Datacard CD Series Card Printers: Service Manual

Datacard® CD Series Card Printers
Service Manual
March 2011
Part No. 539944-001, Rev A

Liability Statement
Please do not attempt to operate or repair this equipment without adequate
training. Any use, operation, or repair you perform that is not in accordance with
the information contained in this documentation is at your own risk.
Proprietary Notice
All figures and information herein are the property of DataCard Corporation. All
unauthorized use and reproduction is prohibited.
Trademark Acknowledgments
Datacard is a registered trademark and service mark of DataCard Corporation in
the United States and other countries.
Windows and Internet Explorer are registered trademarks of Microsoft

Corporation.
Firefox is a registered trademark of Mozilla.
All other product names are the property of their respective owners.
Datacard Group
11111 Bren Road West
Minnetonka, MN 55343-9015
Phone: 952-933-1223
Fax: 952-933-7971
www.datacard.com
© 2011 DataCard Corporation. All rights reserved.

Printed in the United States of America.
ii
Contents
Chapter 1: Introduction __________________________________________ 1-1
About This Manual ____________________________________________________ 1-3
Intended Audience _______________________________________________ 1-3
Symbol Conventions_______________________________________________ 1-3
Precautions___________________________________________________________ 1-3
Introduction to Printers ________________________________________________ 1-4
Simplex Printer ____________________________________________________ 1-4
Duplex Printer _____________________________________________________ 1-5
Functional Block Diagrams ____________________________________________ 1-6
Simplex Print Engine _______________________________________________ 1-6
Duplex Print Engine ________________________________________________ 1-7
Basic Integrator Smart Card________________________________________ 1-8
SCM Dual Smart Card _____________________________________________ 1-9
Duplex Module___________________________________________________ 1-10
Printer Components __________________________________________________ 1-11
Sensors __________________________________________________________ 1-11
Motors ___________________________________________________________ 1-12
Circuit Boards ____________________________________________________ 1-13
LCD Display _________________________________________________________ 1-14
Status Lights______________________________________________________ 1-15
LCD Menu Overview _____________________________________________ 1-16
Printer Manager _____________________________________________________ 1-18
Zero Configuration Networking____________________________________ 1-18
Connecting to Printer Manager ___________________________________ 1-18
Ethernet Connection _________________________________________ 1-19
USB Connection ______________________________________________ 1-20
Using Bonjour to Connect to Printer Manager __________________ 1-21
Logging in to Printer Manager ________________________________________ 1-22
Printer Manager Language Support _______________________________ 1-22
User Access Levels _______________________________________________ 1-22
Printer Manager Passwords _______________________________________ 1-22
Printer Manager Menu Options _______________________________________ 1-23
Status____________________________________________________________ 1-23
Printer Settings ___________________________________________________ 1-24
Troubleshooting __________________________________________________ 1-27
Maintenance ____________________________________________________ 1-29
Log Out__________________________________________________________ 1-29
Printer Manager Updates _____________________________________________ 1-29
Chapter 2: Theory of Operation___________________________________ 2-1
Sequence of Operation _______________________________________________ 2-3
Power-on Initialization _____________________________________________ 2-3
1
Power Down Sequence ___________________________________________ 2-3
Default Card Production Sequence ________________________________ 2-4
Duplex Sequence _________________________________________________ 2-4
Smart Card Sequence _____________________________________________ 2-6
Card Feed____________________________________________________________ 2-7
Card Cleaning ____________________________________________________ 2-7
Acceptable Card Thickness and Types _____________________________ 2-7
Card Transport ________________________________________________________ 2-8
Card Printing _________________________________________________________ 2-9
Color Printing Sequence ___________________________________________ 2-9
Monochrome Printing Sequence __________________________________ 2-10
Ribbon Advance_____________________________________________________ 2-12
Magnetic Stripe Encoding ____________________________________________ 2-14
Magnetic Stripe Write Operation __________________________________ 2-15
Magnetic Stripe Read Operation__________________________________ 2-16
Color Management __________________________________________________ 2-17
Overview ________________________________________________________ 2-17
Color Variations __________________________________________________ 2-17
Example _________________________________________________________ 2-18
Color Variation Factors ___________________________________________ 2-19
What You See Is Not What You Get________________________________ 2-19
Monitor Calibration_______________________________________________ 2-20
Magnetic Cards _____________________________________________________ 2-21
Magnetic Data Principles _________________________________________ 2-21
Magnetism ___________________________________________________ 2-21
Magnetic Media _____________________________________________ 2-22
Electrical Current and Magnetism _____________________________ 2-22
Writing Data__________________________________________________ 2-22
Reading Data ________________________________________________ 2-23
Magnetic Data _______________________________________________ 2-24
Encoding Format_________________________________________________ 2-25
Bit Density ____________________________________________________ 2-25
Word Length _________________________________________________ 2-25
Record Length _______________________________________________ 2-26
Parity Check _________________________________________________ 2-26
Data String ___________________________________________________ 2-26
Leading/Trailing Clock Pulses __________________________________ 2-26
Specific Data_________________________________________________ 2-27
Start Sentinel/End Sentinel_____________________________________ 2-27
Longitudinal Redundancy Check (LRC) ________________________ 2-27
Magnetic Stripe Primary Data Standards ______________________________ 2-28
ISO/IEC 7811 (Parts 2 and 6)_______________________________________ 2-28
AAMVA DL/ID-2000 _______________________________________________ 2-28
Saflok, Ving and Timelox __________________________________________ 2-28
Multiple Record Format (SDS) _____________________________________ 2-29
2
JIS X 6302 (Type I and Type II Cards) _______________________________ 2-29
Magnetic Media Locations _______________________________________ 2-30
Data Track Locations _____________________________________________ 2-31
Summary of Specifications ________________________________________ 2-32
7-bit Alphanumeric Character Set as Defined by ISO/IEC 7811 __ 2-33
5-bit Numeric Character Set as Defined by ISO/IEC 7811 ________ 2-34
Smart Card Technology ______________________________________________ 2-35
Contact Smart Cards _____________________________________________ 2-36
Contactless Smart Cards _________________________________________ 2-37
Communication ______________________________________________ 2-38
Signal Modulation ____________________________________________ 2-38
Signal Modulation Summary Diagram __________________________ 2-39
Reader to Card Communication ______________________________ 2-40
Card to Reader Communication ______________________________ 2-40
Chapter 3: Adjustments __________________________________________ 3-1
Factory and Power-On Settings ________________________________________ 3-2
Viewing Printer Status _________________________________________________ 3-2
Viewing and Changing Printer Settings _________________________________ 3-2
Communication __________________________________________________ 3-2
Activity Log _______________________________________________________ 3-3
Activity Log Example ______________________________________________ 3-4
Behavior __________________________________________________________ 3-6
Vital Product Data ________________________________________________ 3-6
Front Panel Options _______________________________________________ 3-7
Print Settings __________________________________________________________ 3-8
Print Misadjustment __________________________________________________ 3-23
Pick Settings _________________________________________________________ 3-23
Transport Settings ____________________________________________________ 3-27
Magnetic Stripe General Settings _____________________________________ 3-27
Magnetic Stripe Custom Track Settings ________________________________ 3-31
Magnetic Stripe Track Height Adjustment______________________________ 3-33
Start Sentinel Position Adjustment _____________________________________ 3-34
Flipper (Duplex) Adjustments _________________________________________ 3-36
Chapter 4: Troubleshooting_______________________________________ 4-1
General Notes ________________________________________________________ 4-2
General Troubleshooting Procedures___________________________________ 4-2
Non-Clearing Repetitive Messages ____________________________________ 4-2
Sensors_______________________________________________________________ 4-3
Test the Sensors ___________________________________________________ 4-3
Test the Sensors Using Continuous Update __________________________ 4-3
Determine if the Sensor Has Failed__________________________________ 4-4
Test Card _____________________________________________________________ 4-5
Troubleshooting Motors_______________________________________________ 4-10
Testing the Ribbon and Pick Motors________________________________ 4-10
Testing the Cam and Transport Motors_____________________________ 4-11
3
Other Troubleshooting Procedures ____________________________________ 4-12
Placing Cam in Uninstall Position __________________________________ 4-12
Testing the Thermal Printhead (TPH) Fan ___________________________ 4-12
Diagnosing the Ribbon RFID Antenna______________________________ 4-12
SSA Test__________________________________________________________ 4-12
Testing Smart Cards __________________________________________________ 4-13
Dual Contact/Contactless ________________________________________ 4-13
HID iClass Reader/Writer __________________________________________ 4-16
Basic Smart Card Integrator_______________________________________ 4-18
Performance Problems _______________________________________________ 4-19
Printer Initialization Errors __________________________________________ 4-19
Card Jams at Card Input _________________________________________ 4-20
Card Stalls at Output Stacker _____________________________________ 4-20
Card Jams in Printing Area ________________________________________ 4-21
Ribbon Break Errors _______________________________________________ 4-21
Error Codes __________________________________________________________ 4-22
General Notes ___________________________________________________ 4-22
Lost or Jammed Cards____________________________________________ 4-22
Driver Errors ______________________________________________________ 4-23
Printer Errors _____________________________________________________ 4-24
Print Misadjustment _______________________________________________ 4-27
Chapter 5: Routine Maintenance _________________________________ 5-1
Required Tools and Supplies ___________________________________________ 5-2
For Remove and Replace Procedures ______________________________ 5-2
For Magnetic Stripe Option ________________________________________ 5-3
For Smart Card Option_____________________________________________ 5-3
Avoiding Electrostatic Discharge_______________________________________ 5-4
Screw Torque Specifications ___________________________________________ 5-5
Preventive Maintenance Procedures ___________________________________ 5-6
Mechanical Inspection ____________________________________________ 5-6
Cleaning the Interior of the Printer _________________________________ 5-12
Lubricating the Grease Points _____________________________________ 5-12
Lubricating the Magnetic Stripe Assembly _________________________ 5-16
Cleaning the Rollers ______________________________________________ 5-17
Maintaining the Smart Card Module ______________________________ 5-19
Visual Inspection for Card Quality _________________________________ 5-20
Maintaining the Magnetic Stripe Module __________________________ 5-20
Operator Maintenance_______________________________________________ 5-21
Cleaning the Thermal Printhead (TPH) _____________________________ 5-21
Using the Cleaning Card__________________________________________ 5-21
Updating Printer Settings______________________________________________ 5-23
Replacing the Print Engine Drive Board ________________________________ 5-25
Downloading Settings File for Board _______________________________ 5-25
Updating Settings ________________________________________________ 5-26
Enabling the Proprietary Magnetic Stripe Option _______________________ 5-27
4
Downloading Settings File for Magnetic Stripe Option ______________ 5-27
Updating Settings ________________________________________________ 5-28
Verifying Proprietary Magnetic Stripe Option _______________________ 5-28
Chapter 6: Removal and Replacement ___________________________ 6-1
Introduction to this Chapter____________________________________________ 6-3
General Notes ____________________________________________________ 6-3
Required Tools ____________________________________________________ 6-3
Safety ____________________________________________________________ 6-3
Symbols __________________________________________________________ 6-3
Printer Components _______________________________________________ 6-4
Cable Routing ____________________________________________________ 6-4
Transport Cables_______________________________________________ 6-4
Smart Card and Duplex Cables ________________________________ 6-5
Swingarm Cable Routing_______________________________________ 6-6
Freeing Cables from Clamps _______________________________________ 6-7
Functional Block Diagrams _________________________________________ 6-7
Exterior Components __________________________________________________ 6-8
Ribbon Cartridge__________________________________________________ 6-8
Ribbon Cartridge Lid ______________________________________________ 6-9
Swingarm Lid and Enclosure Flap__________________________________ 6-11
Enclosures _______________________________________________________ 6-12
Card Tray____________________________________________________________ 6-16
100-Card Input Lid and Cover_____________________________________ 6-16
Tray Assembly ____________________________________________________ 6-17
Front Bezel, LCD Interface Panel, and 25-Card Output _____________ 6-18
LCD Interface Panel Routing ______________________________________ 6-19
Simplex Base _____________________________________________________ 6-20
Tray _________________________________________________________________ 6-21
Pick Gate and Pick Gate Spring___________________________________ 6-21
Pick Roller Assembly ______________________________________________ 6-22
Picker Crankshaft, Pick Block Assembly ____________________________ 6-23
Transport Components _______________________________________________ 6-24
Timing Belt _______________________________________________________ 6-24
Belt Plate ________________________________________________________ 6-25
Platen Roller Assembly ____________________________________________ 6-26
Card Guide/Spring and Registration Drive Assembly________________ 6-27
Drive Pulleys and Idler Pulleys _____________________________________ 6-29
Backup Roller, Registration Backup and Top Cleaning Rollers _______ 6-30
Backup Roller Springs and Brackets, Capstan Roller Sleeve _________ 6-31
Belt Tensioner and Spring, Idler Pulleys _____________________________ 6-32
Cam Slide _______________________________________________________ 6-33
Cam, Cam Shaft, Cam Gear, Cam Idler Gear _____________________ 6-34
Swingarm Components ______________________________________________ 6-35
Ferrite Bead______________________________________________________ 6-35
Thermal Printhead (TPH) __________________________________________ 6-36
5
Fan ______________________________________________________________ 6-37
Swingarm, Torsion Spring, Damper_________________________________ 6-38
Print Engine Sensors __________________________________________________ 6-41
Head Latch Sensor _______________________________________________ 6-41
Ribbon Index Sensor, Ribbon Bridge _______________________________ 6-42
Card Input Sensor ________________________________________________ 6-43
Card Exit Sensor __________________________________________________ 6-44
Cam Home Sensor _______________________________________________ 6-45
Print Engine Motors ___________________________________________________ 6-46
Pick Motor and Pick Drive Gear ___________________________________ 6-46
Ribbon Motor, Ribbon Drive Gear _________________________________ 6-47
Cam Drive Motor Assembly _______________________________________ 6-48
Transport Motor Assembly_________________________________________ 6-49
Circuit Board Components ___________________________________________ 6-50
Print Engine Drive Board __________________________________________ 6-50
Sensor Encoder Cable Assembly (RFID) ____________________________ 6-52
Ribbon Motion Magnetic Encoder Board __________________________ 6-53
Magnetic Stripe Option ______________________________________________ 6-54
Magstripe Board ISO (IAT) and JIS (NTT) ____________________________ 6-54
Magstripe Optical Encoder and Mounting Bracket _________________ 6-55
Magstripe Rocker Assembly and Read/Write Head_________________ 6-56
Smart Card Options __________________________________________________ 6-57
Smart Card Assembly_____________________________________________ 6-57
Smart Card Circuit Board _________________________________________ 6-58
Smart Card Lid Assembly _________________________________________ 6-59
Smart Card Contact Board _______________________________________ 6-60
Smart Card Station Spring_________________________________________ 6-61
Smart Card Gate Roller ___________________________________________ 6-62
Smart Card Cable Connector_____________________________________ 6-63
Card Guide ______________________________________________________ 6-64
Dual Reader Board (Contact/Contactless) ________________________ 6-65
i-Class Read/Write Board _________________________________________ 6-66
Duplex Components _________________________________________________ 6-67
Duplex Frame ____________________________________________________ 6-67
Duplex Home Sensor _____________________________________________ 6-68
Duplex Transport and Flipper Motors_______________________________ 6-69
Duplex Circuit Board _____________________________________________ 6-70
Duplex Backup Idler Roller, Springs ________________________________ 6-71
Flipper Assembly and Transport Gear ______________________________ 6-72
Duplex Drive Rollers and Body Gear _______________________________ 6-73
6
Revision Log
Datacard CD Series Card Printers Service Manual
Revision Date Description of Changes
A March 2011 First release of this manual.
Regulatory Compliance
Notice for USA (FCC Notice)
This equipment generates, uses, and can radiate radio frequency energy. If it is
not installed and used in accordance with this instruction manual, it may interfere
with radio communications. This equipment has been tested and found to be
within the limits for Class A computing devices, pursuant to Title 47 CFR Part 15
Subpart B of FCC rules, designed to provide reasonable protection against radio
interference in a commercial environment. Operation of this equipment in a
residential environment may possibly cause interference. In the event of
interference, the users, at their own expense, will be required to take whatever
measures are necessary to correct the problem.
Notice for Canada

This digital apparatus does not exceed the Class A limits for radio noise for
digital apparatus set out in the Radio Interference Regulations of the Canadian
Department of Communications. The term “IC:” before the equipment
certification number only signifies that the Industry Canada technical
specifications were met.
Le présent appareil numérique n'émet pas de bruits radioélectriques dépassant

les limites applicables aux appareils numériques de la classe A prescrites dans le
Règlement sur le brouillage radioélectrique édicté par le ministère des
Communications du Canada.
Safety
All Datacard products are built to strict safety and reliability specifications in
accordance with UL60950-1 and CUL requirements; therefore, safety issues
pertaining to operation and repair of Datacard equipment are primarily
environmental and human interface.
The following basic safety tips are given to ensure safe installation, operation, and
maintenance of Datacard equipment and are not to be considered as
comprehensive on matters of safety. For more safety information refer to
“Precautions” on page 1-3, and “Avoiding Electrostatic Discharge” on page 5-4.
7
Safe Environment
• Connect equipment to a grounded facility power source. Do not defeat or
bypass the ground lead.
• Place the equipment on a stable surface, and ensure that the floors in the work
area are dry and non-slip. Insulated rubber floor mats are preferred.
• Know the location of equipment branch circuit interrupters or circuit breakers

and how to turn them on and off in case of emergency.
• Know the location of fire extinguishers and how to use them. Use only ABC
type extinguishers on electrical fires.
• Know local procedures for first aid and emergency assistance at the customer
facility.
• Use adequate lighting at the equipment.
• Maintain the recommended range of temperature and humidity in equipment

area.
• Do not use this product in an environment containing volatile or flammable

compounds.
Safe Human Interface

• Use proper lifting techniques when moving or installing the equipment.
• Use standard electrostatic discharge (ESD) precautions when working on or

near electrical circuits.
• Do not defeat or disconnect safety interlocks on covers.

Warning: To avoid a possible electric shock, always unplug the system before
servicing.
8
Chapter 1: Introduction
This chapter provides an introduction to card printer components

and the Printer Manager application.
About This Manual ___________________________________________________ 1-3

Intended Audience _______________________________________________ 1-3
Symbol Conventions _______________________________________________ 1-3
Precautions __________________________________________________________ 1-3
Introduction to Printers________________________________________________ 1-4
Simplex Printer_____________________________________________________ 1-4
Duplex Printer _____________________________________________________ 1-5
Functional Block Diagrams ___________________________________________ 1-6
Simplex Print Engine _______________________________________________ 1-6
Duplex Print Engine ________________________________________________ 1-7
Basic Integrator Smart Card ________________________________________ 1-8
SCM Dual Smart Card _____________________________________________ 1-9
Duplex Module ___________________________________________________ 1-10
Printer Components _________________________________________________ 1-11
Sensors___________________________________________________________ 1-11
Motors ___________________________________________________________ 1-12
Circuit Boards ____________________________________________________ 1-13
LCD Display _________________________________________________________ 1-14
Status Lights ______________________________________________________ 1-15
LCD Menu Overview______________________________________________ 1-16
Printer Manager _____________________________________________________ 1-18
Zero Configuration Networking ____________________________________ 1-18
Connecting to Printer Manager ___________________________________ 1-18
Ethernet Connection __________________________________________ 1-19
USB Connection ______________________________________________ 1-20
Using Bonjour to Connect to Printer Manager___________________ 1-21
Logging in to Printer Manager ________________________________________ 1-22
Printer Manager Language Support _______________________________ 1-22
User Access Levels ________________________________________________ 1-22
Printer Manager Passwords________________________________________ 1-22
Printer Manager Menu Options _______________________________________ 1-23
Status ____________________________________________________________ 1-23
Printer Settings____________________________________________________ 1-24
CD Series Card Printers Service Manual 1-1

Troubleshooting __________________________________________________ 1-27
Maintenance ____________________________________________________ 1-29
Log Out__________________________________________________________ 1-29
Printer Manager Updates _____________________________________________ 1-29
1-2 Introduction
About This Manual
Intended Audience
This manual is for authorized representatives who are responsible for the
maintenance, service, and repair of the card printer. Service representatives must
complete an authorized service training course and be certified prior to servicing
the printer.
Symbol Conventions
The following symbols are used in this manual.
Designates a procedure that involves electrostatic discharge sensitive

ESD!
components. ESD procedures should be used.
Caution: Indicates a strong cautionary message to avoid serious

damage to the printer.
Warning: Indicates a strong warning message to prevent personal
injury to the technician.
Indicates a reminder message or other additional information for the
customer engineer.
Warns the technician to wear safety glasses during the procedure.
Precautions
While working with the printer, observe the following precautions:
• Remove power and unplug the system when performing maintenance
• Remove watches, jewelry, and rings before servicing equipment
• Avoid wearing loose clothing when working around moving parts
• Be aware of your surroundings when servicing the equipment
• Ensure that you are properly grounded at all times
• Wear protective eyewear when replacing parts on the system
For more safety information refer to the “Safety” section in the Revision Log and
“Avoiding Electrostatic Discharge” on page 5-4.

Introduction to Printers
Simplex Printer
The figure below shows the main parts of the standard CD800 simplex card
printer. The main features and options available for the printer are:
• Single side color and monochrome printing • 200-card input and 100-card output tray
options
• 100-card input tray • Lock option
• Output tray with 25-card capacity • Magnetic stripe options (ISO and JIS)
1-4 Introduction
Duplex Printer
The figure below shows the main parts of the CD800 duplex card printer. The
main features and options available for the printer are:
• Double side color and monochrome • 200-card input tray with card detection
printing option
• 100-card input tray • 100-card output tray option
• Output tray with 25-card capacity and • Lock option

reject tray
• Smart Card reader/writer • Magnetic stripe options (ISO and JIS)

Functional Block Diagrams
Simplex Print Engine
1-6 Introduction
Duplex Print Engine

Basic Integrator Smart Card
1-8 Introduction
SCM Dual Smart Card

Duplex Module
1-10 Introduction
Printer Components
This section describes the sensors, motors, and circuit boards in the printers.
Sensors
The sensors that may be in a card printer are listed in the following table. See
“Functional Block Diagrams” on page 1-6 for connection information.
Name Function
Card Present This optional sensor on manual input printers detects when a card is
present and ready to be picked.
Card Present This sensor in the input hopper frame detects when the card input tray is
(Hopper Empty) empty.
Card Input This wide-slot photocell detects the presence of a card entering the print
engine from the input hopper.
Ribbon Motion The sensor body is a chip that monitors the magnetic field of the magnet
on the ribbon cartridge to track the movement of the ribbon. Also see,
“Ribbon Motion Encoder Board” on page 1-13.
Ribbon Index This sensor is used to determine the position of the print ribbon panels. The
sensor bounces a beam off the reflective sticker on the printhead. When
the index mark, or K-panel, on the ribbon passes between the sensor and
the reflector, the beam is broken (not reflected). The Y, M, C, & T panels
do not interrupt the beam.
Head Latch This sensor detects when the swingarm is open.
Cam Home As the printhead cam rotates, a flag on the cam interrupts the beam of
the cam sensor. This sensor allows the printer to detect the position of the
printhead lifters, which move the printhead away from the platen roller
when no printing is occurring.
Card Exit Located just after the rear rollers on the right side of the printer, this sensor
detects the presence of a card exiting the exit rollers.
MS Encoder This encoder monitors the rotation of the idler roller in the magnetic stripe
module. It provides positional feedback to the module to ensure proper
magnetic encoding.
Flipper Home This sensor determines the rotational position of the duplex flipper using
three flags that pass through the sensor.

Name Function
Smart Card This sensor determines whether a card is present in the smart card
Registration/ module.
Position
Smart Card This switch detects a contact smart card is in position.

