Page 373: Card Exit Sensor
Card Exit Sensor Rotate cam (1a) so that the cam slide (1b) is not in the way of the sensor, and disconnect cable from J24 of print engine board. Remove by pushing sensor (2) out of the printer from the inside. EPLACEMENT Push into place using two Torx drivers and even pressure until fully seated.
Page 374: Cam Home Sensor
Cam Home Sensor Use a flat head driver to rotate the cam motor (1a) to move the cam slide (1b) out of the way. Disconnect cable from J23 of 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.
Page 375: Print Engine Motors
Print Engine Motors Pick Motor and Pick Drive Gear Align the pick drive gear with screws (1) as shown. Disconnect the connector from J19 of print engine board. Remove two T6 torx screws (2) and remove the pick motor (3). EPLACEMENT Align the pick drive gear, place the motor into the hopper frame, and replace the screws.
Page 376: 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.
Page 377: 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 motor and secure with the two screws. The cam drive motor assembly cable is oriented toward the rear of the printer.
Page 378: 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 print engine board. Pull the motor from the printer. EPLACEMENT Replace motor and secure with the two screws. The transport motor assembly cable is oriented toward the front of the printer.
Page 379: Circuit Board Components
Circuit Board Components Refer to also “Smart Card Circuit Board” page 8-60 “Duplex Circuit Board” page 8-74. Print Engine Drive Board The main board of the printer component is under the printer. It may contain daughter boards for Magnetic Stripe and/or Smart Card. Remove covers as described in “Removing Multi-Hopper Covers and Enclosure”...
Page 380 EPLACEMENT The replacement control board has a tag with an AuthKey number. Save that number. When you replace the board, you need to logon to PartnerPage, provide that number and the printer’s serial number to download a file to use to complete the board replacement as described in “Loading Settings File into Drive Board”...
Page 381: Loading Settings File Into Drive Board
Loading Settings File into Drive Board Use the following procedure to download the current settings update file from PartnerPage to use in the new main control board. Log in to www.PartnerPage.com. Hover over Services & Support on the top menu. Select Card Printers under Desktop ID Solutions.
Page 382 Enter the Auth Key from the tag on the new Board and the Serial Number of the printer (on a label attached to the side of the swingarm or from VPD). Click Submit. Click the link to download the file. Save the file on the hard disk of your PC.
Page 383: Sensor Encoder Cable Assembly (Rfid)
Sensor Encoder Cable Assembly (RFID) Note routing of cables for the RFID board (1), ribbon motor (2), fan (3), and printhead (4) from main control board. Lift the bottom left side of the RFID board (5) to lift from the standoff, and then pull the board up (6) to remove.
Page 384: Ribbon Motion Magnetic Encoder Board
Ribbon Motion Magnetic Encoder Board Disconnect cable. Push up from the bottom of the encoder (1) and pull it out of the printer. EPLACEMENT Push the encoder into place with even pressure until fully seated. Reconnect the cable. Refer to “Cable Routing”...
Page 385: Duali Daughter Board
Duali Daughter Board The Duali daughter board is for the single-wire Duali smart card. Access the Print Engine Drive Board page 8-49. Disconnect the USB cable from the board. Gently pull the connector (1) on the daughter board from the printer board. Dislodge the daughter board from the standoffs (2).
Page 386: Magnetic Stripe Option
Magnetic Stripe Option Magnetic Stripe Board ISO (IAT) and JIS (NTT) Refer to “Print Engine Drive Board” page 8-49 for how to remove the print engine board. As you remove the board from the printer, the cable connections prevent you from moving the board more than a short distance from the printer.
Page 387: Magnetic Stripe Optical Encoder And Mounting
Magnetic Stripe Optical Encoder and Mounting Loosen setscrew on collar (1) with special four-flute spline wrench. Refer to “For Magnetic Stripe Option” page 8-5. Remove two phillips screws (2) and remove optical encoder (3). Bend spring (4) forward and remove. Remove Torx screw (5) and remove encoder mounting bracket (6).
Page 388: Magnetic Stripe Rocker Assembly And Read/Write Head
Magnetic Stripe Rocker Assembly and Read/Write Head Disconnect the magnetic stripe head cable. Refer to “Magnetic Stripe Board ISO (IAT) and JIS (NTT)” page 8-56. Remove the magnetic stripe rocker assembly (1) by unsnapping from printer. Pull back on retaining clip to release and then push head (2) up from bottom to remove. EPLACEMENT Replace head and rocker assembly and reconnect cables.
Page 389: Smart Card Options
Smart Card Options Smart Card Assembly Remove the flipper assembly as described on page 8-76. Remove the smart card assembly by pulling tabs (1a) out on both sides while lifting out the smart card assembly (1b). SD/CD/CE Service Manual 8-59...
Page 390: Smart Card Circuit Board
Smart Card Circuit Board Disconnect USB (1) and power connection (2). Push tab (3a) down while lifting board (3b) out enough to release. Lift tab (4a) while lifting board (3b) again to release board. Slide board (5) out from under tab (6) and remove board. 8-60 Removal and Replacement...
Page 391: Smart Card Lid Assembly
Smart Card Lid Assembly Remove the smart card assembly as described on page 8-59. Push tabs (1a) on both sides to release catches (1b). Lift smart card lid assembly (2) out. SD/CD/CE Service Manual 8-61...
Page 392: Smart Card Contact Board
Smart Card Contact Board Disconnect the assembly by pushing the contact mount back and holding it steady with left index finger (1) while pushing down and out at 2a and 2b with your thumbs. Separate from contact connection (3). 8-62 Removal and Replacement...
Page 393: Smart Card Station Spring
Smart Card Station Spring Remove smart card lid assembly as described on page 8-60. Unhook spring (1) and lift from smart card base assembly. SD/CD/CE Service Manual 8-63...
Page 394: Smart Card Gate Roller
Smart Card Gate Roller Push smart card guide (1a) back while pushing tab (1b) out and lifting contact mount (1c) up to release. Slide contact mount (2) back and out on the slots and pegs (3). Remove connection (4) from contact guide. Remove gate roller (5) from guide.
Page 395: Smart Card Cable Connector
Smart Card Cable Connector Maneuver plug (1) up through the opening in the smart card base lid (2) when it is not necessary to remove the reader board (3). SD/CD/CE Service Manual 8-65...
Page 396: Card Guide
Card Guide Slide card guide (1) forward until it stops, and lift peg (2) from keyway slot. 8-66 Removal and Replacement...
Page 397: Dual Reader Board (Contact/Contactless)
Dual 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 all new adhesive pads when reassembling.
Page 398: I-Class Read/Write Board
i-Class Read/Write Board Place a flat screwdriver between the base (1) and reader board, and then carefully twist the screwdriver to release adhesive pads (2). Lift reader (3) off. Be sure to use all new adhesive pads when reassembling. Place them near the center of the board.
Page 399: Duali Single Wire Smartcard
Duali Single Wire Smartcard Place a flat screwdriver between the base (1) and reader board, and then carefully twist the screwdriver to release adhesive pads (2). Lift reader (3) off. Be sure to use all new adhesive pads when reassembling. Place them near the center of the board.
Page 400 Duplex Installation 8-70 Removal and Replacement...
Page 401: Duplex Frame
Transfer (Duplex) Components Duplex Frame Disconnect cables from tie downs as indicated on page 8-9. Disconnect cables (1) at J13 and J29 on print engine board. Pull out tabs (2a) on both sides while sliding the frame (2b) away from the main frame. Pull frame (3) away and up to remove.
Page 402: Duplex Home Sensor
Duplex Home Sensor Disconnect sensor cable (J5) from duplex circuit board. Push tab (1a) out while lifting duplex circuit board (1b) to clear tab. Slide board (2) out from under tab (3) to remove. Remove flipper home sensor (4). 8-72 Removal and Replacement...
Page 403: Transfer (Duplex) Transport And Flipper Motors
Transfer (Duplex) Transport and Flipper Motors Disconnect motor cable(s) from connector on duplex board: J7 for Transport or J3 for Flipper. Push tab (1a) in while rotating motor (1b) in direction shown. Remove motor (2). SD/CD/CE Service Manual 8-73...
Page 404: Duplex Circuit Board
Duplex Circuit Board Disconnect cables from duplex circuit board. Feed cable through the frame as indicated in “Cable Routing” page 8-6. Push tab (1a) out while lifting duplex circuit board (1b) to clear tab. Slide board (2) out from under tab (3) to remove. 8-74 Removal and Replacement...