Contact
Motors
A printer has two 24-volt DC motors used for ribbon movement and card
picking; their speed is controlled by pulse width modulation. All other motors
are stepper motors. See “Functional Block Diagrams” on page 1-6 for connection
information.
Name Function
Pick Motor This DC motor drives the card picking mechanism.
Transport Motor This stepper motor drives the print engine.
Cam Motor This stepper motor drives the mechanism that lifts the cam rollers and
printhead.
Ribbon Motor This DC motor drives the print ribbon take-up roll.
Duplex Transport This 2-phase (4-wire), 24-volt stepper motor turns the duplex drive rollers.
Motor
Duplex Flipper This 2-phase (4-wire), 24-volt stepper motor rotates the entire flipper
Motor assembly.
TPH Fan The fan cools the thermal printhead (TPH). The airflow direction is toward
the heat sink.
1-12 Introduction
Circuit Boards
The printer has several boards that are connected to the print engine drive board.
See “Functional Block Diagrams” on page 1-6 for connection information.
Name Function
RFID Antenna Board The RFID antenna circuit board is a simple loop antenna that
communicates with the RFID chip in the ribbon supply spool.
Magnetic Stripe The circuit board controls the magnetic stripe head and provides an
Daughter Board interface for the encoder.
Ribbon Motion When the ribbon cartridge is installed in the printer the diametric
Encoder Board magnet is located next to the Ribbon Encoder board. The diametric
magnet is a specially built magnet that has its poles on opposites
halves of the round surface. As the magnet rotates, the sections of the
magnet where the two poles meet pass the chip on the encoder
board and generate pulses. An 8-bit chip monitors the magnitude of
the magnetic field to determine true position. It measures 256
interrupts per revolution.
Smart Card Daughter This circuit board provides a communication interface between the
Board application computer and the smart card module. Most of the
communication aspects and the data transfer are controlled by an
external software application that is transparent to the printer.
Duplex Board This circuit board contains two stepper motor drivers for the duplex
transport and duplex flipper motors. The sensor signal is passed
through directly from the main control board.

LCD Display
The LCD display panel shows printer status information and has menu options to
print a test card, run a cleaning card, view printer information, and configure the
printer.
The power button is an actual switch. Press it to turn on the printer. The four flat
“buttons” on the panel are not actual switches; you just pass your finger near the
buttons to activate them. They do not respond to being pushed or touched with
an object.
• Power button - Press to power on; press and hold (1 second) to power off.
• User button - Touch lightly to pause and resume printing or respond to, and
clear, error conditions. The user button is also an indicator light.
The following sections list the status indicator light conditions and the LCD
display menu information. For adjustment information see “Front Panel
Options” on page 3-7.
1-14 Introduction
Status Lights
The following table lists the status light conditions on the LCD display and
indicates what they mean.
Light Light Condition Indication
Ribbon Off Ribbon is OK.

Status
Steady Green Ribbon is low. The default is less than 10% remaining. This value
can be configured using Printer Manager. See “Front Panel
Options” on page 3-7.
Green/Amber Both green and amber lights appear during power-on

sequence.
Steady Amber Out of ribbon or ribbon is missing.
Blinking Amber Ribbon error.
Card Status Off Card supply is OK.
Steady Green Cleaning card cycle is due.

sequence.
Steady Amber Card not picked.
Blinking Amber No card in manual position or in the hopper.
User Off Printer power is off.

Button/
Status Steady Green Printer is ready.
Blinking Green Printer is busy.

sequence.
Steady Amber Printing is suspended or paused.
Blinking Amber Error condition.

LCD Menu Overview
The following is an overview of the LCD menu for the card printers. The table
below describes the items and options from the Main menu. When the option you
want appears on the screen, touch the Enter button to select.
Main Menu Option Submenu Item Option
Maintenance Cleaning Card Has options to start the card cleaning and to exit.
Test Card Has options to start printing a test card and to exit.
Exit Exit to Main menu.
Status Serial Number Displays the serial number of the card printer.
FW Revision Displays the revision number for the firmware.
Network Status The following options are available on the Network

Submenu:
Address Mode
IP Address
Subnet Mask
Gateway Address
MAC Address
Exit
USB IP Address Displays the USB IP address, if any.
Card Counters The following counters are available:

Card Count
Cycle Count
Completed Cards
Rejected Cards
Lost Cards
Exit
Ribbon Type Displays the type of ribbon being used in the printer.
Magstripe Coercivity
Exit
1-16 Introduction
Main Menu Option Submenu Item Option
Configuration LCD Backlight Sets the LCD backlight intensity.

Range: 0 to 100%
Default: 100%
DHCP/Static IP DHCP
Static IP
Apply/Restart
Exit
Network IP Address
Subnet Mask
Gateway Address
Apply/Restart
Exit
K Power -100 to 100
Magstripe Coercivity (High, Low, NTT1, NTT2, NTT3, Apply, Exit)

Exit
Menu Style: Legacy

Style: Modern
Exit

Printer Manager
Printer Manager is the printer interface that contains the card printer settings,
options, and diagnostics. The menus are used to find printer status, make
adjustments, use tests to troubleshoot, perform exercises for preventive
maintenance, and upload printer settings files.
There are three access level logins for Printer Manager: user, administrator, and
service. Menu options are appropriate for each access level.
The card printer connects to a PC or network using either a USB or an Ethernet

cable. Printer Manager is accessed via a Web browser. Supported Web browsers
include Internet Explorer v7 and 8 and Firefox v3.6.
Zero Configuration Networking

When a USB connection is used, the printer uses a USBNET port and zero
configuration networking. Essentially, this enables the printer to use Ethernet
over the USB connection.
After the USB driver has been installed, the printer will have a USB IP (Internet
Protocol) address. Additionally, because zero configuration networking enables
automatic discovery of computers, devices, and services on IP networks, a third-
party application discovery program may be used.
Bonjour is Apple’s trade name for its free implementation of discovery protocol
that can be used with Printer Manager. Bonjour can be downloaded from the
Apple Website (www.apple.com). Bonjour support and manuals are also
available from Apple.
Bonjour will display only USB-connected printers, not Ethernet.
Advantages of using this approach:
• All IP protocols are also available over USB.
• The printer can operate as a Web Server over Ethernet and USB.
• Both Ethernet and USB use the same Internet security levels.
• The USB operates as a class 2.0 device and is faster than Ethernet.
Connecting to Printer Manager

Connect to Printer Manager using either an Ethernet connection and the IP
address of the printer, or by using the USB IP address of the printer. When the
connection is established, Printer Manager operates in the same way over either
connection.
1-18 Introduction
If you are installing both the USB driver and the Ethernet driver, install the USB
driver first because the Ethernet connection takes precedence over the USB
connection.
If you install Ethernet first, you must disconnect the Ethernet cable and reboot the
printer before you can install the USB driver correctly. The USB connection will
not work when the Ethernet cable is connected.
Ethernet Connection
Follow the steps below to connect to Printer Manager using a browser and
Ethernet connection.
Make sure the printer is configured for DHCP (Dynamic Host Configuration
Protocol) as described in “LCD Menu Overview” on page 1-16.
1. Connect the card printer to the network using an Ethernet cable and turn the
printer on.
2. Use the LCD display to determine the IP address of the printer.
A. At the Ready status touch the User button once.
B. At the Suspended Menu Available status touch Enter once.
C. Touch the Down Arrow once to change the selection from Maintenance to
Status. Touch Enter once.
D. Use the Down Arrow to scroll to Network Status and touch the Enter
button.
E. Use the Down Arrow button to scroll to IP Address and touch Enter.
F. Write down the IP address.
G. Exit the Status Menu by touching the User button until Ready again
displays.
3. Using Internet Explorer or Firefox, open a browser window and enter the IP
address of the printer into the address bar (example: “http://xxx.xx.xxx.xx”)
The Printer Manager login will appear.

USB Connection
Follow the steps below to connect to Printer Manager using a browser and a USB
connection.
The USB printer driver must be installed first to obtain the USB IP address.
The USB IP address is 169.254.1.10 for the first USB printer, 169.254.1.18 for
the second, 169.254.1.26 for the third, etc. (Each final number set increments
by 8.)
1. Connect the card printer to the USB port and turn the printer on.
2. If you wish, use the LCD display to confirm the USB IP address.
A. At the Ready status touch the User button once.

B. At the Suspended Menu Available status touch Enter once.
C. Touch the Down Arrow once to change the selection from Maintenance to
Status and then touch Enter to select it.
D. Use the Down Arrow to scroll to USB IP Address and then touch Enter to
select it.
The USB IP address will be displayed as 169.254.1.10.
3. Open a browser window and enter the IP address of the printer into the
address bar (example: “http://xxx.xx.xxx.xx”)
1-20 Introduction
Using Bonjour to Connect to Printer Manager
Use the following procedure to connect Bonjour to Printer Manager.
Install Bonjour only after the USB connection has been installed. See
“Connecting to Printer Manager” on page 1-18 for more information.
1. Connect the card printer to the PC using the USB cable.
2. Install Bonjour and open the application from within your browser.
A. Open a browser window.
B. Select the card printer from the list on the left.

Logging in to Printer Manager
The initial Printer Manager screen allows the user to select a language and to log
in with a user name and password that determine access levels. Passwords may
either be blank (0 characters) or contain 4 to 32 characters. The characters allowed
are a-z, A-Z, 0-9, +, and /.
Printer Manager Language Support

When you start Printer Manager, first select the language to use from a list
offered in the login window (see sample list in previous figure).
User Access Levels

The access level determines which menu items, options, and adjustments are
available.
WebUser —Allows printing of test cards and minor adjustments.
WebAdmin —Allows an administrator to set up a test card, make minor

adjustments to the printer, configure options, and use diagnostics tools for
troubleshooting. The Administrator level has permission to install feature
upgrades on the printers.
WebService —Permits service access to all of the WebAdmin adjustments with

additional access to offset adjustments.
Printer Manager Passwords

For full service access open Printer Manager, select a language, select WebService
as your access level, and enter the service password (926918).
WebService access can change the passwords for WebService, WebAdmin, and
WebUser. WebAdmin can change only the passwords for WebAdmin and WebUser.
Changing the password from the default value is not recommended. Guard
the password from unauthorized users.
1-22 Introduction
Printer Manager Menu Options
The following sections list and describe the options on the Printer Manager
menus accessible to the Service level login. The Printer Manager has a hover-text
feature in the interface that shows the settings definition information when the
cursor hovers over the description column.
The following tables list menu options and their parameters and describe the
purpose of the options. See “Viewing Printer Status” on page 3-2 and
“Troubleshooting” on page 4-1 for more information on Printer Manager settings.
Status
The options on the Status menu only display information about the card printer;
they cannot be changed here.
Menu Option Description Purpose
VPD 1. Manufacturer Displays vital product data (VPD)

2. Model information including the manufacturer,
model, options, and version information.
3. Agency Model
4. Options Installed
5. Serializations
6. Versions
Printer Status 1. Printer State Displays printer status information

2. Seconds On including the state, seconds on, and the
current conditions of the printer.
3. Current Conditions
Supplies 1. Ribbon Part Number Displays detailed ribbon information

2. Ribbon Lot Code including part number and percentage of
ribbon remaining.
3. Ribbon Remaining
4. Ribbon Max Length
5. Ribbon Serial Number
6. Ribbon Module
7. Ribbon Supported
8. Ribbon Action Sequence
9. Ribbon Supply Code
10. Ribbon Special Code
11. Ribbon Region Code
12. Ribbon Product Code

Audit Data See Printer Manager Layout Displays detailed card printer usage data.
for Audit Data list.
About Printer Displays information about the Printer Manager software version and
Manager copyright.
Printer Settings
The options on the Printer Setting menu display card printer settings and offsets
for adjustments.
Communication 1. EthAddressMethod Displays the default and current values

2. EthGatewayAddress of the communication method
(dynamic or static) and address
3. EthIPAddress information. Changes the current
4. EthMacAddress information or restores the default
5. EthSubnetMask values.
6. USBDeviceMacAddress
7. UsbHostMacAddress
Activity Log 1. ExternalLog Allows you to enable or disable both

2. ExternalLogServer internal and external logs and
designate the external log server IP
3. FilterCardActions address. You can set activity log filters
4. FilterConfigChanges to notify at different levels or turn them
5. FilterJobStates off. Changes the current values or
6. FilterSoapMsgs restores default values. (Soap is Simple
Object Access Protocol.)
7. FilterSystem
8. InternalLog
Behavior 1. FactoryMode Displays the default and current status

2. MSAamvaEncoding of printer operation and encoding
methods. Changes the current
3. MSSaflokEncoding information or restores the default
4. MSTimeloxEncoding values.
5. MSVingEncoding
6. RibbonInitialize
7. WebServer
VitalProduct 1. AgencyModelName Displays the default and current printer

Data 2. Manufacturer information. Changes the current
information or restores default values.
3. ModelName
4. SerialNumber
1-24 Introduction
FrontPanel 1. BacklightBrightness Displays the default, current values, and

2. KeySenseLevel allowed ranges for the front panel
options. Changes the current
3. LCDConfigMenu information or restores the default
4. LEDCardsPickedToCleaning values.
5. LEDPrintheadCyclesTo
Cleaning
6. LEDRibbonLow
7. SpeakerEnabled
Print 1. CableCompMaxStrobe Displays the default, current values, and

2. CardRegistration allowed ranges for the print options.
Changes the current information or
3. CardRegistrationCalibration restores the default values. See
4. ColorManagement descriptions of these items in “Print
5. FanTempOn Settings” on page 3-8. Some items may
6. KPower not be available in the printer.
7. KPower1200
8. KPower600
9. KPowerCalibration
10. KPowerCalibration1200
11. KPowerCalibration600
12. KPowerDuplex
13. KWhiteShade
14. LeadTrim
15. RibbonOffset
16. RibbonStripeOffset
17. SettingsGroupPurpose
18. TPower
19. TPowerCalibration
20. TPowerDuplex
21. TWhiteShade
22. TrailTrim
23. VerticalOffset
24. YMCMinShade
25. YMCPower
26. YMCPower600
27. YMCPowerCalibration
28. YMCPowerCalibration600
29. YMCPowerDuplex
30. YMCWhiteShade

Pick 1. MotorPWM Displays the default, current values, and

2. PickAutoTimeout allowed ranges for the pick offsets.
3. PickCardOffset restores the default values.
4. PickManualTimeout
5. PickReversePwm
6. PickReverseTime
Transport 1. TransMedSpeed Displays the default, current values, and

2. TransportSpeed limits for the transport speed options.
restores the default values.
Flipper 1. FlipperFlippedAngle Displays the default, current values, and

2. FlipperHomeOffset limits for the flipper (duplex) option.
3. FlipperRegistrationOffset restores the default values.
4. FlipperRejectAngle
5. FlipperRotationSpeed
6. SmartInOffset
7. SmartOutOffset
MagStripeGeneral 1. Attempts Displays the default, current values, and

2. AutoCoercivity limits for general magnetic stripe
options. Changes the current
3. Coercivity information or restores the default
4. DataFormat1 values.
5. DataFormat2
6. DataFormat3
7. SSA1
8. SSA2
9. SSA3
10. StripeReadEntryOffset
11. StripeReadEventOffset
12. StripeReadSpeed
13. StripeWriteEventOffset
14. StripeWriteFwdEntryOffset
15. StripeWriteFwdUpOffset
16. StripeWriteSpeed
1-26 Introduction
MagStripeCustom 1. CustomCharHigh(1-3) Displays the default, current values, and

Track(1-3) 2. CustomCharLength(1-3) limits for custom magnetic stripe options
for tracks (1-3). Allows changes to be
3. CustomCharLow(1-3) made to the current information and to
4. CustomCharMask(1-3) restore the default values.
5. CustomCharMax(1-3)
6. CustomDensity(1-3)
7. CustomEndSentinel(1-3)
8. CustomLrc(1-3)
9. CustomParity(1-3)
10. CustomSdsNulls(1-3)
11. CustomSdsRecords(1-3)
12. CustomSdsSs(1-3)
13. CustomStartSentinel(1-3)
Update Password Allows you to update and confirm a new password.

Note: Changing the service level password is not recommended.
Troubleshooting
The options on the Troubleshooting menu allow for testing motors, sensors, and
the fan; they provide access to audit and historical information.
Sensors Card Present Displays the current and historical value

Card Input along with the jumper number and
Ribbon Motion type for each sensor in the card printer.
Ribbon Index Also has options to start an update and
to reset the sensor history. The
Head Latch (swingarm)
continuous Update Interval can be
Cam Home adjusted from this display.
Card Exit
MagStripe Encoder
Flipper Home
Smart Card Reg.
Smart Contact
Test Card 1. TestCards Displays the default and current settings

2. Copies for test cards. Allows you to select from
a number of test card options.
3. TestPattern

Test Transport 1. Direction Displays the default, current values,

2. Speed and limits for the transport step motor.
Allows you to test the motor, make
3. Steps changes to the current values, and
restore the default values.
Test Pick 1. Direction Displays the default, current values,

2. PWM and limits for the pick motor. Allows you
to test the motor, make changes to the
3. Time current values, and restore the default
values.
Test Cam 1. Direction Displays the default, current values,

2. Speed and limits for the cam motor. Allows you
to test the motor, make changes to the
3. Steps current values, and restore the default
values.
Test Ribbon 1. PWM Value Displays the default, current values,

2. Time and limits for the ribbon motor. Allows
you to test the motor, make changes to
the current values, and restore the
default values.
Test Fan Displays the default, current value, and limits for the timing of the fan in
milliseconds. Allows you to test the fan, make changes to the current
value, and restore the default value.
Test Flipper 1. Direction Displays the default, current value, and

2. Speed range for the Flipper in milliseconds and
steps. Allows you to test the Flipper,
3. Steps make changes to the current value,
and restore the default value.
Test Flipper Trans 1. Direction Displays the default, current value, and
2. Speed range for the Flipper transport in
milliseconds and steps. Allows you to
3. Steps test the stepper, make changes to the
current value, and restore the default
value.
SSA Test Clicking Run starts the Start Sentinel Adjustment (SSA) Test command
using the settings shown.
Activity Log Allows you to download the audit information and save it to a text file.
Reset Log Allows you to reset the log. Clicking Run in the reset log submenu will
remove all of the entries from the Audit Log.
1-28 Introduction
Reset Counters Allows you to reset those counters in the printer that can be reset. Current
card counts are reset, but life counters or total card counts cannot be
reset.
Printer Reset Allows you to reset the card printer. Click Run in the Printer Reset submenu
to perform a cold restart on the printer. This is the same as powering the
printer off and on again. After the printer has reset, you can resume using
Printer Manager without logging in again.
Maintenance
For more information on card printer maintenance see “Preventive Maintenance
Procedures” on page 5-6.
Menu Item Description
Cleaning This option is used to run a cleaning card through the printer.
Updates This option allows you to browse to a settings file and upload it to the
printer.
Log Out
Select Log Out from the menu to close the current Printer Manager web session.
Click the “x” to close the browser window and go back to the previous session.
Printer Manager Updates

A separate utility, the Card Printer Firmware Update tool, can be used to update
the firmware for the card printer. Printer Manager updates are included with
firmware updates.

1-30 Introduction
Chapter 2: Theory of
Operation
This chapter provides the theory of operation for the card printers.
Sequence of Operation ______________________________________________ 2-3

Power-on Initialization______________________________________________ 2-3
Power Down Sequence ____________________________________________ 2-3
Default Card Production Sequence ________________________________ 2-4
Duplex Sequence _________________________________________________ 2-4
Smart Card Sequence _____________________________________________ 2-6
Card Feed ___________________________________________________________ 2-7
Card Cleaning ____________________________________________________ 2-7
Acceptable Card Thickness and Types _____________________________ 2-7
Card Transport _______________________________________________________ 2-8
Card Printing_________________________________________________________ 2-9
Color Printing Sequence ___________________________________________ 2-9
Monochrome Printing Sequence __________________________________ 2-10
Ribbon Advance ____________________________________________________ 2-12
Magnetic Stripe Encoding ___________________________________________ 2-14
Magnetic Stripe Write Operation __________________________________ 2-15
Magnetic Stripe Read Operation __________________________________ 2-16
Color Management _________________________________________________ 2-17
Overview ________________________________________________________ 2-17
Color Variations __________________________________________________ 2-17
Example _________________________________________________________ 2-18
Color Variation Factors ___________________________________________ 2-19
What You See Is Not What You Get ________________________________ 2-19
Monitor Calibration _______________________________________________ 2-20
Magnetic Cards_____________________________________________________ 2-21
Magnetic Data Principles _________________________________________ 2-21
Magnetism ___________________________________________________ 2-21
Magnetic Media______________________________________________ 2-22
Electrical Current and Magnetism _____________________________ 2-22
Writing Data __________________________________________________ 2-22
Reading Data ________________________________________________ 2-23
Magnetic Data _______________________________________________ 2-24
Encoding Format _________________________________________________ 2-25

Bit Density ____________________________________________________ 2-25
Word Length _________________________________________________ 2-25
Record Length _______________________________________________ 2-26
Parity Check _________________________________________________ 2-26
Data String ___________________________________________________ 2-26
Leading/Trailing Clock Pulses __________________________________ 2-26
Specific Data_________________________________________________ 2-27
Start Sentinel/End Sentinel_____________________________________ 2-27
Longitudinal Redundancy Check (LRC) ________________________ 2-27
Magnetic Stripe Primary Data Standards ______________________________ 2-28
ISO/IEC 7811 (Parts 2 and 6)_______________________________________ 2-28
AAMVA DL/ID-2000 _______________________________________________ 2-28
Saflok, Ving and Timelox __________________________________________ 2-28
Multiple Record Format (SDS) _____________________________________ 2-29
JIS X 6302 (Type I and Type II Cards) _______________________________ 2-29
Magnetic Media Locations _______________________________________ 2-30
Data Track Locations _____________________________________________ 2-31
Summary of Specifications ________________________________________ 2-32
7-bit Alphanumeric Character Set as Defined by ISO/IEC 7811 __ 2-33
5-bit Numeric Character Set as Defined by ISO/IEC 7811 ________ 2-34
Smart Card Technology ______________________________________________ 2-35
Contact Smart Cards _____________________________________________ 2-36
Contactless Smart Cards _________________________________________ 2-37
Communication ______________________________________________ 2-38
Signal Modulation ____________________________________________ 2-38
Signal Modulation Summary Diagram __________________________ 2-39
Reader to Card Communication ______________________________ 2-40
Card to Reader Communication ______________________________ 2-40
2-2 Theory of Operation

Sequence of Operation
Power-on Initialization
1. When the power button on the front of the printer is pressed, the printer
begins its initialization routine.
2. As the print engine board is initialized, the display backlight turns on, the
card status and ribbon status lights and the user button on the front panel of
the printer are steady amber. Four asterisks appear to indicate power on
initialization and that the board is being initialized.
3. The display backlight flickers to show that the board is initialized. The card
status lights, ribbon status lights, and the user button on the front panel of the
printer change to green and then amber.
4. The display shows Busy, and a series of tones play as the display shows Ready
while the user button flashes green and then turns steady green.
5. While the control board examines and initializes external components, the
user light flashes green.
A. The cam motor cycles and homes.
B. The transport is initialized and then operated for sufficient time to ensure
that the card track is clear.
C. The ribbon type is identified. This may or may not result in the ribbon
motor being energized for a short time to detect a ribbon encoder change.
6. The duplex (if applicable) is placed in the flipper reject angle.
7. When the printer finishes its initialization procedure and is ready to process
cards, the status light turns green.
Power Down Sequence

The printer requires a formal shutdown much like a computer. Do not interrupt
power from the printer until it completes the shutdown. A sudden shutdown
may damage the printer’s operating system.
1. When the power button on the front of the printer is depressed for about two
seconds, the printer begins its power down routine.
2. The display shows Shutting Down and the user button glows steady amber.
3. The backlight turns off and the display still indicates Shutting Down as the
user button still glows steady amber.
4. The message disappears and the user button goes dark.