Page 405: Duplex Backup Idler Roller, Springs
Duplex Backup Idler Roller, Springs Push spring (1a) out from under tab (1b) to release spring. Remove spring (2). Repeat to remove other spring, and remove both backup idler rollers (3). SD/CD/CE Service Manual 8-75...
Page 406: Flipper Assembly And Transport Gear
Flipper Assembly and Transport Gear Hold flipper assembly (1a) firmly while separating it from frame (1b) until mis-aligning the shaft (1c). Lift flipper assembly (2) by maneuvering it up through the frame assembly. If gear (3) did not fall out, remove it. 8-76 Removal and Replacement...
Page 407: Duplex Drive Rollers And Body Gear
Duplex Drive Rollers and Body Gear Remove flipper assembly as described on page 8-76. Push drive roller (1) into larger hole until you hear a hard snap. Remove drive roller (2) from frame (3). Repeat for other drive roller. SD/CD/CE Service Manual 8-77...
Page 408: Lock Components
Lock Components The CE series system printer has mechanical and electrical locks for security. This section provides removal procedures for the related components in the printer unit. Refer to the Embosser Service Manual for procedures for removing lock components in the embosser. 8-78 Removal and Replacement...
Page 409: Lock Assembly
Lock Assembly The lock assembly is located on the side of the printer opposite the door. It may need to be removed for servicing its components. EMOVAL Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on...
Page 410: Lock Motor
Lock Motor The lock motor is located in the lock assembly. EMOVAL Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on page 7-11. Remove the printer with hopper(s) from the base as described on page 7-15.
Page 411: Eccentric Gear, Swingarm Latch, And Springs
Eccentric Gear, Swingarm Latch, and Springs EMOVAL Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on page 7-11. Remove the printer with hopper(s) from the base as described on page 7-15.
Page 412: Lock Control Board
Lock Control Board Use proper grounding techniques when working with circuit boards. ESD! EMOVAL Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on page 7-11.
Page 413 EPLACEMENT Refer to page 1-43 for cable connections.  Refer to the following figures for cable routing.  SD/CD/CE Service Manual 8-83...
Page 414: Lock Home Sensor
Lock Home Sensor This sensor detects when the printer cover is locked. EMOVAL Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on page 7-11.
Page 415: Single Hopper Open Sensor
Single Hopper Open Sensor This sensor is on the back of the lock bracket in a system with a single card hopper unit. EMOVAL Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on...
Page 416 8-86 Removal and Replacement...
Page 417: Chapter 9: Multi-Hopper Removal And Replacement
Chapter 9: Multi-Hopper Removal and Replacement This chapter provides removal and replacement instructions for the multi-hopper and its components. Multi-Hopper Unit............. 9-2 General Notes .
Page 418: Multi-Hopper Unit
Multi-Hopper Unit This procedure removes the entire multi-hopper unit for FRU replacement or for repair of its components. General Notes If multi-hoppers are disassembled, always return them to the same location as their cable  lengths vary. It is easiest to install the 1 and 4 hopper stack first and to remove hopper stack 3 and 6 first. ...
Page 419 Separate the hopper unit from the printer unit by lifting up on the hopper until it is freed from the hooks on the printer. Inside wall of the multi-hopper unit. Disconnect the following cables: (Option) On/off for touch screen (J39) from the corner of the main printer board. ...
Page 420 Printer LCD panel displays (J15) from the main printer board. Reach inside the printer and  lift the flap to release the cable. Note position of blue side for replacement. Opened Flap Closed Flap Blue Side (Option) Black touch screen connector from main printer board (J45). (Reach inside the ...
Page 421: Assemblies In Multi-Hopper Unit
Assemblies in Multi-Hopper Unit The major assemblies in the hopper unit are depicted in the following figure. The touch screen is optional. Card Shuttle Hopper Touch Screen Tower Assembly XY Drive Assembly Six Card Multi-Hopper LCD Panel SD/CD/CE Service Manual...
Page 422 Shuttle Assembly and Components The shuttle is the assembly that accepts cards from the appropriate hoppers and delivers them to the printer. Removal Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on...
Page 423 Remove the drive gear by squeezing the side tabs to the center and pulling the gear straight off the shuttle. (Note that spine side of gear faces away from the shuttle during replacement.) Squeeze tabs together to free gear. Remove the bottom cover that protects the shuttle board by pressing in on the A side and pulling it straight down.