5. The printer is now in energy saver power mode.
If upon powerup the printer displays the Improper Shutdown message, this
indicates power to the printer was interrupted.
Default Card Production Sequence

1. After the card data has been sent to the printer, it begins the card
personalization process.
2. The card is picked and passes through the cleaning rollers.
3. After the leading edge of the card passes through the cleaning rollers, the card
is detected by the input sensor. The trailing edge of the card is registered for
positioning.
4. The card is then sent toward the entrance of the printing area where it will be
sent to the magnetic stripe module first, if applicable.
A. The leading edge of the card is registered by the magnetic stripe sensor.
B. The optical encoder measures the distance the card is traveling during the
encoding process.
C. All tracks on the card are written simultaneously.
D. The card data is verified on the return pass.
5. The card is returned to the input sensor and registered for graphics printing.
A. When the leading edge of the card reaches the platen roller, the cam
engages and lowers the printhead onto the card.
B. The ribbon motor is engaged. The motor is over-driven, and the spindle
clutch slips as needed to match the speed of the card.
C. After a panel is printed, the printhead is raised and the card is returned to
the input sensor.
D. The ribbon motor advances to the next panel by examining the ribbon
encoder.
E. The process is repeated for the remaining panels.
6. After printing, the card is moved into the output tray.
Duplex Sequence
1. Before the card enters the duplex module, the flipper rotates to the home
position to receive the card. It then proceeds through the following steps:
A. The flipper home flag passes through the flipper home sensor and moves
the distance defined by the Flipper Home Offset.

B. Depending on where the card needs to be, the flipper rotates and is
positioned using the flipper home sensor and either the flipper flag or the
flipped flag.
2. As a card leaves the main printer chassis and its trailing edge passes through
the card exit sensor, it is positioned in the flipper. The card moves the distance
defined by the Flipper Registration Offset so the card is in the flipper and no
jam will occur when the flipper rotates.
3. The flipper moves both clockwise and counterclockwise during normal

operation. (It can also be manually rotated in either direction without being
damaged.) Since the flipper moves in both directions, the edge of the flags
used for rotational positioning may be either the leading or trailing edge.
View the following chart for flag information.
4. The four flipper positions are:
• Home: the flipper is close to horizontal.
• Reject: the flipper is positioned here after initialization. It is also the

position the flipper is in during printing so that it does not interfere with
the card. This position has the drive roller closer to the printer chassis and
raised higher than the home position. A rejected card will hit the bottom
of the flipper and be deflected downward into the reject tray.
• Flipped: position is approximately 180 degrees from the home position.
• Smart Card: the drive roller further from the printer chassis is raised
higher than the home position to send the card upward into the smart
card module.

Smart Card Sequence
The smart card module sequence depends on the type of smart card installed. To
program a smart card, the card must be in the proper location to communicate
with the reader. Either the SCM Dual Smart Card Reader option or a contactless
only option (such as the iClass Read/Write) may be installed.
1. When the SCM dual reader is installed, it includes a contact block board with
the smart card contact switch. When the printer detects the SCM option, the
firmware calls a routine that uses the switch as follows:
A. The card is parked in the smart card module. The printer driver sends a
park command to the firmware.
a. As the card enters the module, the leading edge is detected by the
smart card registration sensor.
b. The card continues to move the distance defined by the SmartinOffset.

c. When the card has moved this distance, the smart card contact switch
is closed. The card is successfully parked and the firmware informs
the printer driver. (If it does not close the switch, the card is advanced
a small amount more. If the switch is not closed at this point, Error 102
is issued.)
B. When programming of the card is complete (or to clear an error), the card
moves out of the module back into the flipper assembly.
C. When the trailing edge of the card clears the smart card registration
sensor, the card continues to move the distance defined by the
SmartoutOffset. When this distance has been reached, the card is centered
in the flipper assembly.
2. A contactless-only reader may be installed as part of a third-party integrator

option or the iClass option. Because there is no contact block board and
switch to detect, the firmware uses another routine and the smart card
registration sensor to position the card.
A. The printer driver sends a park command to the firmware.
B. As the card enters the module, the leading edge is detected by the smart
card registration sensor.
C. The card continues to move the distance defined by the SmartinOffset.

When it has moved this distance, the firmware informs the driver that the
card is parked and ready to be programmed.
D. When the trailing edge of the card clears the smart card registration
sensor, the card continues to move the distance defined by the

SmartoutOffset. When this distance has been reached, the card is centered
in the flipper assembly.
Card Feed
The card is fed into the printer through the automatic card tray. If a card is
present, the printer picks the card.
When a card feed is requested from an automatic card tray, the pick motor
powers the pick roller that draws the card into the printer toward the cleaning
rollers. The pick gate assembly ensures that only one card at a time may be fed to
the pick roller. The pick block assembly pushes a single card into the pick roller
assembly. After a successful feed or a time-out for an unsuccessful feed, the pick
motor reverses to return the pick block assembly to the home position. There is no
home sensor for the pick block assembly. The motor will simply energize for a
period of time.
For information about the settings and troubleshooting methods for the card feed
see “Pick Settings” on page 3-23 and “Testing the Ribbon and Pick Motors” on
page 4-10.
Card Cleaning
The pair of cleaning rollers clean debris from the card as it enters the printer.
While the rollers clean the card, the cleaning sleeve (located on the ribbon
cartridge) cleans the cleaning rollers.
Acceptable Card Thickness and Types

Cards with a thickness of 0.254 to 0.762 mm (0.010 to 0.030 inch) may be used in
the card printer without any adjustments. The card must have a PVC or dye
receptor surface to print on.

Card Transport
The transport motor powers the rollers that move the card through the printer as
the card is processed. Each roller pair in the printer has a bracket and spring on
each side that provide tension to enable the rollers to grip a card.
Three sensors are used during card transport: the card input, card exit, and cam
home sensor. The card input sensor and the card exit sensor monitor card
movement through the printer. These sensors monitor for card jams and lost
cards. The card input sensor is located just after the cleaning rollers and can
detect a successful card feed. The cam sensor monitors the position of the cam
slide.
The cam stepper motor moves the cam and cam slide to raise and lower the roller
assemblies during the processing of a card. When the card is being transported
without any other operation, such as during printing or encoding, all of the
rollers are down and driving the card.
As the card moves through the printer the card guide and spring hold the card
toward the right side of the printer.
For information about the settings and troubleshooting methods for the card feed
see “Transport Settings” on page 3-27 and “Troubleshooting” on page 4-1.

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).
To transfer pigment (for monochrome), topcoat, or dye (with YMC printing) from
the print ribbon to the card, the respective thermal element (pixel) heats up until
the temperature reaches the transfer threshold. At this point, pigment from the
print ribbon will adhere to the card.
The process for printing a full color card is slightly different from a monochrome
card. The differences are explained in the following sections.
For information about the settings and troubleshooting methods for card printing
see “Print Settings” on page 3-8 and “Troubleshooting” on page 4-1.
Color Printing Sequence

The color print process places the card in the print position to print each of the
panels, reverses to place the card to the home position, and advances the ribbon
to the next panel between passes. The first pass prints the yellow panel, the
second prints magenta, followed by cyan, the K panel for black, and the last pass
is for the Topcoat.

When a card is requested, the pick and transport motors turn on and a feed error
check begins. When the leading edge of the card reaches the card input sensor,
the card is also between the cleaning rollers. At this point the pick motor is no
longer transporting the card, so it reverses to return the pick block assembly to its
home position. The feed error check is also terminated; however a jam check is
initiated.
When the trailing edge of the card passes the card input sensor, the jam check is
terminated and the card continues to move a fixed distance. Next, the transport
motor reverses direction and the card once again covers the sensor. The card then
moves a fixed distance determined by the firmware and stops. The card is now
ready to be printed in full color. The back and forth movement is necessary to
ensure that the printer knows the precise location of the card. This precision is
required for printing each panel of the multi-panel full color ribbon at exactly the
same location on the card to register the colors.
Monochrome Printing Sequence

The difference when preparing to print a monochrome card is that the transport
motor does not reverse during the feed process to register the card for printing.
Because only one panel of ribbon is printed, the extra accuracy gained by backing
up the card to register before initial printing is not necessary. This savings
increases throughput.

The figure below shows the process the printer uses to print a monochrome card.

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 will be identified as black
monochrome. The ribbon motor advances the ribbon until the ribbon index is
seen by the ribbon index sensor and then moves the ribbon an additional amount
as specified by the ribbon offset. All other ribbon movement is controlled by the
firmware monitoring the ribbon encoder board.
Ribbons for the card printer have a proprietary ribbon identification tag on the
take-up spool that can send signals to the RF antenna board. This communication
allows the printer to automatically identify the ribbon type and approximate
amount of ribbon remaining on the supply. These RFID tags should not be
removed and the card printer ribbon is not backward compatible; it cannot use
printer ribbons from previous models.
When the ribbon cartridge is installed in the printer, the diametric magnet is
located next to the Ribbon Encoder Board.
The diametric magnet is specially-built with its poles on opposites halves of the
round surface, as shown above. As the magnet rotates, the sections of the magnet
where the two poles meet pass the chip on the encoder board. This generates

pulses. An 8-bit chip monitors the magnitude of the magnetic field in order to get
true position. This way 256 interrupts per revolution can actually be measured.
Two sensors that affect the advancing of the ribbon are the Ribbon Motion and
the Ribbon Index. The Ribbon Index sensor detects the index mark on the ribbon
and the Ribbon Motion Encoder monitors the movement of the ribbon. Use this
test to ensure that the sensors change state when going from covered to
uncovered, and back again.
See “Sensors” on page 4-3 for information on testing sensors. For information
about the settings and troubleshooting methods for the ribbon advance see “Print
Settings” on page 3-8 and “Testing the Ribbon and Pick Motors” on page 4-10.

Magnetic Stripe Encoding
Magnetic stripe write operations are performed while the card is moving from
the card input sensor towards the card exit sensor. Read operations are
performed while the card is moving from the card exit sensor back towards the
card input sensor. The card input and card exit sensors monitor the card position.
During the read and write operations the cam motor moves the cam slide which
in turn raises and lowers the rollers and thermal printhead.
When the card is picked, it advances until the trailing edge clears the input
sensor. Then it reverses direction and the card moves towards the card input
sensor. When the card covers the sensor, the cam motor lifts the cleaning roller,
and the card continues moving towards the input hopper. When the card has
moved 225 steps (0.75 inch) the cleaning roller is lowered. This raising and
lowering is done to prevent stalls as the card enters the cleaning roller. The card
continues moving toward the input hopper until the new trailing edge clears the
card input sensor and then moves an additional 50 steps. Next, the card reverses
and moves toward the mag stripe head. This action is exactly like registering the
card for color printing.
The magstripe encoder determines when to turn the mag stripe head on and off
for accurate positioning of the data on the magnetic stripe. It also generates the
write bits by reversing the direction of write current for each transition while
writing the data.

Magnetic Stripe Write Operation
The menu options in the following text are found in the Printer Manager. See
“Magnetic Stripe General Settings” on page 3-27 for settings information.
When the leading edge of the card reaches the card input sensor, it continues to
move the number of steps defined by the StripeWriteFwdUpOffset. Then the cam
motor moves to raise the printhead, the cleaning roller, and the rear roller.
The card continues to move the number of steps defined by the

StripeWriteFwdEntryOffset, and then data is written on the magnetic stripe. Data is
clocked out based on encoder pulses. If the encoder is not turning or fails, the
data may be missing or incorrectly positioned.
Data continues to be written to the magnetic stripe while the card continues to
move the distance defined by the StripeWriteEventOffset (roughly the length of the
card). When this distance has been reached, the writing ceases; however the card
continues to move another 259 steps before stopping. This is to ensure that the
card is past the head drive rollers when stopped. Note that the card may not
actually be moving during those last steps after it clears the head drive roller
because the cam is up. Then the cam motor moves to lower the cleaning roller and
the rear roller.
When the leading edge of the card reaches the card exit sensor, the card stops and
reverses direction.

Magnetic Stripe Read Operation
The menu options in the following text are found in the Printer Manager. See
“Magnetic Stripe General Settings” on page 3-27 for settings information.
When the trailing edge of the card clears the card exit sensor, the card continues
to move the number of steps defined by the StripeReadEntryOffset. Then the cam
motor moves to raise the printhead, the cleaning roller, and the rear roller. Now
the read process begins.
While the data is read back for verification, the card continues to move the
number of steps defined by the StripeReadEventOffset (roughly the length of the
card). When this distance has been reached, data read back ceases. Then the cam
motor moves to lower the cleaning roller and the rear roller.
If the read indicates the card is good, the card continues until the leading edge of
the card passes the card input sensor and the print cycle begins. However, if the
read was bad, the card continues until the trailing edge passes, continues 50 more
steps, reverses, and then repeats the entire process.
For information about tools, troubleshooting methods, and remove and replace
procedures for magnetic stripe encoding, see page 5-3 and chapter 4,
Troubleshooting.

Color Management
Overview
Color Management is a process for enhancing color reproduction and increasing
accuracy and consistency of color over a variety of input and output devices. A
color management system maps colors between devices such as cameras,
monitors, scanners, and printers. This map helps to transform colors from one
color space to another (for example, RGB to CMYK), and provides a more
accurate on-screen or print preview. Color management cannot guarantee
identical color reproduction, as this is rarely possible, but it allows more control
over variations across devices.
Devices have various color gamuts, or ranges of colors they can recognize or
reproduce. Some printing processes have much larger gamuts than others,
meaning there are more colors to choose from. The human eye can perceive many
more colors than devices can produce. Even when a device receives information
from another device in a language it understands, it may attach different
interpretations to the information. Color management serves as the translator of
languages so devices can communicate accurate, standard color information.
Communication is never perfect because device gamuts vary, but color
management helps you achieve your best results on a given set of devices.
A color management system helps to overcome these limitations by providing a

communication framework for software and publishing devices. It helps to
decrease color differences and produce colors more predictably. The color
management setting in the card printer must be enabled for the printer to convert
colors using color management.
Color Variations
Without a standard color management system, color results can vary widely
among programs and hardware devices. You might adjust a color based on how it
appears on the monitor and then find that, when printed, the color is

considerably different from what you expected. A printed copy of a scanned
original document may have noticeable differences in color. Maybe the reds
appear pink and the blues become purples.
A color profile is installed when a new device is added to your PC, and this
profile is used every time colors are displayed or printed. Each program used to
input or output the color data supplies color profiles not only for the software
itself, but also for many kinds of devices. As a result, color consistency is
achieved through trial and error.
A color management engine maps the image data, using its current color space
from an input device, into an output color space that matches.
For simple publishing programs, color management can be configured to work

automatically. However, with color management set to None, the printer uses its
native interpretation of RGB. This provides full control for users with specialized
needs, such as graphic artists and desktop publishers, who can manually specify
which color profile the printer uses or which rendering intent is used for images
or pages with special requirements.
Example
For example, you might want to use the length of your foot as a unit of
measurement. We will call this your “native” measurement.
You and your friend are both told to measure out a distance of 10 feet. Your foot
and your friend’s foot will be different lengths and yet still be one unit, so you
and your friend will most likely end up with different lengths. It is also very
unlikely that the distances that you and your friend measure will be 10 standard
feet, as defined by the National Bureau of Standards.

This is what happens without color management. The same numbers (RGB
values) arrive, but each device does a “native” interpretation of those numbers. It
will only match the standard if the dye chemistry, etc. are an exact match to the
standard. This is similar to a person who has an exactly 12-inch long foot that
could match the standard. Since the sRGB standard is based on monitors, our
printer does not come very close natively.
So in our foot example, you and your friend can both measure 10 standard feet.
We just need a conversion that tells us how many native feet = 1 standard foot.
This conversion factor will be different for you and your friend. Think of the
conversion factor as a color profile.
Color Variation Factors

Factors that affect variations in color printing:
• Ribbon-to-ribbon variation - Although minimal, there is still variation from
one ribbon to another.
• Printhead - The printhead angle is optimized in manufacturing, but there is

still a tolerance from printhead to printhead.
• Card Stock - A white card is preferred, but there are variations in the “white”
of blank cards from various manufacturers. Some cards are slightly yellow or
have a slight tint. This affects how the dye is transferred to the card.
What You See Is Not What You Get

Monitors have a black background and use additive colors RGB. Printers usually
print on a white card and use subtractive colors YMC. Because of this, you will
never have exact color matching. Monitors show many more colors, as indicated
in the following color gamut comparison charts.

RGB monitors can display more colors than can be matched in print. Conversely,
some CMYK colors cannot be matched on-screen. Moreover, RGB gamuts vary
widely between devices with some gamuts being considerably wider than others.
While this may seem beneficial, wider RGB gamuts can be problematic when
outputting to a printer. The colors in the RGB gamut outside the CMYK gamut
must be compressed (that is, mapped to a space within the CMYK gamut). This
always entails a loss to the quality of the original design so what you see is not
what you get.
Monitor Calibration
To print digital images with colors and a tonal range that approximate what you
see on your monitor, you’ll need to do a basic monitor calibration. The simplest
way to accomplish this is to adjust your monitor's gamma. After this basic
calibration is done, it’s usually not very difficult to get a feel for the adjustments
you’ll need to make with your imaging program’s color and tonal range tools and
your printer’s tools to get a close match between the printed output and the color
and tonality of the image represented on your computer screen.
If you need exact color matching, you may want to consider buying a monitor
calibration software/hardware solution. A number of companies offer color
calibration products that allow you to make an ICC profile based on your
monitor's actual color characteristics.
Recommended reading for more on Color Management:
1. Adobe Technical Guide:

http://dba.med.sc.edu/price/irf/Adobe_tg/manage/cmsdef.html
2. Overview Of Color Management:

http://www.cambridgeincolour.com/tutorials/color-management1.htm
3. Digital Darkroom Imaging and Printing Tech Tips:

http://www.sphoto.com/techinfo/wdtech.html

Magnetic Cards
The information presented in the following section is not required for the card
printer but is presented to augment your training and knowledge base.
Magnetic Data Principles

This discussion is intended to be a primer for those who are not completely
familiar with the principles of writing data to and reading data from a magnetic
stripe. It covers some advanced theory, but is not intended to be a comprehensive
discussion into the physics of electromagnetism. Those wishing to delve deeper
into the physics of electromagnetism should be able to find additional
information on the Internet or from their local library (search topics include:
Electromagnetism, Gauss, Magnetic Stripe).
Magnetism
All magnets, including the Earth, have a North Pole and a South Pole. These poles
always appear in North/South pairs, and there will never be one without the
other. A magnetic field is comprised of Magnetic Lines of Force, or Magnetic Flux,
which travel from North to South between the poles. Even though magnetic flux
is invisible, the effects of these lines can be seen as they interact with particles of
iron.
If a piece of paper is placed over a common bar magnet, and iron filings are
sprinkled across the paper, the iron particles will line up in a fashion similar to
the figure below1. The greater the density of these lines, the stronger the
magnetism. In the following figure, note that the magnetic field is strongest near
the poles.
1. This is the same principle used with magnetic stripe developing fluid. The fluid contains magnetic particles in an evap-
orative fluid. When the fluid evaporates, the particles align on the strongest magnetic areas.

Magnetic Media
Magnetic media (stripe material) contains small magnetic particles. Before
information is encoded on the stripe, the poles of the magnetic particles are
randomly oriented (top image below). To encode information, the poles of the
individual particles are oriented in the same direction (middle image below). The
effect of having all of the small particles oriented in the same direction is the same
as having one large magnet with a single North pole and single South pole
(bottom image below).
Electrical Current and Magnetism

There is an interrelationship between magnetic fields and electrical current.
When an electrical current moves through a wire, a magnetic field is generated
around the wire1. Reciprocally, when a magnetic field moves past a wire, a
current2 will be generated (induced) in the wire.
Note that in the case of magnetic stripe cards, a static (non-changing) magnetic
field is physically moving past the conductor. This would be analogous to flying
over the mountains in an airplane. The hills and valleys make the distance
between the airplane and the ground increase and decrease, but the landscape
itself does not change.
If the magnetic field (landscape) were changing, the result would be the same,
and induction would occur. What is important is that the magnetic field is either
changing or moving for induction to occur.
Writing Data
To write data to the magnetic material on a card, it is necessary to create a
magnetic field near the stripe. This aligns all of the magnetic particles nearby in
1. From Ampere's Law.

2. Mathematically, Faraday's Law of Induction states that a voltage is induced in the conductor. However, for reasons of
symmetry with Ampere's Law, it is common practice in discussion to refer to the energy transfer as “induced current.”
This is appropriate as long as the conductor forms a closed circuit and Ohm's Law can be applied.

the same orientation (polarity). The Magnetic Write Head contains a small coil of
wire wrapped around a semicircular iron core1. (The head coil and iron core are
used to focus and concentrate the magnetic field.) When electrical current passes
through the head coil, a small but concentrated magnetic field is generated across
the open ends of the core. The magnetic stripe on the card is magnetized with the
opposite magnetic polarity from the head. This is shown in the image below.
To change the polarity of the magnetic stripe under the magnetic head, the
polarity of the current in the head coil is reversed. This reverses the magnetic
polarity of the iron core, which in turn reverses the polarity of the magnetic
stripe.
Reading Data
To read the magnetic information from a card, the magnetic field on the card is
used to generate a current in the magnetic head. This is possible because a
moving magnetic field induces a current (or voltage) in a conductor.
The magnitude of the current is dependant on the rate of change of the magnetic
field passing by the head. The greater the change, the larger the current. A simple
way of understanding this is that current will be induced when the read head cuts
through a line of flux. When the read head is traveling parallel to a flux line, no
current will be induced.
Because the flux density is greatest at the poles of a magnet, the current will also
be greatest as the magnetic pole passes below the head. This is illustrated in the
figure below. If the magnetic stripe were comprised of a single North-to-South
magnet, no current would be induced in the magnetic head for the majority of the
length of the card.
1. Other materials may also be used for magnetic cores.

When two North Poles or two South Poles are adjacent to one another, the
magnetic field is compressed and becomes even more dense. The higher the
density of the magnetic field, the larger the current that is induced in the
magnetic head.
For this reason, magnetic data is comprised of Transition Points where the polarity
of the magnetism reverses, which results in North-to-North or South-to-South
polarity.
Magnetic Data
The method for recording information on a magnetic stripe is called two-
frequency, coherent phase encoding (also known as F/2F). Although the name is
complex, the concept is simple: two signals are merged together and written as a
single signal. The significance of this format is that a timing signal is embedded in
the data stream (called self-clocking data). This method allows the data to be read
properly regardless how fast or slowly a person swipes the card past a read head.
The clock signal is evenly spaced pulses that are recorded for the whole length of
the stripe. The binary data is written between each of the clock pulses. These two
signals are merged together into a serial data stream and sent to the magnetic
head as an alternating current of varying frequency.
In the example below, the binary data to be written to the card is “011001.” When
this is merged with alternating clock pulses, the result is “1011111010111.” To
write this merged data string to the magnetic stripe, the polarity of the magnetic
head is reversed when a “1” is in the data stream, and left unchanged when a “0”
is in the data stream.

When this information is read back from the magnetic stripe, the current in the
magnetic head appears as alternating pulses. This is shown as the bottom graph
in the figure above.
Encoding Format
As described in the preceding section, the data on a magnetic stripe is nothing
more than a series of binary 1’s and 0’s. However, for this data to be usable, it is
necessary to know how to extract and interpret the information. By specifying
how information is recorded to the stripe, it can be assured that the read device
will extract and interpret the information correctly.
Bit Density
The lowest level encoding format is the recording density. This is typically
specified as bits per millimeter, or bits per inch. A high bit density will allow
more information to be stored on the magnetic track.
Word Length
Each piece of information written to the magnetic stripe is a binary coded
character. These characters (numeric or alphanumeric) are represented by a
binary number known as a binary word. Typically, these binary words are
between 4 and 8 bits in length.
The number of bits per word is determined by how many possible characters
there are in a character set. The common alphanumeric character set requires 6
bits for the binary character code, but a numeric character set requires only 4 bits

for the character code. Once the number of bits per word has been specified, all
characters in the same data string will have the same number of bits per word.
Record Length
The record length is the total number of binary words (characters) that can be
stored on a magnetic track. Bit density, word length, and the physical length of
the stripe determine the maximum record length.
Parity Check
A parity check is a method of determining if an error has occurred. This is
accomplished by adding one extra bit to the end of a binary character code. The
purpose of the parity bit is to make the sum of data bits in a binary word either
even or odd. This way, all words throughout the data string will have the same
parity. In the table below, note that the sum of all the bits in each row is an odd
number. This is called odd parity. With even parity, the sum of the rows would be
an even number.
Parity Binary Char Code Bit

Char 5 4 3 2 1 0
Bit 2 2 2 2 2 2 Sum
$ 0 0 0 0 1 0 0 1
A 1 1 0 0 0 0 1 3
B 1 1 0 0 0 1 0 3
C 0 1 0 0 0 1 1 3
S 1 1 1 0 0 1 1 5
W 0 1 1 0 1 1 1 5
Z 1 1 1 1 0 1 0 5
Data String
Regardless what type of information is written on a magnetic stripe, there is a
basic layout that is followed. This basic layout is shown below.
Leading Longitudinal Trailing
Start End
Clock Specific Data Redundancy Clock
Sentinel Sentinel
Pulses Check Pulses
Leading/Trailing Clock Pulses

The actual information written to a magnetic stripe cannot extend fully to the
edges of the stripe. The main reason for this is because the card reader needs to
synchronize its timing to the speed at which the card is swiped through the
reader. Leading and trailing clock pulses permit the reader to gauge the speed of
the card without losing data. (The timing is continuously updated as the whole
card is read, but the leading and trailing clock pulses provide a starting point
without data loss.)