Page 424 Disconnect the data cable from the shuttle board by lifting the flap on the board to free it and pulling it straight out. (Note that the black side is up for replacement.) Remove the clamp from the Y-plane belt by placing the shuttle so that the single T10 Torx screw is visible through the opening in the side of the tower.
Page 425 Using the T10 driver, remove the three screws that secure the shuttle to the tower vertical rail slides. Two are accessible through the hole from which the motor pulley was removed. The other is under the shuttle by the auxiliary board. Catch the shuttle, which is now free. Screw Access Holes.
Page 426: Static Brushes In Shuttle
Static Brushes in Shuttle The static brushes in the shuttle assembly are attached with adhesive. Just pull them off the assembly and attach new ones at the same location. Rollers in Shuttle The shuttle has three types of rollers: a transport roller, two drive rollers, and two pressure rollers.
Page 427 Drive Roller Removal The drive rollers can be removed without separating the shuttle from the XY transport. Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on page 7-11.
Page 428 Transport Roller Removal Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on page 7-11. Remove the printer/hopper assembly from the base and separate the two units as described starting on page 9-2.
Page 429: Xy Transport And Tower Assembly
XY Transport and Tower Assembly This procedure removes the entire XY transport assembly with shuttle and tower from the multi- hopper. Removal Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on page...
Page 430 Remove 2 screws (T20) from each rail to free the XY transport assembly. Avoiding the X belt and freeing from the pair of retainers, lift the transport out of the hopper unit. To remove the tower assembly from the vehicle, disconnect the remaining cables from the elevator board, remove two screws, and slide the tower out from under the pair of retainers.
Page 431: Lcd Panel
LCD Panel The LCD panel is located below hopper 2 in the multi-hopper. (Refer to page 8-16 in the previous chapter for LCD panel removal in a single hopper printer.) Removal Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on...
Page 432: Hoppers
Hoppers The six hoppers are very similar, but the upper ones have longer cables. They must be returned to the correct locations. It is easiest to install the 1 and 4 stack first and to remove stack 3 and 6 first. Note cable routing as you remove components.
Page 433 Disconnect motor and sensor cables for the stack from the main hopper board. Remove the stack by depressing two tabs on its back (about a third of the way up from the bottom of the stack) and lifting it off the four clips. Depress tabs here.
Page 434 Separate the four major components in the stack as needed. Press in on the tab and lift the top mount. 1. Push in here. 2. Lift. 4. Push in here. 3. Slide out. Slide the upper hopper out of the stack. Push in on the tab to release the hopper holder.
Page 435: Hopper Picker Crankshaft And Pick Block
Hopper Picker Crankshaft and Pick Block Removal Remove the stack of hoppers and separate the hoppers as described on page 9-16. On the side of the hopper without gears, snap the end of the crankshaft into the larger hole. Snap the pick block off the crankshaft and pull out the crankshaft with its gear and spring. To remove the pick block, slide it forward.
Page 436 Grasp the spring as you pull the gate from the hopper. Lift the spring off the tab. Lift off tab to release both sides. Hold spring as you pull away the bracket. After the pick gate is out of the way, remove the pick roller as follows: Snap up both ends of the pick roller to move it out of the smaller opening.
Page 437: Hopper Motors
Hopper Motors Shuttle Horizontal (X) Motor and Belt Removal Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on page 7-11. Separate the hopper unit from the printer unit as described on page 9-2.
Page 438: Shuttle Vertical (Y) Motor And Belt
Shuttle Vertical (Y) Motor and Belt Removal Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on page 7-11. Separate the hopper unit from the printer unit as described on page 9-2.
Page 439: Shuttle Card Transport Motor
Shuttle Card Transport Motor The shuttle card transport motor drives the rollers that move the card through the shuttle to the printer. Removal Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on...
Page 440 From outside of shuttle, slightly depress the motor retaining tab, rotate the motor 1/8th turn counterclockwise to free it, and push it in though the hole. 2. Rotate motor. 3. Push in through opening. 1. Press in here. Replacement Note Route motor cable as indicated in these figures.
Page 441: Hopper # Pick Motors And Gears
Hopper # Pick Motors and Gears Each hopper in a multi-hopper has a motor that drives the card from the stack to the shuttle. Removal Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on...