Specific Data
This is the actual data that personalizes the card. This data can represent a
person’s name, birth date, account number, etc. The actual content of this data is
determined by the card issuer or one of the many international standards. (Refer
to the Magnetic Stripe Primary Data Standards section for a description of some
common standards.)
Start Sentinel/End Sentinel

The specific data on a card is bracketed by a Start Sentinel and an End Sentinel.
These are used to identify where valid data begins and ends. These two sentinels
are reserved characters and cannot be used for any other reason on the magnetic
stripe. For this reason, the sentinel characters will not be standard letters or
numeric characters. (Just like any other character written to the card, the
sentinel’s binary word also includes a parity bit.)
Longitudinal Redundancy Check (LRC)

This is a final parity check for the entire data string. Unlike the parity bit
mentioned in the preceding section, the LRC is a complete binary word itself,
with the same number of bits as the specific data characters.
Each bit in the LRC binary word (except its own parity bit) represents a single
parity check for all of the preceding bits in the same position. This can best be
explained by examining the binary data in the tabular form shown below. Each
character’s parity bit makes the horizontal sum of bits an odd number. The LRC
makes the vertical sum of all the individual bits an even number. (The LRC’s own
parity bit sets the parity for the LRC word in the same manner as it would for any
other character.)
Parity Binary Char Code

Name Bit Sum Char
Bit 25 24 23 22 21 20
Start Sentinel 1 0 0 0 1 0 1 3 %
Sample Data 1 0 1 0 1 1 1 5 7
Sample Data 0 1 0 0 0 1 1 3 C
Field Separator 0 1 1 1 1 1 0 5 ^
Sample Data 1 1 1 0 0 1 1 5 S
Sample Data 1 1 1 1 0 1 0 5 Z
End Sentinel 0 0 1 1 1 1 1 5 ?
Pre-LRC Sum 4 5 3 4 6 5
LRC 0 0 1 1 0 0 1 3
Post-LRC Sum 4 6 4 4 6 6

Magnetic Stripe Primary Data Standards
The magnetic stripe on a card can store binary data in any form you wish;
however, to maintain consistency, national and international standards are
followed. A primary data standard is one that specifies how information is stored
on a card. A secondary standard is one that specifies the content of the
information stored on a card.
ISO/IEC 7811 (Parts 2 and 6)

This is the primary standard for recording that most other formats and standards
are based on. This standard dictates how information is written to a card, but
does not describe the content of the information. It covers 2-track and 3-track
magnetic stripe cards, where 1, 2, or 3 tracks may be used.
In the past, this 3-track recording standard was referred to as IAT, which is an
acronym for IATA, ABA, and TTS. This acronym should not be used to describe a
3-track card, because it describes the “content” and not the “technique.” It is more
accurate to describe these tracks as ISO-1, 2, or 3.
Abbreviated Former
Full Name
Name Designation
ISO/IEC 7811 part 2 or 6 Track 1 ISO-1 IATA
ISO/IEC 7811 part 2 or 6 Track 2 ISO-2 ABA
ISO/IEC 7811 part 2 or 6 Track 3 ISO-3 TTS
Note that this standard permits the use of a single-track recording, but doing
so does not make the recording a JIS Type-II card. That is a completely
different standard and is discussed below.
AAMVA DL/ID-2000
This is the national standard for the U.S. driver license and identification card.
The specification is published by the American Association of Motor Vehicle
Administrators (AAMVA). It follows the ISO standard except for some changes
in data type and record length. Technically, this is not a primary standard, but
since it modifies some aspects of the primary ISO/IEC standard, it is treated as
though it were a primary standard.
Saflok, Ving and Timelox

These are proprietary formats that the printer is capable of encoding; however,
the specifics of these formats cannot be published. For these standards you would
need to contact the format manufacturer.

Multiple Record Format (SDS)
This is a special format that is used most often by the casino industry. The main
purpose for the change in format is to introduce redundancy into the data to
protect against misreads at the card readers. Because the cards are not intended to
be universal from one provider to another, there is no specific standard format.
Each card issuer can have their own variations on the basic format. Some of the
aspects that may be encountered within this format are shown in the table below.
Parameter Comments
Number of Records Each track is permitted to repeat the primary data record as many
times as the issuer chooses. Each duplicate record contains its own
start and end sentinels and error checking characters.
Number of Start Sentinels Each data record is permitted to repeat the start and end sentinel
any number of times. This is to ensure that the beginning and end of
the record has been detected.
Number of Nulls Between duplicate data records, there can exist empty, non-
recorded space. This separates the records to ensure that two
adjacent records are not misread as one record.
JIS X 6302 (Type I and Type II Cards)

JIS X 6302 is the Japanese standard for magnetic striped cards and identifies two
distinct card formats.
Type I:
A JIS Type I card is a 3-track card. As of the 1998/1999 revision of this standard,
the Type I card standard conforms to the ISO/IEC standard for 3-track cards. For
this reason, Type I cards will not be discussed separately from ISO/IEC cards.
However, note that some card issuers may still be producing cards under the
1979/1988 version of JIS X 6302. This manual does not cover that standard, but
the system will nonetheless support the format.
Type II:
A JIS Type II card is a single-track card, and does not have an ISO/IEC
equivalent. In the past, this type of card has frequently been referred to as
J-Stripe, J-Track, NTT, or simply JIS Type II. (JIS Type II is now preferred.)

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 two or
three track card (ISO/IEC and JIS Type I). (Note that under the ISO and JIS
standards, even if only one of the three tracks is used, the minimum track size
follows this specification.)

Data Track Locations
The positions where data can be recorded on a 3-track stripe are described in the
graphic below. This applies to all three of the aforementioned standards, but does
not apply to a JIS Type II card.

Summary of Specifications
The preceding sections described where magnetic data can reside on a card. This
section describes the general format of that magnetic data. The following table
summarizes the data specifications for the primary standards.
ISO/IEC 7811
JIS Type I JIS Type II
Parameter Track 1 Track 2 Track 3 Single Track
Bit Density 210 75 210 210
Total Length 79 40 107 72
Record Length 76 37 104 69
Data Type 7-bit A/N 5-bit N 5-bit N 7-bit A/N
Start Sentinel % ; ; DEL
End Sentinel ? ? ? DEL
Field Separator ^ = =
Word Parity ODD EVEN
LRC Parity EVEN EVEN
N = Numeric character set

A/N = Alphanumeric character set

Character Encoding
7-bit Alphanumeric Character Set as Defined by ISO/IEC 7811
Binary Binary
Note Char Parity Note Char Parity
25 24 23 22 21 20 25 24 23 22 21 20
Space 1 0 0 0 0 0 H @ 0 1 0 0 0 0 0
H ! 0 0 0 0 0 0 1 A 1 1 0 0 0 0 1
H “ 0 0 0 0 0 1 0 B 1 1 0 0 0 1 0
R # 1 0 0 0 0 1 1 C 0 1 0 0 0 1 1
$ 0 0 0 0 1 0 0 D 1 1 0 0 1 0 0
S % 1 0 0 0 1 0 1 E 0 1 0 0 1 0 1
H & 1 0 0 0 1 1 0 F 0 1 0 0 1 1 0
H ‘ 0 0 0 0 1 1 1 G 1 1 0 0 1 1 1
( 0 0 0 1 0 0 0 H 1 1 0 1 0 0 0
) 1 0 0 1 0 0 1 I 0 1 0 1 0 0 1
H * 1 0 0 1 0 1 0 J 0 1 0 1 0 1 0
H + 0 0 0 1 0 1 1 K 1 1 0 1 0 1 1
H , 1 0 0 1 1 0 0 L 0 1 0 1 1 0 0
- 0 0 0 1 1 0 1 M 1 1 0 1 1 0 1
. 0 0 0 1 1 1 0 N 1 1 0 1 1 1 0
/ 1 0 0 1 1 1 1 O 0 1 0 1 1 1 1
0 0 0 1 0 0 0 0 P 1 1 1 0 0 0 0
1 1 0 1 0 0 0 1 Q 0 1 1 0 0 0 1
2 1 0 1 0 0 1 0 R 0 1 1 0 0 1 0
3 0 0 1 0 0 1 1 S 1 1 1 0 0 1 1
4 1 0 1 0 1 0 0 T 0 1 1 0 1 0 0
5 0 0 1 0 1 0 1 U 1 1 1 0 1 0 1
6 0 0 1 0 1 1 0 V 1 1 1 0 1 1 0
7 1 0 1 0 1 1 1 W 0 1 1 0 1 1 1
8 1 0 1 1 0 0 0 X 0 1 1 1 0 0 0
9 0 0 1 1 0 0 1 Y 1 1 1 1 0 0 1
H : 0 0 1 1 0 1 0 Z 1 1 1 1 0 1 0
H ; 1 0 1 1 0 1 1 R [ 0 1 1 1 0 1 1
H < 0 0 1 1 1 0 0 R \ 1 1 1 1 1 0 0
H = 1 0 1 1 1 0 1 R ] 0 1 1 1 1 0 1
H > 1 0 1 1 1 1 0 F ^ 0 1 1 1 1 1 0
E ? 0 0 1 1 1 1 1 H _ 1 1 1 1 1 1 1
Code Description
H The following 14 characters !”&’*+,:;<=>@_ are reserved for hardware control and
cannot be part of the data content. (These may or may not be used by various
device manufacturers.
R Additional reserved characters.
S,E,F Reserved characters for Start Sentinel, End Sentinel, and Field Separator

5-bit Numeric Character Set as Defined by ISO/IEC 7811
Binary
Note Char Parity 23 22 21 20
0 1 0 0 0 0
1 0 0 0 0 1
2 0 0 0 1 0
3 1 0 0 1 1
4 0 0 1 0 0
5 1 0 1 0 1
6 1 0 1 1 0
7 0 0 1 1 1
8 0 1 0 0 0
9 1 1 0 0 1
H : 1 1 0 1 0
S ; 0 1 0 1 1
H < 1 1 1 0 0
F = 0 1 1 0 1
H > 0 1 1 1 0
E ? 1 1 1 1 1
Code Description
H These characters are used to control the hardware and cannot be part of the
data content. (These may or may not be used by different device manufacturers.)
S,E,F Reserved characters for Start Sentinel, End Sentinel, and Field Separator

Smart Card Technology
The information presented in the following section is not required for servicing
the printers but is presented to augment your training and knowledge base.
The underlying concept of smart cards is fairly simple: A chip is embedded inside
a plastic card. The chip may be microprocessor based or a simple memory device.
The capabilities of a smart card, however, are a little more complex. They can be
as simple as a means of identification, or as complex as a financial database.
Although it is not a mandated parameter (and some overlap may exist), all
smart cards have a unique identifier that indicates the card type, the
manufacturer, and the specific card. Most card manufacturers present this
unique identifier as part of the “answer to reset,” which is discussed below.
Even if the card protocol permits it, this identifier should not be altered.
There are two basic types of smart cards; Contact Smart Cards and Contactless
Smart Cards (or a combination of both types, as shown in the following graphic).
Contact smart cards connect to the external interface via a set of eight electrical
contact points. Contactless smart cards interact with the external interface
through a principle called inductive coupling. There are many variations on the
basics of smart cards, including proprietary designs. The following discussion is
limited to smart card architecture as defined under ISO/IEC 7816 (1-10) and ISO/
IEC 14443 (1-4).
The above photograph is an actual transparent card with magnetic stripe, a

contact-type processor, a 125 kHz contactless type processor, and a 13.56 MHz
contactless type processor. This graphic (without annotations) was provided by
HID Corporation and is shown here for educational purposes. The printed image
on the card is an artist's rendering.

Contact Smart Cards
A contact smart card needs to connect to an external interface to provide the
processor with power and to set up serial communication. The eight terminal
contacts are described in the table below. (Note that two contacts are reserved for
future use.)
There are two classes of contact smart cards: Type-A cards operate at 5 volts, and
Type-B cards operate at 3 volts.
No. Name Purpose No. Name Purpose
C1 VCC Supply voltage (3 or 5 V) C5 GND Ground
C2 RST Resets the processor C6 VPP Variable voltage for

programming
C3 CLK Provides the timing (clock) C7 I/O Data line

signal
C4 N/A Reserved for future use C8 N/A Reserved for future use
Initiating Communication
When the card is inserted into a reader, it needs to be initialized and have its
communication protocols defined. Note that steps 1 through 6 all occur while the
card is forced to remain in a reset state (no activity).
1. The card reader senses that the card is in position under the contacts. In most
cases, this is a mechanical switch that detects the presence of a card (any type
of card).
2. The Reset line (C2) is held low. (The active-low reset forces the card to remain
in the reset state until released.)
3. Power is applied to the VCC and GND contacts.
• Type-A reader will apply 5 volts to the card. (Type-B cards must accept
the overvoltage, but are not allowed to respond.)

• Type-B reader will apply 3 volts to the card.
• Type-A/B reader will first apply 3 volts to the card. If no response is

received, it removes power, waits, and reapplies power at 5 volts.
4. The I/O line is held in the Receive mode (high impedance).

5. If the card is a Type-A card, the programming voltage (VPP) is placed in the
pause value, which is equal to VCC.
6. The clock signal is activated.
7. The reader releases the Reset by bringing it to a high voltage.
8. The card then issues its Answer To Reset (ATR). ATR is a hexadecimal string
of up to 32 characters and contains:
• The format of the communication

• Permissible baud rates
• Parameters of the circuitry in the card
• Required programming voltage on VPP
• The make and model of the card

• Other information the manufacturer chooses
9. With communication parameters known, the interface can begin to

communicate with the card.
10. Serial communication across the I/O line commences.
11. If necessary, the voltage on VPP is altered, and information can be written to
the card.
Contactless Smart Cards

Whenever a new technology is developed by multiple manufactures, there tend
to be multiple protocols for the device. For example, during the 1980's there were
as many personal computer types as there were manufacturers. In time, the
number of computer types dwindled as designs were standardized. The same is
true with smart card technology, except that many off-standard card types still
exist.
The primary information in this section is geared toward the ISO/IEC 14443
Type-A and Type-B cards although a few other formats are still widely used.
The photograph on page 2-35 shows a combicard with both a 125 kHz antenna
and the standardized 13.56 MHz antenna. This card is used to help facilitate the
transfer from the 125 kHz system to the common 13.56 MHz system. The lower

frequency format is not supported by any of the ISO/IEC standards. These low
frequency cards are frequently referred to as Wiegand cards and generally
provide a unique ID only when energized.
The FeliCa card format was developed by the Sony Corporation and is similar to
the standard Type-A card, except that it uses a 212 kb/s data rate instead of the
standardized 106 kb/s data rate. There are also some variations on the
modulation protocol.
The Mifare card is fairly common because it is based on an open standard used by
many manufacturers. According to the Phillips Corporation this format is fully
compliant with the ISO/IEC 14443-A standard.
Communication
Communication with contactless smart cards is slightly more complicated
because there is no physical connection between the interface and the card. The
card reader sends out a radio frequency broadcast, which not only provides
power to the card, but also establishes communication. This is called inductive
coupling.
Inductive coupling works the same way as a transformer does, except that the
two coils are farther apart (called loosely coupled). The operating field of the card
reader has a frequency of 13.56 MHz. This is called the carrier frequency.
Signal Modulation
The concept of signal modulation arises from the relationship between frequency
and required antenna size. Namely, the antenna needs to be on the same order as
the wavelength of the signal. The lower the frequency and the longer the
wavelength, the larger the antenna required to transmit or receive the signal.
An audio signal, for example, would require an antenna of approximately 300

Km in length. This would not fit very well in the trunk of your car for listening to
your favorite music, and a portable radio would be totally out of the question.
Instead, the lower frequency (the data signal) is combined with a higher
frequency (the carrier). The higher frequency is more easily transmitted and
received. Combining two signals together is called modulation.
There are many types of signal modulation, but they all have three basic
parameters: amplitude, frequency, and/or phase of the carrier signal.
You are probably familiar with the terms Amplitude Modulation and Frequency
Modulation because these are used by most consumer radios. We know them as
AM and FM radios. Because of their nature, digital signals can utilize many
variations on these basic modulation schemes.

Signal Modulation Summary Diagram
The following diagrams show the two basic modulation schemes as well as the
variants used by digital signals. The AM and FM modulation diagrams are shown
with analog data signals, but phase-shift modulation is easiest to show with a
digital signal.
Amplitude Modulation:
The magnitude (height) of the carrier
signal is varied according to the height
of the data signal. This is what is used in
AM radio.
Note: The blue data signal is shown here
for clarity. It is not actually present in the
actual modulated signal.
Frequency Modulation:
The frequency of the carrier signal is
varied according to the height of the
data signal. This is what is used in FM
radio.
Note: The modulated frequency
remains close to the carrier frequency,
but the drawing is exaggerated for
clarity.
Amplitude Shift Keying:

This is a digital variant on the AM
modulation. It comes in two common
forms: 100% and 10%.
Note: 10% modulation (ASK10%) means
the carrier is modulated by only 10%.
100% modulation means that the carrier
signal is fully modulated. Both of these
variants are shown to the right.
Load Modulation:
The card switches the resistance of its
antenna, which alters the current in the
transmitter.
Note: This is a complex topic and will be
discussed in greater detail later.
Phase Modulation:
A data transition is signified by a shift in
the signal's phase. In this case, the
phase is shifted 180 degrees by inverting
the signal.

Reader to Card Communication
The reader communicates with the card by sending an amplitude modulated
signal at 13.56 MHz. The modulation variant depends on the class of card. Type A
cards use 100% Amplitude Shift Keying (ASK100%). Type-B cards use ASK10%
modulation. These two variants are shown in the previous graphics.
The benefit of ASK100 is that it is more immune to noise and errors because there
is a strong difference in amplitude at bit transitions. The drawback to this is that
the card does not receive power during the low cycle of the modulation. The card
does not turn off during these times, but the effect is that less overall (average)
power is being transmitted to the card.
ASK10 provides more power to the card because the modulated signal remains
within 10% of the maximum amplitude. The tradeoff is that the difference
between high and low amplitudes is minimal. This can lead to slightly more data
transmission errors.
Card to Reader Communication

The communication method back to the reader is a passive communication
because the card does not really send a signal back to the reader—it modifies the
signal emanating from the reader. This is called Load Modulation, and is based
on a loosely coupled transformer (two coils separated by distance and without an
iron core).
A normal transformer is frequently thought of as a method for changing one

voltage to another, such as a computer power supply that takes 120 volts and
reduces it to 12 volts. While the voltage decreases across the transformer shown
below, the current increases proportionally. The value of the current in the
secondary winding is dependant on the load being powered. Consequently, the
current in the primary winding is inversely proportional to the load on the
secondary winding. As a result, if the load is varying with time, the circuitry on
the primary side of the transformer can detect the change in current draw.
When the card engages and disengages (switches) resistance in its own antenna,
the reader detects this change by examining the current draw within its antenna.

Type-A Card Modulation
The type of return modulation from the card to the reader differs with the two
classes of cards (Type-A and Type B). Type-A cards use a simple On-Off-Keying
modulation (OOK). This is the binary equivalent of amplitude modulation. The
card switches the resistance seen by the card reader at a frequency of 1/16th the
frequency of the carrier signal. This means that during a modulation period, the
carrier signal is attenuated every eight cycles. The data stream is even slower than
this (1/128th of the carrier frequency) so each data bit will have several
transitions from modulation to non-modulation of the carrier.
Type-B Card Modulation
Type-B cards use a combination of amplitude modulation and phase modulation,

called Binary Phase Shift Keying (BPSK). This method sends a constant subcarrier
frequency of 847 kHz using amplitude modulation, but shifts the phase of the
subcarrier by 180 degrees (inverted) at each data transition. In other words, the
carrier is always modulated with the subcarrier, but during data transitions, the
subcarrier signal is altered (inverted). The subcarrier is permitted to invert only at
its own transition points (which is why the frequencies are even multiples of each
other).

Chapter 3: Adjustments
This chapter includes navigation and use of the Printer Manager

application to view and make changes and adjustments to the card
printer.
Factory and Power-On Settings _______________________________________ 3-2

Viewing Printer Status_________________________________________________ 3-2
Viewing and Changing Printer Settings ________________________________ 3-2
Communication ___________________________________________________ 3-2
Activity Log _______________________________________________________ 3-3
Activity Log Example ______________________________________________ 3-4
Behavior __________________________________________________________ 3-6
Vital Product Data_________________________________________________ 3-6
Front Panel Options________________________________________________ 3-7
Print Settings _________________________________________________________ 3-8
Print Misadjustment__________________________________________________ 3-23
Pick Settings ________________________________________________________ 3-23
Transport Settings ___________________________________________________ 3-27
Magnetic Stripe General Settings_____________________________________ 3-27
Magnetic Stripe Custom Track Settings _______________________________ 3-31
Magnetic Stripe Track Height Adjustment _____________________________ 3-33
Start Sentinel Position Adjustment ____________________________________ 3-34
Flipper (Duplex) Adjustments ________________________________________ 3-36

Factory and Power-On Settings
The card printer is shipped with default factory settings, but settings may be
changed as needed to customize how the printer operates.
Printer Manager option interfaces that contain changeable values have either a
drop-down menu to select from or a text box to enter a value. At the bottom of the
interface are the Set Current and Restore Default buttons.
The Set Current button allows you to save the changed settings on that page. The
Restore Default button restores the factory-default settings only to the values on
that page of the Printer Manager interface. When a current value is changed from
the default and the Set Current button is clicked, the current settings are then
used by the printer until the factory values are restored. The following sections
explain adjustments that can be made from the Printer Manager options menu.
Viewing Printer Status

Basic information about the printer and printer status can be viewed from the
submenus of the Status Option in Printer Manager. The Printer Manager Options
in the status menu show information about the printer but cannot be changed.
See the section titled “Status” on page 1-23 to see what information is available
from the Status submenus.
Viewing and Changing Printer Settings

Communication
The following settings on the communication menu can be adjusted.
Option Description
EthAddressMethod This is the method used to obtain the Ethernet network IP

Address. When the value is STATIC, EthIPAddress,
EthSubnetMask and EthGatewayAddress can be set. When the
value is DHCP, EthIPAddress, EthSubnetMask, and
EthGatewayAddress are written automatically.
EthGatewayAddress This is the Gateway IP Address for the Ethernet network. When
EthAddressMethod is STATIC, you can set this value. When
EthAddressMethod is DHCP, the DNS server controls this value.
EthIpAddress IP Address of the Ethernet network. When EthAddressMethod is

STATIC, you can set this value. When EthAddressMethod is
DHCP, the DNS server provides this value.
EthMacAddress MAC Address for the Ethernet network.
3-2 Adjustments
Option Description
EthSubnetMask Subnet Mask for the Ethernet network. When

EthAddressMethod is STATIC, you can set this value. When
EthAddressMethod is DHCP, the DNS server controls this value.
UsbDeviceMacAddress MAC Address for the USB device on the USB network.
UsbHostMacAddress MAC address for the USB host on the USB network.
Activity Log
Enable or disable an internal or external activity log using this menu option. It
lists the activities that can be included in the logs and allows you to set the
severity level for when the activity should be written to the log. Severity level
options include: off, critical, error, warning, notice, information, and debug.
Option Description
ExternalLog Enable or disable writing the Activity Log to an external Syslog

server.
ExternalLogServer Sets the IP Address of the external Syslog server.
FilterCardAction Writes the start and completion of card action, with this severity
and higher, to the Activity Log. Values range from Critical to
Information similar to Syslog severities.
FilterConfigChanges Write configuration change actions, with this severity and

higher, to the Activity Log. Values range from Critical to
FilterJobStates Write changes to the state of a print or exception job, with this
severity or higher, to the Activity Log. Values range from Critical
to Information similar to Syslog severities.
FilterSoapMsgs Write DPCL/Soap messages from the printer, with this severity
and higher, to the Activity Log. Values range from Critical to
FilterSystem Write system information, with this severity and higher, to the
Activity Log. A value of Information results in most events being
written to the log. Values range from Critical to Information
similar to Syslog severities.
InternalLog Enable or disable the Activity Log on the printer.

Activity Log Example
Following is an example of an external activity log using an application to
monitor the system log.
1. In Printer Manager select ActivityLog from the Printer Setting menu. In this
example:
• The ExternalLog option has been enabled
• The external log server IP address has been entered
• The FilterSOAPMsgs option has been set to filter for SOAP messages at the
Warning level or higher and add them to the log.
This example uses a free third-party application called Syslog Watcher for
Windows Personal Edition. This software is made by SNMPSoft Company
and can be downloaded for free from their Web site.
3-4 Adjustments
1. On the PC acting as the External Log Server, an application is running that
monitors messages from the printer. The following figure depicts the initial
screen before any messages have been received.
2. As errors occur, the log entries accumulate. If the log watcher is kept
minimized, messages like those shown at the bottom right appear above the
Task Bar whenever they are received.

Behavior
These options control the printer operation and magstripe encoding. See
“Enabling the Proprietary Magnetic Stripe Option” on page 5-27 for information
about using proprietary magstripe encoding.
Option Description
FactoryMode Enable or disable factory mode. This setting is set to disable by

the factory and cannot be changed.
MSAamvaEncoding Enable or disable encoding the AAMVA magstripe data

format. Disabled by default.
MSSaflokEncoding Enable or disable encoding the Saflok magstripe data format.

Disabled by default.
MSTimeloxEncoding Enable or disable encoding the Timelox magstripe data format.

MSVingEncoding Enable or disable encoding the Ving magstripe data format.

RibbonInitialize Enable/Disable initialization of the ribbon at power on.
WebServer Enable/Disable the Printer Manager. This setting is set by the

factory and cannot be changed.
Vital Product Data

This option displays the default and current values of vital product data.
Option Description
AgencyModelName Agency model
Manufacturer Name of printer manufacturer
ModelName Printer model name, assigned by the manufacturer or dealer
SerialNumber The serial number setting may need to be reset if replacing the
Print Engine Board.
3-6 Adjustments
Front Panel Options
This option has settings for the LCD panel, buttons, and the indicator lights. See
“LCD Display” on page 1-14 for information on the LCD display.
Option Description
BacklightBrightness Sets the LCD backlight intensity.

Range: 0 to 100
Default: 100
KeySenseLevel Sets sensitivity of front panel keys.

Range: 0 to 10
Default: 5
LCDConfigMenu Use the Front Panel LCD Configuration Menu.

Maintenance and Status menus cannot be disabled.
LedCardsPickedToCleaning Set the number of cards picked between cleaning. Card

LED shows steady Amber when the printer reaches this
value. When this value is 0 (zero), cards between cleaning
are not tracked.
Range: 0 to 1000000 cards
Default: 1500 cards
LedPrintheadCyclesToCleaning Set the number of printhead cycles between cleaning.

Card LED shows steady Amber when the printer reaches
this value. When this value is 0 (zero), cycles between
cleaning are not tracked.
Range: 0 to 1000000 cycles
Default: 2500 cycles
Explanation:
When the printer is using a 5-panel ribbon (YMCKT), there
are 5 printhead cycles per card. Logically you would set
the LedPrintheadCyclesToCleaning setting to 5 times that
of the LedCardsPickedToCleaning setting.
LedRibbonLow Set the percentage of ribbon remaining that would

indicate the ribbon was low. The ribbon LED shows steady
Green when the printer reaches this value.
Range: 0 to 100%
Default: 10%
SpeakerEnabled Use the speaker to provide sound indicators along with text
and lights on the front panel.

Print Settings
The print options that control the quality of the printing are listed in the
following table. The Print density is the overall lightness or darkness of the
printing and is a result of a combination of the CableCompMaxStrobe, the
YMCPowerCalibration, and the YMCPower. The first two, CableCompMaxStrobe
and YMCPowerCalibration, are factory adjustments. The third, YMCPower, is
adjustable in the field.
CableCompMaxStrobe
Adjusting this setting can balance print density where areas of strong contrast
come together. This adjustment is applied to all panels and affects overall
lightness and darkness. It is used to remove any transition lines.
Range: 0 to 100 special units
Default: 25 special units
Symptoms:
• Increase to increase density in most areas.
• Decrease to reduce unexpected lightness in smaller areas.
Note: This is a factory adjustment. The default value determined by Engineering
should not need adjustment in the field.
3-8 Adjustments
CardRegistration
This customer setting is the distance in millimeters (1mm 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 above zero will add to the total
card movement.
• Decreasing the CardRegistration adjustment below zero will subtract from
the total card movement.
Avoid setting this distance too short. If the card is not under the printhead when
it heats up to print, the ribbon will break cleanly. This is because the card is not
there to absorb the heat.
Explanation:
The card registration adjustments control the horizontal print margin on the card
by adjusting the distance the card moves after the trailing edge of the card
clears the Card Input sensor.
The CardRegistration calibration is done at the factory and may also be
adjusted by the technician in the field. The Card Registration adjustment
compensates for slight variations in card stock. The sum of the values of these
two adjustments determines the amount of card movement. For example,
StickIcards are slightly shorter than standard CR80 cards. When this adjustment is
set at the default of zero, the value of the previous adjustment,
CardRegistrationCalibration, is solely responsible for the position of the card.
Since the distance to the thermal printhead is fixed, varying the distance the
card moves will determine where on the card the printhead begins printing
when it is lowered.

CardRegistrationCalibration
This is a factory setting, but may be adjusted by the technician. It sets the
distance in millimeters (1mm 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 CardRegistration Calibration and the Card Registration setting
will equal the horizontal print margin.
Range: 0.5 to 100 mm (0.019 to 3.937 inches)
Default: 1.905 mm (0.075 inch)
Symptom:
• Increasing this adjustment moves the card further into the printer before the
printhead is lowered. This has the effect of moving the alignment bar farther
from the leading edge of the card.
Procedure:
To adjust the CardRegistrationCalibration:
1. Set the CardRegistration to its default value of zero.
2. Print Test Card 5 using the K Panel.
3. The trailing edge of the alignment bar should be exactly 5 mm (0.196 inch)
from the leading edge of the card. If it is not, adjust the CardRegistration
Calibration.
3-10 Adjustments
ColorManagement
Use color management in the printer. The sRGBColorSpace renders images to

look similar to those displayed on PC monitors using sRGB color. MatchSP will
result in printing that closely matches the legacy printers. None causes the
printer to use its native interpretation of RGB. Choose the type of color
management or none.
Options: None, sRGBColorSpace, MatchSP
Default: sRGBColorSpace
Explanation:
With None selected the printer uses its native interpretation of RGB. If enabled,
there are two choices. The sRGBColorSpace is a standard that ensures that
input colors are correctly mapped to output colors. The result is that the printer
output closely matches the colors viewed on the monitor. If you select MatchSP,
the result is printing that more closely matches the legacy printers. You may opt
to use this if you are replacing a legacy printer with the new card printer.
The figure below shows solid red, green, and blue cards using each of the Color
Management options. Since these were scanned, their appearance is affected
not only by your monitor, but also by the scanner’s profile. For additional
information on Color Management see “Color Management” on page 2-17.
FanTempOn
The printhead temperature in degrees Centigrade at which to operate the fan.

The fan goes on when the temperature is at or above this level. The fan turns off
when temperature drops 2 degrees below this value.
Range: 20 to 100° C (68 to 212° F)
Default: 42° C (107.6° F)
Notes: Setting the fan temperature too high may affect color balance of the
first cards in the run.

KPower
This customer setting increases or decreases print intensity for K panel or K

ribbon. Increase it to make single-color printing thicker. Decrease for crisp bar
codes or if the ribbon breaks when printing the K panel. This adjustment controls
the overall lightness or darkness of the K panel.
Range: -100 to 100 special units
Symptoms:
• Increase to make color printing more intense.
• Decrease to reduce intensity or to prevent ribbon breaks while printing
colors.
Example:
In this example, the first card has the
KPower set too low, resulting in voids in
the bar code.
The second card may have the

KPower set too high.
Printing a bar code in the landscape orientation, as shown here, could cause
bar width growth in which the bars are printed wider than they should be and
get even wider toward the trailing edge.
The correct method to adjust the KPower is to reduce the power until there are
voids in the bar code. Then increase the KPower until they just fill in. The printing
may look a little light to the eye, but this provides the best results for a bar code
reader.
3-12 Adjustments
Kpower1200

ribbon printed at 1200 DPI. Increase it to make single-color printing thicker.
Decrease for crisp bar codes or if the ribbon breaks when printing the K panel.
This adjustment controls the overall lightness or darkness of the K panel.
Symptoms:
colors.
Kpower600

ribbon printed at 600 DPI. Increase it to make single-color printing thicker.
Decrease for crisp bar codes or if the ribbon breaks when printing the K panel.
This adjustment controls the overall lightness or darkness of the K panel.
Symptoms:
colors.
KpowerCalibration
Change intensity of printing for the K ribbon or panel. Increase the power used
to print the K panel and make single-color printing thicker. Decrease for crisp
bar codes or if the ribbon breaks while printing the K panel.
Note: This is a factory setting.
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 single-color printing thicker.
Decrease for crisp bar codes or if the ribbon breaks while printing the K panel.

KpowerCalibration600
Change intensity of printing for the K ribbon or panel at 600 DPI. Increase the
power used to print the K panel and make single-color printing thicker.
Decrease for crisp bar codes or if the ribbon breaks while printing the K panel.
KPowerDuplex
This customer adjustment is for increasing or decreasing the print intensity for the
backside K panel or K ribbon.
Range: -100
Default: 100
Symptoms:
• Increase value to make single-color printing thicker.
• Decrease for crisp bar codes or if the ribbon breaks when printing the K
panel.
KWhiteShade
Power applied to the printhead to reduce ribbon friction without transferring

material. This adjustment affects the melting of the wax-like ribbon backcoating
to provide a slippery surface for the printhead. This prevents the printhead from
chattering (slightly catching and releasing) as it moves across the ribbon.
Range: -100 to 100 shades
Default: 0 shades
Symptoms:
• Reduce this value if material transfers to the card that should not.
3-14 Adjustments
LeadTrim
Number of millimeters (1mm is 0.040 inch or about 1.25 dot rows) to remove from
the leading edge of a full-size image to keep it within the print area.
Range: 0 to 5.08 mm (0 to 0.2 inch)
Explanation:
Image Trimming settings are used to achieve
the best results for edge-to-edge printing.
Not all applications send an image that is
exactly the same size as the card. Lead Trim
affects the left edge of the card when
viewed in the landscape mode as shown
here.

RibbonOffset
Distance in millimeters (1mm is 0.040 inch) to move the ribbon after the Index
Sensor event to start printing.
The printhead is physically downstream from the ribbon index sensor. The ribbon
offset setting represents the distance that the print ribbon is advanced after the
trailing edge of the index bar is detected.
This positions the ribbon such
that the printing begins about
8mm (0.315 inch) into the
yellow panel.
To adjust the Ribbon Offset,
ensure that the printer is set for
edge-to-edge printing and
then print a test card that has
printing on the leading edge.
When the card is complete,
examine the ribbon panels
used.
The gap from the end of the
index mark to the beginning of
print in the yellow panel should
be approximately 8mm (0.315
inch). If it is not, increase or
decrease the offset as indicated and repeat the process.
Range: 0.254 to 25.4 mm (0.01 to 1 inch)
Symptoms:
• If set too low or high, the card may be discolored on the left or right edge.
• If set too high or low, part of the ribbon index mark may stick to the card
and cause a jam.
Possible Mechanical Causes:
• Loose screws that secure the printhead to heatsink/housing
• Swingarm spring not secure
• Printhead not installed correctly in printer.
3-16 Adjustments
RibbonStripOffset
Distance in millimeters (1mm 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 may stick to the card when the
printhead heats up to transfer the dye from the ribbon to the card. While the
card and ribbon are both moving, this movement peels the ribbon from the
card. At the end of the printing process, the card moves an additional distance
to complete the process of peeling the ribbon (stripping it) from the card. The
RibbonStrip offset determines the distance the card continues to move after the
printing is complete.
Note: Engineering states that this should not require adjustment.
Range: 0.762 to 25.4 mm (0.03 to 1 inch)
Symptoms:
• If set too low, the ribbon may stick to the card.
• If set too high, decreased throughput may result.
SettingsGroupPurpose
Describe the purpose of the settings group. Group names are not changeable,
so use this setting to state the reason for creating the settings group.
Default: Print
Explanation:
In the future there will be 10 user groups available to save customized groups of
settings. This setting is a means to provide a description for the group. If you
were to customize several print settings for a particular job, you could save
them as a group and use this setting to define the purpose.
TPower
Customer setting to modify the intensity of printing for the T ribbon panel.
Symptoms:
• Increase to make printed topcoat thicker or more uniform.
• Decrease to prevent ribbon breaks while printing topcoat.
Note:
Beware that low energy settings can yield acceptable topcoat edges but may
affect long term durability due to poor adhesion.

TPowerCalibration
Modify the intensity of printing for the T ribbon panel. Increase this setting to
increase the power used to print the topcoat ribbon panel and make printed
topcoat thicker or more uniform. Decrease to prevent ribbon breaks while
printing topcoat.
TPowerDuplex
This customer adjustment is for increasing or decreasing the print intensity for the
backside T ribbon panel.
Range: -100
Default: 100
Symptoms:
• Increase value to make topcoat thicker and more uniform.
• Decrease value if the ribbon breaks when printing the topcoat.
TWhiteShade
Power applied to the printhead to reduce ribbon friction without transferring

material. This adjustment is to melt the wax-like ribbon backcoating to provide a
slippery surface for the printhead. This prevents the printhead from chattering
(or slightly catching and releasing) as it moves across the ribbon.
Default: 0 shades
Symptoms:
• Reduce this value if material transfers to the card that should not.
3-18 Adjustments
TrailTrim
Number of millimeters (1mm is 0.040 inch or about 1.25 dot rows) to remove from
the trailing edge of a full-size image to keep it within the print area.
Range: 0 to 5.08 mm (0 to 0.2 inch)
Explanation:
Trail Trim affects the right edge of the
card when viewed in the landscape
mode as shown in the figure.These trim
settings have no effect on the horizontal
print margin. When you perform the
Card Registration adjustments, the
values of the trim settings do not matter.

VerticalOffset
This offset aligns printing with the long edges of the card. It is the number of
printhead dots to shift printing toward the top or left side of the card. You
cannot change the number of dots between the long edges of the card.
Range: -100 to 100 dots
Default: 17 dots
Explanation:
The Vertical Offset positions the image on
the card by changing the elements used
to print the image. The printhead has
more heating elements than required to
cover the card vertically. The image’s
serial data is clocked into a shift register
within the printhead. The outputs of the
shift register are tied to the inputs to the
drivers in the printhead. To position the
image higher on the card, the serial data
is loaded higher in the shift register, which
causes higher heating elements to be
used. To lower the printed image, the
serial data is loaded lower in the shift
register.
YMCMinShade
This is the minimum shade value at which YMC color begins to transfer from the
ribbon to the card.
Default: 0 shades
Symptoms:
• If a white shirt in a photo does not print, increase this value.
• If highlights are washed out (grayish), decrease this value.
3-20 Adjustments
YMCPower
Customer setting to modify the intensity of printing for the Y, M, and C ribbon
panels. This adjustment controls the overall lightness or darkness of the YMC
panels.
Symptoms:
colors.
YMCPower600
Customer setting to modify the intensity of printing for the Y, M, and C ribbon
panels at 600 DPI. This adjustment controls the overall lightness or darkness of
the YMC panels.
Symptoms:
colors.
YMCPowerCalibration
Changes intensity of printing for the Y, M, and C ribbon panels. Increase the
power used to print the color panels to make colors stronger; decrease to
reduce intensity or prevent ribbon breaks while printing color panels.
This is set using a densitometer. It also affects the overall lightness or darkness of
the YMC panels printing. Prior to making this adjustment, set the field adjustment
of YMCPower to zero.

YMCPowerCalibration600
Changes intensity of printing for the Y, M, and C ribbon panels at 600 DPI.
Increase the power used to print the color panels to make colors stronger;
decrease to reduce intensity or prevent ribbon breaks while printing color
panels.
This is a factory setting made using a densitometer. It affects the overall lightness
or darkness of the YMC panels printing. Prior to making this adjustment, the field
adjustment of YMCPower600 is set to zero.
YMCPowerDuplex
Customer setting to modify the printing of the backside Y, M, and C ribbon

panels. Increase the power to print stronger color panels; decrease to reduce
intensity or prevent ribbon breaks while printing color panels.
This is set using a densitometer. It also affects the overall lightness or darkness of
the YMC panels printing. Prior to making this adjustment, the field adjustment,
YMCPower, is set to zero.
Range: -100 to 100
Default: 0
YMCWhiteShade
This setting affects power applied to the printhead to reduce ribbon friction
without transferring color. It affects the melting of the wax-like ribbon
backcoating to provide a slippery surface for the printhead. This prevents the
printhead from chattering (or slightly catching and releasing) as it moves across
the ribbon.
Default: 0 shades
Symptoms:
• Reduce this value if unprinted or white areas of the card have color applied
to them.
• If you decrease this setting too much, you may notice transition lines where
the image changes from a non-printed area to a printed area.
3-22 Adjustments
Print Misadjustment
Misadjustment of CardRegistrationCalibration, CardRegistration, LeadTrim, or
TrailTrim can also cause ribbon registration problems. This happens because the
ribbon is advanced by the thermal printhead when the card is not in position to
prevent the printhead from traveling further than it should.
For example, if the Trail Trim is set too long, the printhead remains down after
the end of the card has passed. This has the effect of the printhead pushing
downward on the ribbon and advancing it slightly. First ensure that the
horizontal print margin is correct. Then adjust the trim settings.
Pick Settings
The Pick settings control the pick motor and time frames for picking cards. These
adjustments are all related to feeding a card into the printer.
Sensors that might affect the picking of cards are: Card Input and Card Present.
To test sensors and the pick motor see “Troubleshooting” on page 4-1.

Option Description
MotorPWM This offset sets the pick motor PWM to a percentage. The adjustment
of the Pick motor is used to match it to the speed of the Transport
motor. Stalling may occur if the PWM is set too low.
Range: 0 to 100%
Default: 85%
Symptoms:
• If set too high, excessive noise is produced.
• If set too low, motor may stall.
PickAutoTimeOut Number of milliseconds to attempt to pick a card (when the

PickMethod is automatic), before declaring a card-not-picked
condition.
Range: 1000 to 10000 ms
Default: 3000 ms
Symptoms:
• If set too high, there is excessive noise due to extended run time
of the motor.
• If set too low, there may not be enough time to feed the card
into the printer, causing false errors.
Explanation:
A printer using an auto feed hopper makes two attempts at picking
the card. When the pick command is received, the Pick motor will
run for the time designated by this setting. The card must reach the
Card Input sensor within this time frame. If it does not, the pick was
unsuccessful. The time will reset, and the Pick motor will run for a
second time. When the time period of this setting is reached on the
second attempt, an error is issued.
3-24 Adjustments
Option Description
PickCardOffset This is the distance to move the card using the 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.
Note: Engineering does not recommend increasing this setting.
Range: 2.54 to 85.725 mm (0.1 to 3.375 inches)
Symptoms:
• If set too high, double card picking will occur.
• If set too low, the Transport motor may stall and there may be
excessive pick roller wear.
This setting controls the amount of pre-picking of a second card that
will be allowed. Decrease this setting if a second card is being
picked.
PickManualTimeout Number of seconds to attempt to pick a card (when the

PickMethod is Manual) before declaring a card-not-picked
condition.
Range: 1 to 300 seconds
Default: 120 seconds
Symptoms:
• If set too high, there is excessive wait time before an error is
issued.
• If set too low, there may not be enough time to push the card
into the printer, causing false errors.
Explanation:
A printer with the manual feed option has a card inserted into the
manual feed input that covers the card present sensor. The action
turns on the Transport motor and triggers this time period to begin.
The card must reach the Card Input sensor within this time frame or
an error will be issued.

Option Description
PickReversePwm PWM at which the pick motor will run in reverse.

Range: 0 to 100%
Default: 50%
PickReverseTime Milliseconds to run the Pick motor in reverse after picking a card to
prevent picking of two cards.
Range:100 to 300 ms
Default: 200 ms
Symptoms:
• If set too high, this may cause picking errors, especially for thin
cards.
• If set too low, cards may not be picked.
Explanation:
This setting is to ensure that the pick mechanism returns to the home
position. If cards are not being picked, this setting should be
increased. If there are picking errors for this cards, decrease this
setting.
3-26 Adjustments
Transport Settings
Option Description
TransMedSpeed Speed at which to run Transport motor when clearing

errors.
Range: 300 to 1800 steps per second
Default: 800 steps per second
TransportSpeed Transport motor speed for moving the card when not
printing, encoding, or doing other personalization.
Normally this setting should be left at the default value and
not adjusted.
Symptoms:
• If set too high, may stall the motor.
• If set too low, may result in reduced throughput.
This setting has no affect on the CD Series printers as they
have a special boost circuit to achieve this.
Magnetic Stripe General Settings

The Magnetic Stripe General settings are shown in the table below.
Option Description
Attempts Number of times to attempt writing magnetic data if verify is not

successful. Also used for the number of times to attempt reading
magnetic stripe data. A value of 1 means no retries.
Range: 1 to 5 attempts
Default: 3 attempts
AutoCoercivity If the Coercivity is HiCo or LoCo and magnetic stripe read or

verify fails, automatically change the Coercivity and read or
encode the data again. Using this feature doubles number of
retries and can affect how quickly cards are processed.
Options: Disable or Enable
Default: Disable

Option Description
Coercivity Coercivity defines the resistance of magnetic material to

remove encoded data. HICO (High Coercivity) requires more
electrical force (current) to encode data and is more resistant to
magnetic interference.
Options: HICO, LOCO, NTT1, NTT2, NTT3
Default: HICO
DataFormat1 Name of the data format for Track 1.

Options: IATA, ABA, TTS, JIS, AAMVA, AAMVA_ECC, VING,
SAFLOK, TIMELOX, ONITY, CUSTOM, BINARY75, BINARY210, NONE
DataFormat2 Name of the data format for Track 2.

DataFormat3 Name of the data format for Track 3 or single track.

SSA1 Start sentinel adjustment for Track 1. The value is determined by

the SSA test.
Range: -4 to 4 mm (-0.157 to 0.0157 inch)
3-28 Adjustments
Option Description
SSA2 Start sentinel adjustment for Track 2. The value is determined by

the SSA test.
SSA3 Start sentinel adjustment for Track 3 or single track. The value is
determined by the SSA test.
StripeReadEntryOffset Used to set the start of the read transition locations. Must be
bigger than StripeWriteEntryOffset but not past the start bit
location.
Note: Engineering does not recommend changing this setting.
Range: 0 to 500 steps
Default: 97 steps
StripeReadEventOffset Number of steps to move the card after the start of the sensor
event when reading or verifying magnetic stripe data.
Default: 1150 steps
StripeReadSpeed Transport motor speed when reading or verifying magnetic stripe

data.
StripeWriteEventOffset Number of steps to move the card during the write magnetic
stripe operation.
Default: 1050 steps
StripeWriteFwdEntryOffset Number of steps to move the card after the start of the sensor
event, followed by running the Cam motor as specified by
StripeWriteFwdUpOffset.
Default: 120 steps

Option Description
StripeWriteFwdUpOffset Number of steps to move the Cam motor to reach the option
position. When complete, the magnetic stripe data can be
written to the card.
Default: 40 steps
StripeWriteSpeed Transport motor speed while writing the magnetic stripe.