Page 442: Sensors
Replacement Note Be sure to reroute the cabling as it was. Sensors Card Present Hopper # Each hopper in a multi-hopper has a sensor that detects the presence of at least one card in the hopper. Removal Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers...
Page 443: Input Hopper Door
Input Hopper Door This sensor is on the multi-hopper assembly near hopper 1. It detects when the door is opened. Removal Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on page 7-11.
Page 444: Shuttle Vertical (Y) Home/Up Sensors
Shuttle Vertical (Y) Home/Up Sensors The shuttle home and shuttle up sensors on the elevator arm detect when the sensor is at its lowest and highest points for getting ready to accept cards from the upper or lower hoppers. Removal Power down the printer and disconnect the power.
Page 445: Shuttle Horizontal (X) Home/Right Sensors
Shuttle Horizontal (X) Home/Right Sensors The X sensors detect when the elevator assembly is at home (near hoppers 1 and 4) or to the right (near hoppers 3 and 6). Removal Power down the printer and remove power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on...
Page 446: Shuttle Card Entry/Exit Sensors
Shuttle Card Entry/Exit Sensors These sensors detect when a card enters the shuttle from a hopper or exits to the printer. Removal Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer and hopper covers as described on page...
Page 447: Circuit Boards
Circuit Boards Multi-Hopper Main Board The main hopper board is located under the multi-hopper unit and faces down. Removal Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on page 7-11.
Page 448: Elevator (X, Aux 1) Board
Elevator (X, Aux 1) Board The elevator board is located in the bottom of the elevator assembly facing up. Removal Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on page 7-11.
Page 449: Shuttle (Y, Aux 2) Board
Shuttle (Y, Aux 2) Board The shuttle board is located under the shuttle assembly and faces down. Removal Power down the printer and disconnect the power. Separate the printer from the embosser as described on page 7-9, and remove printer covers as described on page 7-11.
Page 450 Disconnect the data cable from the auxiliary board by lifting the flap on the board to free it and pulling it straight out. (Note that the black side is up for replacement.) Disconnect the other cables to free the board. Replacement Notes Place the new board in position on the underside of the shuttle and reconnect all cables.
Page 451: Alarm Option
Alarm Option The tilt sensor on the floor of the printer base detects when someone has lifted the printer. The cover alarm sensor detects when someone opens the cover. The three small circuit boards used for an alarm system are all the same part number. Note the wiring diagram in the following figure.
Page 452: Tilt Sensor
Tilt Sensor Removal Turn off the alarm, power down the printer, and remove power. Separate the printer from the embosser as described on page 7-9. Remove the printer and hopper(s) from the base as described on page 7-15. Push down on the tab and rotate the sensor clockwise to free it from the base. Rotate from bar.
Page 453: Cover Alarm Sensor
Cover Alarm Sensor The cover alarm sensor needs a magnet over it to defeat it when you are working on a live machine. Removal Turn off the alarm, power down the printer, and remove power. Separate the printer from the embosser as described on page 7-9.
Page 454: Alarm Board In Multi-Hopper
Alarm Board in Multi-Hopper When the cover of the multi-hopper is removed, this small circuit board detects the change and trips the external alarm. Removal Turn off the alarm, power down the printer, and remove power. Separate the printer from the embosser as described on page 7-9.
Page 455: Touch Screen Option
Touch Screen Option Caution: Pay close attention to the power connector on the touch screen board. It must be inserted in only one way. Note the three keys on the connector. Connecting it in incorrectly destroys the main printer board and corrupts the memory card. Removal Power down the printer and remove covers as described on page...
Page 456 Replacement Notes Reattach the cables before placing the cover over the touch screen unit.  Reattach the tabs on the front of the printer first and then the rear tabs.  Caution: When you reattach the power cable to the touch screen board, do not force the connector.
Page 457: Appendix A: Kiosk Option
Appendix A: Kiosk Option The kiosk option allows for the delivery of the card through the rear of the printer by the addition of an rear card port. Kiosk Card Output Location ........... . A-2 Single Hopper Version .
Page 458: Kiosk Card Output Location
Kiosk Card Output Location The physical card output location of the exit transport is shown below. Single Hopper Version...
Page 459 SD/CD/CE Service Manual...