3-30 Adjustments
Magnetic Stripe Custom Track Settings
All of the MagStripeCustom Track adjustments are either User or Administrator
Access Level adjustments. Use Printer Manager to make these magnetic stripe
related adjustments. They are located in the Printer Setting Menu in the
MagStripeTrack1 Submenu. There is an identical Submenu for each mag stripe
track. The track 1 submenu will be used to discuss the adjustments. Track 3
settings are for Track 3 or Single Track.
Option Description
CustomCharHigh1(-3) Numeric value of the highest ASCII character supported for

input data on Track 1.
Range: 1 to 255
Default: 95
CustomCharLength1(-3) The number of bits to represent one byte of data on Track

1, also called bits per character or BPC.
Range: 1 to 8
Default: 6
CustomCharLow1(-3) Numeric value of the lowest ASCII character supported for

input data on Track 1.
Range: 1 to 255
Default: 32
CustomCharMask1(-3) Encoding mask for Track 1. This mask is added to the ASCII
numeric value for data sent to equal the encoded value.
Range: 1 to 255
Default: 32
CustomCharMax1(-3) Maximum number of data characters for Track 1. This value

does not include the Start Sentinel or End Sentinel.
Range: 1 to 255
Default: 76
CustomDensity1(-3) Number of data bits per inch of magnetic stripe media for
Track 1, also called bits per inch or BPI. Allowed values are
75 BPI or 210 BPI.
Range: 1 to 255 bits per inch
Default: 210 bits per inch

Option Description
CustomEndSentinel1(-3) The last character encoded, which identifies the end of

the encoded data for Track 1.
Range: 1 to 255
Default: 63
CustomLrc1(-3) Cumulative parity bit for Track 1. 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
CustomParity1(-3) Character-level parity bit for Track 1. It is encoded after

each character, provides simple error checking, and is also
called Vertical Redundancy Check or VRC.
Range: Allowed values are EVEN, ODD and NONE.
Default: ODD
CustomSdsNulls1(-3) The number of nulls between each copy of the data

record. The default value is 0. Change this value only if you
are setting up the SDS meta-format for Track 1.
Range: 0 to 255
Default: 0
CustomSdsRecords1(-3) The number of times to encode the data record. The

default value is 1. Change this value only if you are setting
up the SDS meta-format for Track 1.
Range: 0 to 255
Default: 1
CustomSdsSs1(-3) The number of Start Sentinels before each data record. The
default value is 1. Change this value only if you are setting
up the SDS meta-format for Track 2. Use Track 3 settings for
a single-track option.
Range: 1 to 255
Default: 1
CustomStartSentinel1(-3) The first character encoded, which identifies the start of

the encoded data for Track 1.
Range: 1 to 255
Default: 37
3-32 Adjustments
Magnetic Stripe Track Height Adjustment
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 verification; this dual-use could cause the card to work properly on the card
printer but not be readable for a customer.
See “For Magnetic Stripe Option” on page 5-3 for the required tools used in this
procedure.
Misadjustment Symptom
Various magnetic stripe read errors.
Solution
Run a magnetic stripe test card, spray with developer, check with sight glass, and
replace the magnetic stripe head as required.
Prerequisite Adjustments or Actions

• Clean the magnetic stripe roller.
• Clean the magnetic stripe head (if necessary)
Follow-up Adjustments
• “Start Sentinel Position Adjustment” on page 3-34
Procedure
1. Print a magnetic stripe test card using Printer Manager.
A. Select Test Card from the TroubleShooting menu.
B. Check MagStripe and click Run.
2. Check the vertical track alignment (track height) with an alignment gauge.
A. Wipe the card with a clean, lint-free cloth.
B. Apply developer to the card.
C. Using the alignment gauge, check the vertical track alignment.
Notes
• Ideally, the encoding should be centered within the etched lines that define
each track. Be sure the encoding for each track does not touch the etched line
above or below it.
• If each of the three tracks are vertically centered within the three sets of etched
lines, the positioning of the magnetic stripe head is correct.

Start Sentinel Position Adjustment
See “For Magnetic Stripe Option” on page 5-3 for the required tools used in this
procedure.
Misadjustment Symptom
Various magnetic stripe start sentinel errors.
Solution
Run a magnetic stripe test card, spray with developer, check with sight glass and
adjust the start sentinel as required.
Prerequisite Adjustments or Actions

• “Magnetic Stripe Track Height Adjustment” on page 3-33
Follow-up Adjustments
• None
Procedure
1. Print a magnetic stripe test card using Printer Manager.
A. Select Test Card from the TroubleShooting menu.
B. Check MagStripe and click Run.

2. Check the start sentinel positioning with an alignment gauge.
A. Wipe the card with a clean, lint-free cloth.
B. Apply developer to the card.
C. Using the alignment gauge, check the start sentinel positioning for each of
the three tracks. The first bit of each start sentinel should lie between the
vertical etched lines on the alignment gauge.
3-34 Adjustments
3. If adjustment is required, use “SSA Test” on page 4-12.

Flipper (Duplex) Adjustments
The Duplex module has adjustments on the Printer Setting menu in the Flipper
submenu of Printer Manager.
Option Description
FlipperHomeOffset There are several rotational offsets, but only the

FlipperHomeOffset should be adjusted because the others
are referenced to it. Incorrect adjustment, either high or
low, of any of these rotational offsets causes card jams. This
adjustment positions the Flipper to receive a card from the
printer chassis.
This is the offset from the sensor to put the duplex at home
position.
Range: 1 to 60
Default: Typically 23
Symptoms:
• If set too high, may cause card jam.
• If set too low, may cause card jam.
This adjustment cannot be done in the field at this time.
FlipperFlippedAngle This is the offset from home when the flipper is upside
down. This offset should not be adjusted as it is referenced
from the FlipperHomeOffset.
Range: 1 to 500
Default: Typical is 250
Symptoms:
FlipperRegistrationOffset This is the offset from the Exit sensor to load the flipper.
Engineering does not want this adjusted.
Range: 1 to 500
Symptoms:
This adjustment cannot be done in the field at this time
because there is no test to put a card in the Flipper.
Evaluate the adjustment by printing a card.
3-36 Adjustments
Option Description
FlipperRejectAngle This is the offset from home clockwise for deflecting cards
into the reject tray. As the card leaves the printer chassis, it
does not enter the Flipper. Instead the Flipper is positioned
so that the card defects off the bottom of the Flipper into
the Reject tray.
Range: 1 to 500
Symptoms:
Engineering does not want this adjusted. This offset should
not be adjusted as it is referenced from the FlipperHome
Offset.
FlipperRotationSpeed This is the speed of the flipper as it rotates. If it needs

adjustment, there is probably a mechanical problem.
Range: 200 to 1200
Symptoms:
• If set too high, excessive noise is generated.
• If set too low, motor may stall.
FlipperSmartAngle This is the angle relative to the homed Flipper for smart
card position. The card is sent and received in the same
angle.
Range: 1 to 499
Symptoms:
• If set too high, cards may jam.
• If set too low, cards may jam.

Option Description
SmartinOffset Offset into the smart card module from the leading edge.
Range: 1 to 300
Symptoms:
SmartoutOffset Offset out of the smart card module from the trailing edge.
This is the distance that the card moves after the trailing
edge clears the Smart Card sensor. When module is
properly adjusted, the card should be centered in the
Flipper.
Range: 1 to 300
Symptoms:
Engineering does not want this adjusted. Testing can only
be done by producing a test card.
3-38 Adjustments
Chapter 4: Troubleshooting
This chapter provides troubleshooting information for the card

printer.
General Notes _______________________________________________________ 4-2

General Troubleshooting Procedures __________________________________ 4-2
Non-Clearing Repetitive Messages____________________________________ 4-2
Sensors ______________________________________________________________ 4-3
Test the Sensors____________________________________________________ 4-3
Test the Sensors Using Continuous Update___________________________ 4-3
Determine if the Sensor Has Failed __________________________________ 4-4
Test Card ____________________________________________________________ 4-5
Troubleshooting Motors ______________________________________________ 4-10
Testing the Ribbon and Pick Motors ________________________________ 4-10
Testing the Cam and Transport Motors _____________________________ 4-11
Other Troubleshooting Procedures ___________________________________ 4-12
Placing Cam in Uninstall Position___________________________________ 4-12
Testing the Thermal Printhead (TPH) Fan____________________________ 4-12
Diagnosing the Ribbon RFID Antenna ______________________________ 4-12
SSA Test __________________________________________________________ 4-12
Testing Smart Cards _________________________________________________ 4-13
Dual Contact/Contactless ________________________________________ 4-13
HID iClass Reader/Writer __________________________________________ 4-16
Basic Smart Card Integrator _______________________________________ 4-18
Performance Problems ______________________________________________ 4-19
Printer Initialization Errors __________________________________________ 4-19
Card Jams at Card Input _________________________________________ 4-20
Card Stalls at Output Stacker______________________________________ 4-20
Card Jams in Printing Area ________________________________________ 4-21
Ribbon Break Errors _______________________________________________ 4-21
Error Codes _________________________________________________________ 4-22
General Notes____________________________________________________ 4-22
Lost or Jammed Cards ____________________________________________ 4-22
Driver Errors_______________________________________________________ 4-23
Printer Errors _____________________________________________________ 4-24
Print Misadjustment _______________________________________________ 4-27

General Notes
The “My XPS Card Printer” help file contains a great deal of information for
troubleshooting the system--such as print quality and software
communication problems. To open “My XPS Card Printer,” click the desktop
icon that was installed with the driver.
General Troubleshooting Procedures

CAUTION: This section is written only for a fully-trained technician.
Performing these procedures in an inappropriate manner will damage the
printer. Even a trained technician should use care in applying these
procedures to avoid permanent damage to the printer.
The following procedures present rough guidelines for isolating the cause of a
failure. These scenarios do not cover every aspect of the devices but should
provide enough information to isolate the root cause.
Many of these procedures assume a familiarity with the printer’s diagnostic

software. For further information about Diagnostics, refer to chapter 5 of this
manual.
Unless instructed otherwise, always unplug the printer before connecting or
disconnecting an electrical device from a circuit board.
Non-Clearing Repetitive Messages

If the printer encounters an error that will not allow it to begin production,
clearing the error message may result in the printer continuing to test for the
same error condition. This will result in a repetitive error message which
prevents the customer engineer from performing diagnostic routines to
troubleshoot the error.
This type of situation may be caused by a failed cam motor, card input sensor,
card exit sensor, etc.
When the error message is displayed and the printer beeps, do not clear the error
message from the computer's screen. Instead, hold the User Button in until the
Light turns green. The printer will cancel its present job and go into suspend
mode. Press the User button again to go back on-line. The printer ignores the
error until a task is performed to reveal the error again. During the course of your
investigation, you may need to repeat this procedure.
4-2 Troubleshooting
Sensors
The Sensors option on the Printer Manager Troubleshooting menu shows a list of
all sensors in the printer with their jumper number, current state (not real-time),
history and type. It also has options to start an update and reset the sensor
history. The continuous update interval can be adjusted from this display.
The current state is not updated to real time until you perform a test of the
sensors. To test the card printer sensors follow the procedures below.
Test the Sensors

1. Using Printer Manager, navigate to TroubleShooting | Sensors.
2. Click Run.
3. The screen blinks while the card printer runs the sensor test.
4. The Current and History columns are updated to reflect any changes detected
during the test.
Test the Sensors Using Continuous Update

1. Using Printer Manager, navigate to TroubleShooting | Sensors.
2. Enter the interval time in seconds and click Start Update.
3. The sensors are sampled at the interval indicated until you click Stop Update.
4. To reset Sensor History click Reset.
Printer Function Associated Sensors

Card Feed and Picking Card Present, Card Input
Card Transport Card Input, Card Exit, Cam Home
Card Printing Card Input, Cam Home
Ribbon Advance Ribbon Index, Ribbon Motion
Magnetic Stripe Read/Write Card Input, Magstripe Encoder, Card Exit
Smart Card none
Flipper Duplex Home

Determine if the Sensor Has Failed
This procedure determines if a sensor has failed or if the main control board is not
seeing the sensor properly. The first step in troubleshooting a sensor is to
determine if the sensor is toggling from an active state to an inactive state as a
physical condition changes.
1. Verify that the sensor is fully plugged into the control board. In some cases,
an unplugged sensor will be displayed as “active” in the Printer Manager
window.
2. Using Printer Manager, observe the sensor status indicator. Unplug the
printer and swap the sensor with another sensor:
• Because this is a test of the sensor, the original sensor does not need to be
removed. Simply unplug the original sensor from the control board and
plug in a replacement sensor.
• If a spare sensor is not available, you can use a compatible sensor from
within the printer. (Except for the ribbon encoder and magnetic stripe
encoder sensors, all sensors are electrically compatible.)
• The sensor does not need to be the same type. For example, a transmissive
sensor can be used in place of a reflective sensor. (The transmissive sensor
is easier to block and unblock.)
Do not swap the ribbon encoder or magnetic stripe encoder sensors with any
other sensor. These sensors are not electronically compatible.
3. If the replacement sensor functions, the original sensor is defective. Verify

this by reconnecting the original sensor.
4. If the replacement sensor is non-functional and other sensors in the printer

are observed to be functional, the main control board is defective. (If none of
the sensors are functional, you may have a communication problem between
the printer and Printer Manager.)
4-4 Troubleshooting
Test Card
The Test Card selections allows you to choose from several Test Patterns and Test
Card Options. You may choose whether or not to encode the mag stripe and also
which ribbon panels will be used. You may also opt to print additional copies.
Option Description
Test Cards Note: No values selected will reset the cam and act like a pick
and eject test.
Options: MagStripe, Color, Monochrome, or Topcoat
Default: Color
Copies Range: 1 - 10
Default: 1
TestPattern1 Full color test card.

Option Description
TestPattern2 Halfcolor testcard.
TestPattern3 Dense blue testcard.
4-6 Troubleshooting
Option Description
TestPattern4 Color step testcard (RGBK/YMC)
TestPattern5 Used to set up card registration.

Option Description
TestPatternRegistration Used to test card registration mechanically. Side/side or lead/

trailing may indicate a chassis, card guide, or roller problem.
TestPatternCheckered Used to test card registration mechanically. Side/side or lead/

trailing may indicate a chassis, card guide, or roller problem.
TestPatternShort Used to print short panel YMCKT.
4-8 Troubleshooting
Option Description
TestPatternGrid Full K panel test card.
The TestPatternManufacturing test cards are used only in manufacturing

setup.

Troubleshooting Motors
Each of the motors of the card printer has a submenu option on the
Troubleshooting Menu. For each motor you can set the parameters and run the
test. The parameters are described in the list below.
Opening the swingarm will cancel the motor test for the transport, pick, cam
and ribbon motors.
Motor Description
Transport You can adjust the Direction, Speed, and Steps. The steps
setting will determine the amount of time the motor runs.
Pick You can adjust the Direction, PWM, and Time. The PWM
controls speed and torque. Decreasing the PWM means
less speed and torque.
Caution: Before running this test make sure you remove all
cards from the Card Hopper. If you do not, you will feed
several cards and jam the printer.
Cam You can control the Direction, Speed, and Steps. The cam
motor can be set to an uninstall position, see “Other
Troubleshooting Procedures” on page 4-12.
Ribbon You can adjust the PWM and Time.

Note: Remove the ribbon cartridge before running this test
so no ribbon in wasted in the process.
Duplex Flipper Use the Test Flipper submenu to verify function of this
motor.
Duplex Transport Use the Test Flipper Trans submenu to test this motor, which
moves the Drive Rollers to transport the card. (This motor is
the upper one on the duplex chassis.)
Fan Use this test to run the printhead fan. You can control only
Time using this test.
The best way to determine if a motor has failed versus a main control board, is to
swap the motor with a similar motor. If a motor has failed, a replacement motor
should function. If the motor’s driver has failed, a replacement motor will not
function either.
Testing the Ribbon and Pick Motors

The ribbon and pick motors are identical, so swapping the two motors can isolate
whether the motor or the print engine board is faulty.
4-10 Troubleshooting
1. Using Printer Manager, test the motor.
Testing the Cam and Transport Motors

The cam and transport motors are identical, so swapping the two motors can
isolate whether the motor or the print engine board is faulty.
1. Swap motor connectors on the print engine board, J12 for the cam motor and
J11 for the transport.
2. Using Printer Manager, test the motor.

Other Troubleshooting Procedures
Placing Cam in Uninstall Position
To place the cam in the correct position for uninstalling the cam slide, use the
following procedure.
1. Select the Test Cam option from the troubleshooting menu in Printer
Manager.
2. Set the Speed to 600 and the Steps to 310 and click Run.
Testing the Thermal Printhead (TPH) Fan

The printhead fan should begin to run when it reaches the correct temperature.
See “FanTempOn” on page 3-11 in the Print Settings. If the fan is not working, the
best way to test it is to connect another fan. There is no compatible jumper on the
board to use to test. If the other fan does not work, the board is the problem.
The fan makes little noise while running so if you are in a noisy location, it
may be difficult to rely on sound to determine if the fan is working.
Diagnosing the Ribbon RFID Antenna

The circuit board for the RFID antenna is very simple and not prone to failure. If a
failure exists in identifying a ribbon, the most likely cause is with the ribbon’s tag.
Test it by replacing the supply spool with a new spool.
If the printer cannot read any ID tags, check the cable leading to the print engine
board. If the cable is connected properly, the print engine board is likely at fault.
SSA Test
This option on the Troubleshooting menu will perform a Start Sentinel
adjustment (SSA) test. Use the SSA test to automatically adjust the position of the
start sentinel for all 3 tracks simultaneously. The adjusted values will be written
to the magstripe general setting in Printer Manager for all three tracks.
Testing Smart Cards
The following procedures are for testing types of smart cards.
Dual Contact/Contactless
Smart PC/SC Diagnostics is used to read the ATR of the smart card. The
diagnostics can be downloaded from SCM Microsystems at:
www.scmmicrosystems.com.
Test Procedure
1. Install the SCM diagnostics (SmartPCSCDiag V2.04 or higher) and the SCM
driver.
2. Connect the USB port on the rear of the printer to a USB port on the PC.
3. Open SCM diagnostics as shown:
4. Click on Connected Readers.

5. Click on SCR331-DI Smart Card Reader.

6. Open Print Manager and display the Troubleshooting tab. Choose the
Testcard test.
7. Clear all Test Card Print Options check boxes to avoid printing on a smart
card.
8. Put a contact smart card into the input tray. Scroll down to Test Card Other
Option. Select the Park Smart Card check box. If desired, change Copies as
well as Smart Card Park Time.
9. Click on Run. The card will be picked and go into the smart card module. The
ATR of the card is read.
10. Click on SCR331-DI USB Contactless Reader.
11. Put a contactless smart card into the input tray. Click on Run. The card will be
picked and go into the smart card module. The ATR of the card is read.

12. The test is complete.
HID iClass Reader/Writer

The RFID1356i Configuration Utility is used to read the Filter Mask, Facility Code
and ID Code from the HID iClass card. The configuration utility can be
downloaded from RFIDeas Inc at: www.rfideas.com.
Test Procedure
1. Install the RFID 1356i configuration utility.
3. Open the RFID 1356i configuration utility.
4. Place an HID iClass card into the input tray.
Testcard test.
6. Clear all Test Card Print Options check boxes to avoid printing on the HID
iClass card.
7. Scroll down to Test Card Other Option. Select the Park Smart Card check
box. If desired, change Copies as well as Smart Card Park Time.
8. Click on Run. The card will be picked and go into the smart card module.
9. From the Advanced Configuration tab, click on the Get ID button to get the
Filter Mask, Facility Code, and ID Code from the card.
10. If necessary, change the time in data is valid for to another elapse time. Once
this time elapses, the card data is discarded. The minimum value is 900. The
figure shows a value of 2500 (or 2.5 seconds).

Basic Smart Card Integrator
Use the diagnostics/smart card driver from the 3rd party smart card
manufacturer to read the ATR on the smart card. Use the configuration utility of
the 3rd party reader or reader/writer manufacturer to read the Filter Mask,
Facility Code, and ID Code from the card.
Test Procedure
1. Install the 3rd party diagnostics/smart card driver or configuration utility.
3. Open the 3rd party diagnostics or configuration utility.
4. Place the 3rd party card into the hopper.
Testcard test.
6. Clear all Test Card Print Options check boxes to avoid printing on the 3rd
party card.
7. Scroll down to Test Card Other Option. Select the Park Smart Card check
box. If desired, change Copies as well as Smart Card Park Time.
8. Click on Run. The card will be picked and go into the smart card module.
9. Verify the 3rd party card can be read.
Performance Problems
Printer Initialization Errors
Symptom Comments
The printer initializes but reports • Check the operation of the card input sensor using the
a card stuck in the transport, sensor screen in printer Diagnostics. If the sensor is
and the transport runs more always blocked, it is either disconnected or not fully
than expected. seated (obscured by part of the chassis).
• Check the operation of the magnetic stripe registration
sensor using the sensor screen in Printer Diagnostics. If
the sensor is always active (non-reflecting):
- The sensor may be disconnected.
- The sensor may not be seated (doesn't reflect off of
rocker).
- The sensor has failed.
The printer initializes but reports • Check the encoder on the ribbon cartridge for
a broken print ribbon. damage.
• Make sure the encoder board is connected and
functioning.
The printer initializes and the Remove the ribbon and close the cover. Check the sensor
ribbon is advanced, but the setting in Diagnostics. If the sensor is not active:
printer reports that the index • Make sure the reflective tape is present on the
mark could not be found. printhead.
• Make sure the sensor is plugged in.
• Replace the sensor.
Frequent time-out errors occur If there are other USB devices on the same computer, they
at the beginning of printing. may interfere with timely communication with the printer.
Specifically look for the following:
• Is the card creation program saving its file or database
to a USB device?
• USB mass storage devices, where some program
application is set to auto-save to the device.
• A program application that is using or referencing a USB
device on a regular basis.

Card Jams at Card Input
Symptom Comments
A card is not picked from the • Clean the printer.
input hopper. • Use graphic quality cards.
• Fan cards properly.
• Inspect the pick roller for buildup or debris.
• Test the pick motor using Diagnostics.
• Inspect the card gate to make sure it is securely
fastened.
• Inspect the card stock for burrs and excessive static
buildup.
• Inspect the pick roller and test the motor function.
The card is picked but stalls at • Clean the printer.
the cleaning rollers. • Inspect the cleaning rollers for excessive debris.
• Transport not working.
A card is picked and appears to • Clean the card input sensor.
be properly positioned, but the • Check the position of the card input sensor and make
error is still reported. sure it is fully and firmly seated into the transport.
• Check the operation of the card input sensor using the
sensor diagnostics.
• If the sensor is always blocked, it is either disconnected,
or not fully seated (obscured by part of the transport).
• If the sensor never blocks, either the cable has a short
circuit, or the sensor is not seated at all (outside of the
card track).
Card Stalls at Output Stacker

Symptom Comments
Completed cards frequently fail • Clean the rollers in the printer.
to drop into the card output • This situation is more likely to occur with thinner cards or
stacker. cards printed on one side only.
• Reduce static in the area of the printer by increasing the
relative humidity.
• Use thicker cards.
• Empty output tray often.
• Make sure the static brushes are installed.
Card Jams in Printing Area
Symptom Comments
Card stops prior to reaching the • Clean the rollers in the printer.
platen roller. • Increase the card registration distance.
Card stops under the printhead. • Inspect the card for improper print ribbon panel
placement. Printing with the wrong panel can cause the
ribbon to adhere to the card.
• Decrease the printing brightness setting.
• Inspect the card guide for placement and damage.
Card stops past the printhead.
Ribbon Break Errors

Symptom Comments
Ribbon did not break, but the • Clean the printhead. It may be preventing the ribbon
error is reported. from advancing.
• Check the ribbon encoder wheel. Verify that it is
positioned in the sensor and is not damaged.
• Check the ribbon encoder sensor cable to make sure it is
connected.
• Check the sensor to make sure it is functional and
correctly aligned.
• Check the ribbon motor and make sure it is functional.
• Check the ribbon motor gear and take-up spool gear for
damage or broken teeth.
• Check the ribbon cartridge clutch.
• Check that the ribbon is attached to the take-up ribbon
core.
• Check to see that the ribbon is not sticking to the card.
The ribbon frequently breaks. • Check the Card Registration Offset.
• Adjust the image trimming farther from the edge of the
card.
• Make sure the printing intensity is not too dark. On an
edge-to-edge image when the leading edge of the
image uses 100% of a color (Y, M, or C), the ribbon may
get burned if the card is not fully under the printhead to
absorb the heat.
• Check for burrs on the edges of the cards.
• Make sure the cards being used are not already printed.

Error Codes
When an unexpected or undesired event occurs, the printer and/or software will
generate an error code to be displayed on the monitor. Many times the error code
is informational to instruct 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.
General Notes
This section is not intended to instruct the user on how to handle routine errors.
For errors considered to be routine, the solution presented assumes that the error
is repetitive. For example, a simple card jam can occur periodically without a
specific cause. However, a repetitive card jam would indicate a problem with the
printer.
Lost or Jammed Cards

There is a significant difference between a card being lost versus stuck (or
jammed). A lost card means it was not seen by a sensor. A jammed card means
the sensor never cleared. These two distinctions can be helpful when determining
the cause of an error. For example, if the printer is reporting a jammed card but
the card is not located under the sensor, the first place to begin troubleshooting is
with the sensor (it is possibly unplugged).
Driver Errors
Error Code Symptom Cause
500 The printer is not available. The driver cannot communicate with
The card cannot print. the printer.
Comments:
USB Connection
• Make sure the LCD display shows ready
• Check the USB cable
• Make sure the PC’s USB port is functioning. The USB port must be USB 2.0 as well
as a HUB if used.
• Bonjour must be installed and the service running
• PC should not be connected to a network using VPN
• In device manager under network adapters, check to see if 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. Run the ping command as follows on the command prompt: ping
Axxxxx.local.
• Verify that bidirectional setting is checked in the ports tab.
• The configure port in the ports tab should have Axxxxx.local. set (This is based
on the serial number -> serial number + .local. string)
Ethernet Connection
• Make sure the LCD shows ready.
• Check the Ethernet cable.
• Make sure the computer Ethernet port is functioning.
• Check the network activity light on the printer network connector to see if
there is any network activity.
• PC should not be connected to a network using VPN.
• Check if printer is communicating. To check for this, you need to ping the
Ethernet printer. Run the ping command as follows on the command prompt:
ping IP Address.
• Verify that bidirectional setting is checked in the ports tab.
• The configure port in the ports tab should have the IP Address set.
501 The printer connection was lost. Printing The connection to the printer was
the card is canceled. broken after printing started.
502 The card data is missing or is not usable. The driver could not use the prepared
The card cannot print. data.
503 The magnetic stripe data is missing. The The driver is set to encode magnetic
card cannot print. stripe data only.
505 Bonjour is not installed. Unable to Install Bonjour.
connect to printer.
506 The driver is currently processing an Wait until the current card is complete
interactive job. and then send the card again.

Printer Errors
Error Symptom Cause Comments
Code
100 Request not supported The printer cannot • Change the data to match
interpret the data. printer features and settings
101 Job could not complete The card took too much
time to print.
102 Card not in position (Print) The card is either lost in • Use diagnostics to check
the printer (not seen by a sensors
sensor) or the card is stuck
in the printer (sensor
never cleared).
Card not in position Card exit or entry on • Card jams getting into or
(magnetic stripe) photocell. out of magnetic stripe
registration photocell
• Mechanical offsets need
adjustment
103 Printer problem The printhead cam is not • Check the printhead cam
in the correct position to sensor
print. • Inspect the cam gear for
damage
• Test the cam motor
• Test the transport motor
104 Critical problem
105 Magnetic stripe data The printer could not • Run a cleaning card
error verify the magnetic stripe • Try different card stock
data written on card • Check the printer’s
(parity, start sentinel, LRC, coercivity setting to make
end sentinel). sure it matches the card
being used
• Bad or missing track on
card
• The start sentinel may not
be adjusted correctly
• Mechanical offsets may
need adjustments
• Check the magnetic stripe
head
optical encoder
daughter board
• Check the main control
board
Code
106 Magnetic stripe data not The printer could not find • Card is backwards
found. magnetic stripe data on • Magnetic stripe read or
the card. write head failure
107 Magnetic stripe read The printer could not read
data error. the magnetic stripe data
on the card.
108 Magnetic stripe read no The printer did not find • Card is backwards
data. any magnetic stripe data • Magnetic stripe read head
on the card. failure
109 Print ribbon problem. The print ribbon is not • Ribbon is missing
moving properly.
110 Print ribbon out or missing. The printer does not have • Check encoder in
usable ribbon. diagnostics
111 Card not picked. The printer did not pick a • Clean the printer
card. • Use graphic-quality cards
• Fan cards properly
• Inspect the pick roller for
buildup or debris
• Test the pick motor using
diagnostics
• Inspect the card gate to
make sure it is securely
fastened.
• Inspect the pick roller and
test the motor function
112 Card hopper empty. The printer does not • Check sensor using
detect cards in the input diagnostics
hopper or slot.
113 Close cover to continue. The printer must be closed • If the cover was not
to print. opened, check the sensor
for a loose connection
• Use diagnostics to test the
sensor
114 Cover open during job. The printer must be closed • If the cover was not
to print. opened, check the sensor
for a loose connection
• Use diagnostics to test the
sensor

Code
115 Wait for print temperature Printer is waiting for the • Printing the card will resume
printhead to cool. on its own
• Check the printhead fan
and its connections; it may
be defective
• Check for blocked air flow
• Check the printhead
assembly for the following
failed components:
- Printhead
- Cartridge
- Cable
• Main control board
• Connect cable to the
printhead cartridge
116 Magnetic stripe not Magnetic stripe option is • Remove the magnetic
available. not installed. stripe data from the card
and print the card
• Board is missing
• Hardware failure on board
or connector
117 Reader not available. The printer does not have • Remove the reader data
a reader option. from the card to print the
card
• Board is missing
• Hardware failure on board
or connector
118 Print ribbon type problem. The printer cannot use the • Use ribbon designed for the
ribbon installed. printer model and brand
• Check antenna board
• Check antenna cable
119 Print ribbon not The printer cannot use the • Use ribbon designed for the
supported. ribbon installed. printer model and brand
120 User paused the printer. A person pressed the user
button on the printer
while a card was in
process
121 Print ribbon ID problem. The ribbon data is
damaged.
Code
122 Magnetic stripe format The magnetic stripe data • Check the data entered to
problem. sent does not match the see if application is sending
format setting in the data to match correct
printer. track format.
• Check the application and
the printer configuration to
see that they match and
are set correctly
• Invalid data for track
defined
• Check track formats
selected
• Track is locked proprietary
• If this occurs frequently:
- Run a cleaning card
- Check the magnetic
stripe head
stripe optical encoder
stripe daughter board
123 Insert a new card then This is an exception job Insert the card in the printer
continue. such as a cleaning card
or manual card.
124 Insert same card then The current card is part of Turn the card over and insert
continue. a two-sided job. the card in the printer.
Print Misadjustment
Misadjustment of the CardRegistrationCalibration, CardRegistration, LeadTrim, or
TrailTrim can also cause ribbon registration problems. This happens because the
ribbon is advanced by the printhead when the card is not in position to prevent
the printhead from traveling further than it should. For more information and an
example see “Print Misadjustment” on page 3-23.

Chapter 5: Routine
Maintenance
This chapter provides card printer maintenance procedures for
both the operator and the service technician.
Required Tools and Supplies __________________________________________ 5-2

For Remove and Replace Procedures ______________________________ 5-2
For Magnetic Stripe Option ________________________________________ 5-3
For Smart Card Option _____________________________________________ 5-3
Avoiding Electrostatic Discharge ______________________________________ 5-4
Screw Torque Specifications __________________________________________ 5-5
Preventive Maintenance Procedures __________________________________ 5-6
Mechanical Inspection ____________________________________________ 5-6
Cleaning the Interior of the Printer _________________________________ 5-12
Lubricating the Grease Points _____________________________________ 5-12
Lubricating the Magnetic Stripe Assembly _________________________ 5-16
Cleaning the Rollers ______________________________________________ 5-17
Maintaining the Smart Card Module _______________________________ 5-19
Visual Inspection for Card Quality _________________________________ 5-20
Maintaining the Magnetic Stripe Module __________________________ 5-20
Operator Maintenance ______________________________________________ 5-21
Cleaning the Thermal Printhead (TPH) _____________________________ 5-21
Using the Cleaning Card __________________________________________ 5-21
Updating Printer Settings _____________________________________________ 5-23
Replacing the Print Engine Drive Board _______________________________ 5-25
Downloading Settings File for Board _______________________________ 5-25
Updating Settings_________________________________________________ 5-26
Enabling the Proprietary Magnetic Stripe Option ______________________ 5-27
Downloading Settings File for Magnetic Stripe Option_______________ 5-27
Updating Settings_________________________________________________ 5-28
Verifying Proprietary Magnetic Stripe Option _______________________ 5-28

Required Tools and Supplies
The following tools and supplies are needed for routine maintenance procedures.
Description Part Number
Compressed air (canned) TUL001-018
General purpose, non-abrasive cleaner Any
Lint-free cloth TUL001-020
Isopropanol cleaning pen 557492-001
Isopropanol cleaning card (10-pack) 552141-002
Cleaning sleeve (5-pack) 569946-001
Molykote DX grease 807421-001
Cleaners used on the printer’s exterior should not contain any abrasives, oils,
fragrances, antibacterial agents, solvents, or isopropanol. Do not use soft-
scrubbing cleansers, products with petroleum, or products with mineral,
pine, or lemon oil.
Caution: Use only canned compressed air on this printer. Do not use facility
air as it will have trace amounts of oil and moisture that will accumulate on
surfaces and possibly damage electronic components.
For Remove and Replace Procedures

The following tools and supplies are needed for the remove and replace
procedures.
T-6 Torx Driver
T-10 Torx Driver
Needle-nose Pliers
ESD Grounding Kit TUL006-006
Protective Eye wear
Cable Ties 803190-010
5-2 Routine Maintenance

For Magnetic Stripe Option
The following tools and supplies are needed for a printer with the magnetic stripe
option.
Small Phillips Screwdriver (Jewelers Type)
Four Flute Spline Wrench 0.048-Inch Diameter Bristol S-048-4L

Wrench Part Number
®
KY Read dip magnetic tape developer TUL001-014
or equivalent such as TXC, Magna See 804267-915
Kit, Glass Card Gauge, ISO ID-1; or 560585-001

Magnetic Stripe Alignment Gauge 513739-001
Magnetic stripe cards (blank)

HICO 803229-034
LOCO 803229-024
Clean, lint-free cloth
Magnifying glass
Molykote DX grease 807421-001
For Smart Card Option

The following card supplies are needed for a printer with the smart card option.
Contact Smart Card 806062-002
Contactless Smart Card 808573-001

Avoiding Electrostatic Discharge
While working around control boards and other sensitive components, use
proper equipment and procedures to reduce the possibility of damaging the
components.
This section describes the procedure for protecting against damage due to
electrostatic discharge. For more safety information see “Safety” in the Revision
Log at the beginning of this manual and “Precautions” on page 1-3.
Caution: Static electricity can destroy components in a circuit board. Use the
following precautions when handling the board, its components, or tools in
contact with the board or its components.
To avoid electrostatic discharge you can use the tools in the static-grounding kit
(Part No: TUL006-006):
• Static-grounding mat • Wrist strap grounding cable
• Mat-grounding cable • Grounding plug
• Static-grounding wrist strap
Procedure:
1. Wear appropriate clothing. Avoid wool and synthetic fabrics.
2. Remove movable carpet and rugs.
3. Apply the grounding strap to a wrist. Ensure that there is no clothing

between the strap and skin and that the strap is snug enough to maintain
contact with the skin.
4. Connect one end of the grounding cable to the wrist strap.
5. Using the grounding plug, connect the other end of the grounding cable to
the earth ground of a facility AC outlet.
6. Clear a work area, lay the static-grounding mat on the work area, and connect
the movable end of the long grounding cable to the mat.
7. Always set unshielded static-sensitive materials on the grounded anti-static

mat. Whenever possible, place components into static-shielded bags.
8. When bringing two objects into contact (tool to circuit board or board to mat),
first simultaneously touch both objects with fingers.

Screw Torque Specifications
Torque
Screw Location (in-lbs) +/- 10% Torx Bit
Pick Motor 1.5 T6
Ribbon Motor 1.5 T6
Transport Motor 8 T10
Cam Motor 8 T10
TPH Heat Sink 8 T10
TPH Adjustment 8 T10

Preventive Maintenance Procedures
Perform preventive maintenance procedures to extend the life of the printer each
time the printer is serviced.
Caution: Static electricity can destroy components on a circuit board. Follow
the precautions in the section titled “Precautions” on page 1-3 and the section
in this chapter “Avoiding Electrostatic Discharge” on page 5-4, when
handling the board, its components, or tools in contact with the board or its
components.
Refer to removal and replacement procedures in “Removal and

Replacement” on page 6-1 of this manual for more information on
disassembly and reassembly of the card printer.
Caution: Do not spray or pour cleaner directly on or into any electrical
device.
Mechanical Inspection
Inspect the following components and replace as needed.
1. Check the fixed cleaning rollers to make sure they are not nicked or gouged.
Replace them if they are brittle.
2. Check all other rollers for wear or damage.
3. Check springs to verify they are in position and not damaged.

4. Inspect the transport system:
A. Inspect the timing belt for wear and missing teeth.
B. Inspect the idler pulleys and make sure they are securely seated.
C. Inspect the drive pulleys for wear and broken teeth.
D. Inspect the platen roller gear and pulley for wear and broken teeth.

E. Inspect the static brushes for wear and improper placement. The two
located on the chassis are on the ribbon bridge and on the smart card
module. They are meant to be in close proximity to, but not touching, the
card. The static brushes act as a lightning rod to provide a ground for
static electricity. The static is neutralized so it does not harm the machine.
The other brush is located on the duplex module as depicted in the figure
on the following page.

5. Inspect the ribbon drive gear for wear and broken teeth. Make sure it is
securely seated on the motor shaft.
6. Inspect the ribbon cartridge.
A. Inspect the spindle gear for wear and missing teeth.

B. Check the spindles for proper movement and ensure that the clutch
provides a slight drag.
7. Check to see that the cooling fan is running properly by running a test card.

8. If applicable, inspect the duplex module drive and idler rollers for wear and
damage.
9. If applicable, inspect the smart card module.

A. Inspect all the gears depicted in the following figure for wear and missing
teeth.
B. Verify smooth transition of cards through module.

Cleaning the Interior of the Printer
1. Turn the printer off if necessary.
2. Unplug the printer.
3. Remove the printer enclosures.
4. Remove the chassis from the base enclosure.
5. Using canned compressed air:
A. Blow out any debris near the sensors
B. Blow out any dust from the control board and other surfaces of the base.
C. Blow out any dust and debris from the underside of the chassis.
Lubricating the Grease Points

1. Look to see if the grease points have accumulated dirt and debris.
2. For each of the following points, wipe off the grease with a dry cloth, and re-
grease the surfaces with Molykote DX grease.
Caution: Do not add more lubrication than is indicated.

A. Lubricate the platen roller.

B. Lubricate the registration roller.

C. Lubricate the cam shaft.

Lubricating the Magnetic Stripe Assembly
Apply Molykote grease (1) and rotate shaft (2) to spread grease. Apply an
additional amount of grease at (3) while rotating shaft (4) to lubricate encoder
bracket at (5) when assembled.
Caution: Do not apply grease directly on bracket to prevent grease from
accumulating on the end of shaft.

Cleaning the Rollers
The cleaning card is not adequate to clean all of the rubber rollers thoroughly. Use
the following procedure to clean the rollers. Continue cleaning the rollers until
the cleaning cloth no longer becomes discolored after contact with the roller.
Do not use any type of solvent on the cleaning rollers. Use only 90% or greater
isopropyl alcohol. (Do not use 75% alcohol as it has too much water.)
1. Apply isopropyl alcohol to a lint free cloth and then rub directly on the
rollers, wiping them while the rollers are in motion. To activate the rollers, use
the following tests in Printer Manager:
• Use the Test Pick test to move the Pick motor and clean the pick roller
• Use the Test Transport test to move the Transport motor and clean the
cleaning rollers, registration rollers, print platen roller and rear rollers (top
and bottom).

• 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.

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 a smart card goes into the smart card module.
• Using third-party smart card diagnostics, verify ATR or other information can
be read.

Visual Inspection for Card Quality
Print several test cards to verify that the card transport functions properly and
that the horizontal margin is in the proper place. See “Test Card” on page 4-5 for
more information on the test card options. Inspect the test card(s) for obvious
flaws in quality. If you find problems, refer to “Troubleshooting” on page 4-1.
• Vertical Offset should not be greater than 0.254 mm (0.010 inch).
• Card Registration must place the first row of printing at 0.254 ± 0.0762
mm (0.003 inch).
• If topcoat is used, it must completely cover the card from edge to edge.
• Check the card for obvious quality flaws including wrinkling.
Maintaining the Magnetic Stripe Module

Print a few magnetic stripe test cards. See “Test Card” on page 4-5 for more
information. For a list of tools see “For Magnetic Stripe Option” on page 5-3. Then
do the following:
• Clean the magnetic stripe head
• Verify the magnetic stripe track height. See “Magnetic Stripe Track Height
Adjustment” on page 3-33 for the procedure.
• Verify the start sentinel position. See “Start Sentinel Position Adjustment” on
page 3-34 for the procedure.

Operator Maintenance
These procedures are usually done by the operator and are included in this
service manual for reference and in case operator training is required.
Cleaning the Thermal Printhead (TPH)

Clean the printhead using an isopropanol cleaning pen. Open the swingarm and
use gentle pressure as you move the isopropanol tip back and forth along the
edge of the printhead.
Using the Cleaning Card

The cleaning card cleans particles from the cleaning rollers so they do not damage
the printhead. The cleaning card is pre-saturated with isopropanol and must be
used immediately after removing it from the package. Follow the steps below to
use the cleaning card to clean the printer.
1. Remove the print ribbon and cleaning sleeve from the printer.
2. Remove any cards from the printer.
3. To clean the card printer use the procedure in either Printer Manager or the
LCD Panel. Use one of the procedures below.
Procedure 1
Run the cleaning card using Printer Manager:
1. Select Cleaning from the Maintenance menu.

2. Click Run.
Procedure 2
Run the cleaning card using the LCD panel:
1. Begin with the display showing Ready.
2. Press the User button once.
3. At the Suspended Menu available prompt touch Enter lightly.
4. At the Main Menu | Maintenance prompt touch Enter.
5. At the Maintenance | Cleaning Card prompt touch Enter.
6. At the Cleaning Card | Start prompt touch Enter.
7. At the Insert cleaning card prompt, remove the cleaning card from its
wrapper and insert it into the card feeder.

Updating Printer Settings
Use the following procedure to update the printer settings file.
1. Open Printer Manager.
2. Log in as WebService.
3. Select Updates from the Maintenance Menu.
4. Click Browse to select the directory that contains the settings file.
5. Select the settings file and click Open.

6. Click on Upload File.
7. The user status light flash green as the file is being sent to the printer. When
the process is completed, the LCD displays the message, File Upload Complete.

Replacing the Print Engine Drive Board
Follow the procedure for removing and replacing the main control board (see
“Print Engine Drive Board” on page 6-50), and then use the following steps to
download the new settings file from www.PartnerPage.com and to apply the new
settings file to the printer.
Downloading Settings File for Board

Use the following steps to download the settings update file from PartnerPage for
use when replacing the main control board.
1. Log in to www.PartnerPage.com.
2. Hover over Services & Support on the top menu.
3. Choose Card Printers under Desktop ID Solutions.
4. Click on the printer model (CD800) to display its menu.
5. Click on Board Replacement.
6. Click on Click Here to Continue.

7. Enter the Auth Key from the new Board and the Serial Number of the printer
(on a label attached to the side of the swingarm). Click Submit.
8. Click on the link to download the file.
9. Save the file on the hard disk of your PC.
Updating Settings
Use Updating Printer Settings as described on page 5-23 to apply the new main
control board settings file that you downloaded.
Then update the Magnetic Stripe option as described in the following section.

Enabling the Proprietary Magnetic Stripe Option
New printers require this procedure to set the magnetic stripe option. If a print
engine (main control) board is replaced, this procedure should be used to restore
magnetic stripe settings.
Downloading Settings File for Magnetic Stripe Option

Follow the steps below to download the settings update file from PartnerPage to
use when enabling proprietary magnetic stripe options.
1. Log in to www.PartnerPage.com.
2. Hover over Services & Support on the top menu.

3. Choose Card Printers under Desktop ID Solutions.
4. Click on the printer model.
5. Click on Enable Options.
6. Click on Click Here to Continue.
7. Enter the Auth Key for the main control board and the Serial Number of the
printer (on a label attached to the side of the swingarm) and select the
appropriate magnetic stripe option from the list. Click Submit.
8. Click on the link to download the file.

9. Save the file to the hard disk on your PC and proceed to the next section.
Updating Settings
Use Updating Printer Settings as described on page 5-23 to apply the magnetic
stripe option settings file that you downloaded. Then use the following
procedure to verify that the option has been enabled.
Verifying Proprietary Magnetic Stripe Option

This procedure is required after a proprietary magnetic stripe option has been
enabled.
1. Click Behavior from the Printer Setting menu in Printer Manager.