Page 460: Multi-Hopper Version
Multi-Hopper Version The physical card output location of the exit transport is shown below for the multi- hopper version.
Page 461 SD/CD/CE Service Manual...
Page 462: Card Guide Integration
Card Guide Integration System integrators may have to add a card guide onto the exit transport for increased card transfer reliability, depending on the chosen distance between the exit transport and the smart card reader or other external device. The recommended distance between external reader and printer is shown below.
Page 463: Exit Transport Components
Exit Transport Components The exit transport assembly contains sensors and a motor that are required to track and drive card movement through the assembly. Exit Transport Motor Exit Transport 2 Sensor Exit Transport 1 Sensor SD/CD/CE Service Manual...
Page 464: Sensors
Sensors The sensors in the exit transport assembly are listed in the table below. Name Function Jumper On Rear Card Port Assembly: Transport Board: Rear Card Port 1 Detects a card blocking the sensor. Rear Card Port 2 Detects a card blocking the sensor. Motors The motor that is used in the exit transport assembly is listed in the table below.
Page 465: Kiosk Software Adjustments In Printer Manager
Kiosk Software Adjustments in Printer Manager Operational adjustments can be made to the kiosk option using Printer Manager. Troubleshooting Selections for Kiosk New Printer Manager selections have been added to the troubleshooting menu to test exit transport component operation. Exit Transport Sensors The Troubleshooting >...
Page 466: Printer Offsets For Kiosk
Printer Offsets for Kiosk New Printer Manager settings have been added to make software adjustments in kiosk operation. AutoPowerOnBoard The CD800 with the kiosk option includes a circuit board that powers the module on without user intervention when the power cord is plugged in. Symptoms The AutoPowerOnBoard feature must be enabled in order for the firmware to suppress error messages upon startup, thus avoiding user intervention.
Page 467: Rearejectmanualtimeout
RearEjectManualTimeout When the issued card is to be presented to a user, the ejecting card extends partway out the rear card port and be held by printer. Symptoms The card is held at the exit for a settable amount of time. If the user doesn't take the issued card within the wait time, the card is retracted and rejected to the indicated hopper.
Page 468: Rearejectretrycount
RearEjectRetryCount When the RearEjectManualTimeout is set to zero, the printer ejects the card using the rear card port without stopping. Symptoms The printer try/retry to eject the card through the rear card port to the external reader. If an attempt to eject the card fails (i.e., if the card does not clear the rear card port), the printer retracts the card into the flipper and then attempt to eject it again.
Page 469: Kiosk Test Card
Kiosk Test Card To run a test card from Printer Manager to test kiosk operation, select TroubleShooting > Test Card. The Input Hopper Number and the Output Hopper Number each include the option RearException for the rear card port. An example of running a kiosk test card would include setting both the Input Hopper Number and the Output Hopper Number to RearException, check the box for Monochrome on Card Front, and click Run.
Page 470: Kiosk Messages And Conditions
Kiosk Messages and Conditions The kiosk option has a unique message that can display on the printer LCD panel. Color Number LCD Message User LED Ribbon LED Card LED Sound Card not Rear Ejected Amber Alert Responding to Messages The following procedures can be used to clear messages and conditions. 246: Card not Rear Ejected The card failed to eject from the rear card port and has been rejected.
Page 471: Kiosk Option Remove And Replace
Kiosk Option Remove and Replace The kiosk option allows for the delivery of the card though the rear of the printer. Removal and Replacement Remove the printer covers as described in “Removing Covers” page 7-1. Remove the exit transport assembly from the printer. SD/CD/CE Service Manual A-15...
Page 472 Pull out the two retaining tabs (a) and remove the kiosk power board (b). A-16...
Page 473 Snap out and remove the two pressure rollers (c). Pry out the main gear from the kiosk frame (d). The gear shaft (e) and spacer washer (f) releases with the main gear. SD/CD/CE Service Manual A-17...
Page 474 Snap out the drive rollers (g) and remove them from the kiosk frame (h). Remove the two exit sensors (i). The sensors are pressure fit. A-18...
Page 475: Printer Remove And Replace
Printer Remove and Replace Power Switch Board Systems with the kiosk option have a power switch board added that restarts the printer in the event of a power failure. The power button on the display panel is not to be used to turn the system off. If the power button is held to turn power off the unit may not restart properly.
Page 476 A-20...

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