2. Verify that the appropriate magnetic stripe option has a current value of
Enabled.

Chapter 6: Removal and
Replacement
This chapter provides procedures for removing and replacing
components and assemblies in the card printer.
Introduction to this Chapter ___________________________________________ 6-3

General Notes_____________________________________________________ 6-3
Required Tools_____________________________________________________ 6-3
Safety ____________________________________________________________ 6-3
Symbols ___________________________________________________________ 6-3
Printer Components _______________________________________________ 6-4
Cable Routing_____________________________________________________ 6-4
Transport Cables _______________________________________________ 6-4
Smart Card and Duplex Cables _________________________________ 6-5
Swingarm Cable Routing _______________________________________ 6-6
Freeing Cables from Clamps _______________________________________ 6-7
Functional Block Diagrams _________________________________________ 6-7
Exterior Components _________________________________________________ 6-8
Ribbon Cartridge __________________________________________________ 6-8
Ribbon Cartridge Lid_______________________________________________ 6-9
Swingarm Lid and Enclosure Flap __________________________________ 6-11
Enclosures________________________________________________________ 6-12
Card Tray ___________________________________________________________ 6-15
100-Card Input Lid and Cover _____________________________________ 6-15
Tray Assembly ____________________________________________________ 6-16
Front Bezel, LCD Interface Panel, and 25-Card Output ______________ 6-17
LCD Interface Panel Routing ______________________________________ 6-18
Simplex Base _____________________________________________________ 6-19
Tray ________________________________________________________________ 6-20
Pick Gate and Pick Gate Spring ___________________________________ 6-20
Pick Roller Assembly ______________________________________________ 6-21
Picker Crankshaft, Pick Block Assembly ____________________________ 6-22
Transport Components ______________________________________________ 6-23
Timing Belt _______________________________________________________ 6-23
Belt Plate_________________________________________________________ 6-24
Platen Roller Assembly ____________________________________________ 6-25
Card Guide/Spring and Registration Drive Assembly ________________ 6-26
Drive Pulleys and Idler Pulleys______________________________________ 6-28
Backup Roller, Registration Backup and Top Cleaning Rollers _______ 6-29
Backup Roller Springs and Brackets, Capstan Roller Sleeve__________ 6-30
Belt Tensioner and Spring, Idler Pulleys _____________________________ 6-31

Cam Slide _______________________________________________________ 6-32
Cam, Cam Shaft, Cam Gear, Cam Idler Gear _____________________ 6-33
Swingarm Components ______________________________________________ 6-34
Ferrite Bead______________________________________________________ 6-34
Thermal Printhead (TPH) __________________________________________ 6-35
Fan ______________________________________________________________ 6-36
Swingarm, Torsion Spring, Damper_________________________________ 6-37
Print Engine Sensors __________________________________________________ 6-40
Head Latch Sensor _______________________________________________ 6-40
Ribbon Index Sensor, Ribbon Bridge _______________________________ 6-41
Card Input Sensor ________________________________________________ 6-42
Card Exit Sensor __________________________________________________ 6-43
Cam Home Sensor _______________________________________________ 6-44
Print Engine Motors ___________________________________________________ 6-45
Pick Motor and Pick Drive Gear ___________________________________ 6-45
Ribbon Motor, Ribbon Drive Gear _________________________________ 6-46
Cam Drive Motor Assembly _______________________________________ 6-47
Transport Motor Assembly_________________________________________ 6-48
Circuit Board Components ___________________________________________ 6-49
Print Engine Drive Board __________________________________________ 6-49
Sensor Encoder Cable Assembly (RFID) ____________________________ 6-51
Ribbon Motion Magnetic Encoder Board __________________________ 6-52
Magnetic Stripe Option ______________________________________________ 6-53
Magstripe Board ISO (IAT) and JIS (NTT) ____________________________ 6-53
Magstripe Optical Encoder and Mounting Bracket _________________ 6-54
Magstripe Rocker Assembly and Read/Write Head_________________ 6-55
Smart Card Options __________________________________________________ 6-56
Smart Card Assembly_____________________________________________ 6-56
Smart Card Circuit Board _________________________________________ 6-57
Smart Card Lid Assembly _________________________________________ 6-58
Smart Card Contact Board _______________________________________ 6-59
Smart Card Station Spring_________________________________________ 6-60
Smart Card Gate Roller ___________________________________________ 6-61
Smart Card Cable Connector_____________________________________ 6-62
Card Guide ______________________________________________________ 6-63
Dual Reader Board (Contact/Contactless) ________________________ 6-64
i-Class Read/Write Board _________________________________________ 6-65
Duplex Components _________________________________________________ 6-66
Duplex Frame ____________________________________________________ 6-66
Duplex Home Sensor _____________________________________________ 6-67
Duplex Transport and Flipper Motors_______________________________ 6-68
Duplex Circuit Board _____________________________________________ 6-69
Duplex Backup Idler Roller, Springs ________________________________ 6-70
Flipper Assembly and Transport Gear ______________________________ 6-71
Duplex Drive Rollers and Body Gear _______________________________ 6-72
6-2 Removal and Replacement

Introduction to this Chapter
General Notes
• One or more procedures that either precede or follow your procedure may be
needed to access or reassemble the area of the printer where you need to
work.
• Unplug the printer and follow the instructions for removing the “Enclosures”
on page 6-12 before servicing the printer.
• Test motors and sensors to verify that the printer functions correctly after
replacing these parts.
• After completing replacement procedures, always perform preventive
maintenance as described in “Preventive Maintenance Procedures” on page
5-6.
• After completing replacement procedures, run several test cards or a limited

customer production run to verify that the printer functions correctly.
Required Tools
The required tools for the card printer are listed in the maintenance chapter of
this manual. See “Required Tools and Supplies” on page 5-2.
Safety
For safety and precaution information refer to the “Safety” section in the Revision
Log, “Precautions” on page 1-3, and “Avoiding Electrostatic Discharge” on page
5-4.
Symbols
The appearance and purpose of the symbols used in this chapter are presented
below.
This symbol is used to designate a procedure that involves electrostatic

ESD
discharge sensitive components. ESD procedures should be used.
Caution: This symbol indicates a strong cautionary message to avoid
serious damage to the printer.
This symbol indicates a reminder message or other additional
information for the customer engineer.
Safety glasses should be worn when performing this procedure.

Printer Components
See “Introduction to Printers” on page 1-4 for a diagram of the components in
each printer.
Cable Routing
Transport Cables
For more routing information see “Swingarm Cable Routing” on page 6-6 and
“LCD Interface Panel Routing” on page 6-18.
The following figure illustrates the routing of cables in the printer using
one colored strand following the path of the cable through the printer.
The actual cables used in the printer may have multiple strands of
different colors.

Smart Card and Duplex Cables

Swingarm Cable Routing
Note routing of the cables for fan (1), printhead (2), and the ribbon motor (3). See
“Ribbon Motor, Ribbon Drive Gear” on page 6-46, “Fan” on page 6-36, and
“Thermal Printhead (TPH)” on page 6-35 for more information.
Note: Leave 2.5 inches

(6.35 cm) of slack in the
cable so there is room
to reconnect the printh
Note: Feed the cables through the opening.

The printhead cable must be bent to the side
to fit through the opening. It may be easier to
feed the fan and motor cables through the
hole first.

Freeing Cables from Clamps
Use this procedure to remove wires from cable clamps as needed.
1. Group the wires in a line.
2. Slide them out.
Functional Block Diagrams

See “Functional Block Diagrams” on page 1-6 for diagrams of the boards and
connections.

Exterior Components
Ribbon Cartridge
1. Push button (1) to release the swingarm latch (2).
2. LIft the ribbon cartridge out of the printer (3).
Replacement
1. With the swingarm open, place the ribbon cartridge in the printer.
2. Push down the front edge of the swingarm until it latches.
3. Lift the cartridge.

Ribbon Cartridge Lid
Remove the cartridge lid (1) by spreading the sides (2) slightly to free them from
the tabs on the cartridge (3).

Replacement
Attach one tab and then the other by slightly spreading the sides.
When installing the cartridge back into the printer, place the diametric
magnet next to the Ribbon Encoder Board.

Swingarm Lid and Enclosure Flap
1. Remove the lid (1) by pushing in on the tabs on the side opposite the manual
advance knob.
2. Remove the enclosure flap (2) by spreading the enclosure slightly and lifting
the flap off of the pin. Then the opposite side will come off.
Replacement
1. When reassembling, replace enclosure flap before the swingarm lid. Place the
flap around the pins (3) on one side and then the other.
2. Replace the swingarm lid (4) by inserting the tabs into the side with the
manual advance knob first.

Enclosures
First remove the back enclosure cover and then the front one. A special tool (Part
No. 571712-001) is needed for these procedures. If the tool is not available, use
instructions in the CD Series Self-study Training Library DVD (Part No. 539946-
001) or the SD Series service manual.
1. Loosen the back cover:
A. 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. Maintain a light
upward pressure on the cover (2) as you loosen the cover from the tabs on
the base. Repeat this step for the other indented position.
B. Rotate the tool as shown (3) and place that chamfer edge between the base
(3a) and the back cover.
C. Maintain upward pressure on the cover as you push the tool down (4) to
free the cover from the base. Repeat for additional tab on same side (if
present) and tabs on other side to loosen the back cover from the base.

2. 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.

3. Loosen and remove the front cover:
A. 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).
B. Gently turn the printer on its side to expose the tabs (3) on the bottom.
C. Place the tool against the tabs and pull tool down to release the cover from
the base. Repeat for the other side.
D. Lift cover up over platen roller knob (4) and lift cover off.
4. Be sure to place the lip over the pad as you replace the cover.

Card Tray
100-Card Input Lid and Cover
1. Lift the lid (1) and push in on the release tab (2). Lift the lid and cover up and
off the tray.
2. Remove the lid from the cover by lifting the arm from the hinge pin on one
side and then the other.
Replacement
1. Place the arms of the lid (1) onto the pins.
2. Slide the cover onto the tray until it snaps into the tab (2).
The tray can be removed from the printer chassis without removing the cover
and lid.

Tray Assembly
1. Push both latches (1a, 1b) of the input tray frame (2) and lift it
up and off the hooks (3).
2. Carefully disconnect the cables from the main board (4).
Replacement
1. Reconnect cables and close the display panel connector securely after
reconnecting.
2. Place the four openings in the tray over the hooks (3) on the printer and slide
down until it latches in place.
The tray can be removed with the enclosures installed.

Front Bezel, LCD Interface Panel, and 25-Card Output
1. Push out on both clips (1) and slide the bezel forward (2) to remove it from the
input tray (3).
2. The interface panel (4) sits in the front bezel. Slide out to remove.
3. Lift the clips on either side (5) and slide the output tray forward (6).
Replacement
1. Slide the output tray (6) back into the slot until it clips into place.
2. Place the interface panel into the front bezel, tip forward (to hold in place),
and slide the bezel back onto the tray until it clicks into place.

LCD Interface Panel Routing

Simplex Base
1. Simultaneously press the tabs (1a) and pull on the printer
(1b).
2. Lift and remove it from the base (2).
Replacement
1. Line up the four points.
2. Push the printer toward the front until the tabs lock into place.
Caution: If you run the printer without the enclosures or base, do not tip the
printer to the side (the side with timing belt). The power and USB and/or
Ethernet cables could act as levers and damage the board connections.

Tray
Pick Gate and Pick Gate Spring
1. Hold spring (1a) while separating the tabs (1b) of the pick gate from the hinge
pins on both sides.
2. Hold spring (2a) lift pick gate (2b) and pull out of hopper frame.
3. Separate spring (3) from pick gate.
Replacement
1. Place spring on pick gate.
2. Hold spring in place, push pick gate into hopper frame and attach each side
to the hinge pins.

Pick Roller Assembly
1. Pull up on pick roller assembly (1).
2. Remove pick roller assembly (2) from input hopper frame.
Replacement
1. Replace pick roller assembly and snap into place.
See also, “Pick Motor and Pick Drive Gear” on page 6-45.

Picker Crankshaft, Pick Block Assembly
1. Push picker crankshaft (1) forward into larger slot (hard snap).
2. Separate picker crankshaft (2) from pick block assembly (3) and slide block
out of the hopper frame; then slide picker crankshaft (4) from hopper frame.
3. Separate picker crankshaft (5) from pick roller clutch and drive pick gear.
Replacement
1. Replace pick roller clutch and drive pick gear on the crankshaft. Surfaces
must be flush.
2. Slide picker crankshaft into hopper frame and reattach to pick block
assembly, and then snap back into place.
See also, “Pick Motor and Pick Drive Gear” on page 6-45.

Transport Components
Timing Belt
Removal
1. To remove the timing belt (1) push the belt tensioner (2) upward to lock it in
place. This removes tension from the belt.
2. Remove the belt from the three drive pulleys (3), the manual advance knob
(4), and the five idler pulleys (5).
Replacement
1. Replace the belt with the routing shown below.
2. Pull out on the tab (6) to lower the belt tensioner.
Do not stretch or twist the belt. This can break the belt fibers and cause the
belt to wear prematurely.

Belt Plate
Push the tab (1) on the inside of the rear of the printer to release the belt plate (2).
Replacement
Line up the holes with the pins and snap the tab into place.

Platen Roller Assembly
1. See “Ribbon Index Sensor, Ribbon Bridge” on page 6-41 for ribbon bridge
removal.
2. Push to loosen the tabs on the platen roller plate (1) while lifting the manual
advance knob (2) and lift plate (3) from printer.
3. Slide the platen roller assembly (4) out through the hole.
Replacement
1. If needed, lubricate; see “Lubricating the Grease Points” on page 5-12.
2. Place the leading end of the platen roller through the hole and into place, and
push down on the end with the gear to click into place (4).
3. Replace the platen roller plate by inserting the tabs into the slots and
snapping the other side into place.
Clearance is tight, but the parts will flex slightly to permit the platen roller
assembly to get past the flanged drive pulley.

Card Guide/Spring and Registration Drive Assembly
Removal
1. Place one hand over the card guide and spring (1a) while lifting the pulley of
the registration backup roller (1b) to release.
2. Remove the card guide and card guide spring (2) and separate the spring
from the shaft (3).
3. Pull the registration drive assembly (4) out through the cutout.

Replacement
2. Place the registration drive assembly into the printer through the cutout,
insert the leading edge into the hole, and push down on the end with the gear
to click into place.
3. Place the spring on the card guide and snap the card guide into place. Position
the spring against the printer.
See “Ribbon Index Sensor, Ribbon Bridge” on page 6-41 for ribbon bridge
removal or “Magstripe Rocker Assembly and Read/Write Head” on page
6-55.

Drive Pulleys and Idler Pulleys
1. Remove the timing belt, see“Timing Belt” on page 6-23 and “Belt Plate” on
page 6-24.
2. Remove the idler pulleys by pulling them from their shafts (1).
3. To remove the drive pulleys (2) use a needle-nosed pliers to squeeze together
the tabs (3) at the end of the shaft and slip off.
Replacement
1. The idler pulleys can be placed on their shafts from either side.
2. Slip the drive pulleys (2) onto their shafts with the large flange toward the
printer and rotate so that the square key (4) slips into the square keyway.
3. Replace belt and belt plate.
Print several test cards to ensure there are no transport problems.

Backup Roller, Registration Backup and Top Cleaning Rollers
1. Remove the ribbon bridge (see “Ribbon Index Sensor, Ribbon
Bridge” on page 6-41) before pulling out backup roller.
2. Push top of the spring to the side (1) and pull from the shaft (2).
3. Push brackets from the inside of the printer (3a) while pulling up and over the
locking ramp (3b); there is a hard snap as it goes over the ramp.
4. Pull the bracket out of the cutout (4).
5. Tip the rollers (5) and lift out of the printer.
Replacement
1. Insert leading end into holes (7), be sure to replace the capstan roller sleeve (6)
on the registration backup roller before installing.
2. Place the brackets into the cutouts and slide down locking into place.
3. Place springs onto the shafts of the brackets and slide into position.

Backup Roller Springs and Brackets, Capstan Roller Sleeve
See previous page for remove and replace procedure.

Belt Tensioner and Spring, Idler Pulleys
1. If engaged, lift up on the release tab to release the tensioner.
2. Line up the belt tensioner (1) with the cutouts in the printer and lift out (2) of
the printer.
3. Remove the belt tensioner spring.
4. The idler pulleys (4) come right off.
Replacement
1. Place the spring onto the belt tensioner.
2. Insert the tensioner into the cutouts in the printer and slide upward until it
clicks into place.
3. Slide idler pulleys onto their shafts.

Cam Slide
1. Use “Other Troubleshooting Procedures” on page 4-12 to rotate the cam (1)
into position so the tangs (2) match the cutout of the cam slide (3). Or you can
physically move the cam with a flat head screwdriver.
2. Lift the cam slide to remove (4).
Replacement
1. Rotate the cam into position so that the tangs are in position and slip the cam
slide into place.
The tang and cutout positions for the belt side cam slide are at 3 and 6
o’clock on a clock face. The cam slide cutout on the cam motor side will be in
the 6 and 9 o’clock positions.

Cam, Cam Shaft, Cam Gear, Cam Idler Gear
1. On the belt side of the printer, use the edge of a roller to pry downward on the
retainer portion of the cam (1) until it is clear of the groove in the cam shaft (2)
and push cam shaft through cam.
2. On the motor side of the printer pull the cam gear and shaft (3) out of the
printer.
3. Remove the cam idler gear (4).
Replacement
2. Replace cam idler and push cam onto shaft and into the retainer.
3. Align the cam on each side when reinstalling.

Swingarm Components
Ferrite Bead
1. Clip the tie wrap (1) that surrounds the ferrite bead (2) and the printhead
cable (3).
2. Open the ferrite bead to release the fan and ribbon advance cables.
3. Disconnect the cables from the main board.
Replacement
1. Reconnect the cables to the board.
2. Place the ferrite bead around the fan and ribbon advance cables (2).
3. Place a cable tie (1) around the ferrite bead and the printhead cable (3).
See “Cable Routing” on page 6-4 for connection information.

Thermal Printhead (TPH)
1. Hold the printhead (1) while pressing one of the swingarm knuckle release
tabs (2a), and then tip the printhead (2b).
2. Disconnect the printhead cable.
3. Pull the printhead (3) from the swingarm assembly.
Replacement
1. Reconnect the printhead cable.
2. Press and hold one of the swingarm knuckle release tabs and insert the
printhead into the knuckle.
3. Raise the printhead and release the tab.

Fan
Observe cable routing and fan orientation. The fan blows air in the direction of
the printhead.
1. Pull up on the retaining tab (1) and slide the fan out of the frame (2).
Replacement
1. Orient the fan as shown in the figure below.
2. Slide the fan down into the frame, placing the cables through the notch in the
corner.
A tiny arrow on the front side of the fan indicates the airflow direction.
Look for arrow

pointing down.

Swingarm, Torsion Spring, Damper
1. Relieve the torsion spring tension (1) by lifting the spring up and
out of the boss.
2. Rotate the damper counterclockwise (2) to remove.
Note the orientation of the torsion spring (4).
3. Separate and lift slightly on each side of the swingarm (3, 5) to disengage the
swingarm from the hinge pins.
4. Move the swingarm back toward the rear of the printer and then up to
remove (6).

Replacement
1. Place the torsion spring on the printer (4) and then guide the spring into the
cutout in the swingarm as you install the swingarm.
2. With the swingarm nearly vertical, partially engage each side of the
swingarm onto the hinge pins.

3. With both sides partially engaged, bring the swingarm forward on both sides
simultaneously to fully engage both sides.
4. Lift the torsion spring into the boss.
5. Push on and rotate clockwise to replace the damper.
Always relieve the torsion spring tension when the damper has been removed.

Print Engine Sensors
Head Latch Sensor
Disconnect cable from J22 on print engine board and pull on sensor (1) to remove.
Replacement
1. Press sensor into the hole in the printer.
2. Reroute cable as indicated in “Cable Routing” on page 6-4, and reconnect
cable.

Ribbon Index Sensor, Ribbon Bridge
1. Note routing of the ribbon index sensor cable (1), disconnect it from the print
engine board (J21), and pull through the hole in printer.
2. Push to release the retaining clips (2) on either side of the ribbon bridge and
lift bridge (3) from the printer.
3. Pull on the ribbon index sensor to remove from the ribbon bridge.
Replacement
1. Push the sensor into place until fully seated and reroute the cable in the
bridge.
2. Feed the ribbon index sensor cable through the hole, reroute, and reconnect to
the board.
3. Place the ribbon bridge into the printer and into the retaining clips.
See “Transport Cables” on page 6-4 for routing information.

Card Input Sensor
1. Remove cam slide and bracket. See “Backup Roller Springs and Brackets,
Capstan Roller Sleeve” on page 6-30 and “Belt Tensioner and Spring, Idler
Pulleys” on page 6-31.
2. Disconnect cable from J18 on print engine board.
3. Remove by pushing out of the printer from the inside.
Replacement
1. Push into place using two Torx drivers and even pressure until fully seated.
2. Reconnect cable.
See “Cable Routing” on page 6-4 for more information.

Card Exit Sensor
1. Rotate cam (1a) so that the cam slide (1b) is not in the way of the sensor, and
disconnect cable from J24 of print engine board.
2. Remove by pushing sensor (2) out of the printer from the inside.
Replacement
1. Push into place using two Torx drivers and even pressure until fully seated.
2. Reconnect the cable.
Refer to “Transport Cables” on page 6-4 for routing information.

Cam Home Sensor
1. Use a flat head driver to rotate the cam motor (1a) to move the cam slide (1b)
out of the way.
2. Disconnect cable from J23 of print engine board.
3. Insert the torsion spring, or a tool such as a small screwdriver, through the
hole in the sensor to aid in pulling (2) the sensor out.
Replacement
1. Push the sensor into place using even pressure until fully seated.
Refer to “Cable Routing” on page 6-4 for routing information.
Caution: Pulling on the top of the outside of the sensor may break it.

Print Engine Motors
Pick Motor and Pick Drive Gear
1. Align the pick drive gear with screws (1) as shown.
2. Disconnect the connector from J19 of print engine board.
3. Remove two T6 torx screws (2) and remove the pick motor (3).
Replacement
1. Align the pick drive gear, place the motor into the hopper frame, and replace
the screws.

Ribbon Motor, Ribbon Drive Gear
1. Align the drive gear (1) so the screws are visible through the cutout.
2. Disconnect the motor connector from J27 on print engine board.
3. Remove the two T6 Torx screws (2), and lift the motor (3) out of the swingarm
(3).
Replacement
1. Line up the flats on the gear and the ribbon motor shaft and slide the gear
onto the shaft.
2. Place the motor into the swingarm, align the drive gear, and replace the
screws.
The swingarm must be removed to access the ribbon motor. See “Swingarm,
Torsion Spring, Damper” on page 6-37.

Cam Drive Motor Assembly
1. Use a T10 Torx driver to loosen and remove the two screws (1).
2. Disconnect the motor connection from J12 on the print engine board.
3. Pull the motor from the printer.
Replacement
1. Replace motor and secure with the two screws.
The cam drive motor assembly cable is oriented toward the rear of the printer.

Transport Motor Assembly
1. Use a T10 Torx driver to loosen and remove the two screws (1).
2. Disconnect the cable from J11 on print engine board.
3. Pull the motor from the printer.
Replacement
1. Replace motor and secure with the two screws.
The transport motor assembly cable is oriented toward the front of the printer.

Circuit Board Components
See also “Smart Card Circuit Board” on page 6-57 and “Duplex
Circuit Board” on page 6-69.
Print Engine Drive Board

1. Remove enclosure as described in “Enclosures” on page 6-12, and disconnect
cables from the board.
2. Push in on both tabs that hold the board in place at the front of the printer (1),
and then loosen the corners (2) of the board (3) to release it from the printer.
3. If the printer has the magnetic stripe option, those cable connections will
prevent you from moving the board more than a short distance from the
printer. Tip the printer to the side (timing belt side of printer) and disconnect
the cables. Then remove the magnetic stripe board and standoffs. See
“Magstripe Board ISO (IAT) and JIS (NTT)” on page 6-53 for more
information.

Replacement
1. If applicable, install the magnetic stripe board and connect the cables and
standoffs.
2. Insert the back end of the board into the printer, and then push to lock the
board under the front tabs (1).
3. Reconnect cables.
See “Cable Routing” on page 6-4.
4. See “Replacing the Print Engine Drive Board” on page 5-25 for instructions on
loading the new settings file.

Sensor Encoder Cable Assembly (RFID)
1. Note routing of cables for the RFID board (1), ribbon motor
(2), fan (3), and printhead (4) from main control board.
2. Lift the bottom left side of the RFID board (5) to lift from the standoff, and
then pull the board up (6) to remove.
Replacement
1. Slide the RFID board down into the printer and over the standoff.
2. Reroute and connect cables.
See the following procedures for more routing information. See “Ribbon
Cartridge” on page 6-8.

Ribbon Motion Magnetic Encoder Board
1. Disconnect cable.
2. Push up from the bottom of the encoder (1) and pull it out of
the printer.
Replacement
1. Push the encoder into place with even pressure until fully seated.
Refer to “Cable Routing” on page 6-4 for routing information.

Magnetic Stripe Option
Magstripe Board ISO (IAT) and JIS (NTT)
1. See “Print Engine Drive Board” on page 6-49 for how to remove the print
engine board. As you remove the board from the printer, the cable
connections will prevent you from moving the board more than a short
distance from the printer. Tip the printer to the side (timing belt side of
printer) and disconnect the magstripe encoder (2) and head (1).
2. Remove board (3) and standoffs (4).
Replacement
1. Replace standoffs and board and reconnect cables.

Magstripe Optical Encoder and Mounting Bracket
1. Loosen setscrew on collar (1) with special four-flute spline
wrench. See “For Magnetic Stripe Option” on page 5-3.
2. Remove two phillips screws (2) and remove optical encoder (3).
3. Bend spring (4) forward and remove.
4. Remove Torx screw (5) and remove encoder mounting bracket (6).
Replacement
When replacing the optical encoder on the mounting bracket, be sure the two tabs
go into the slots on the encoder.
The encoder mounting bracket replaces the normal backup bracket on
machines with the magnetic stripe option.

Magstripe Rocker Assembly and Read/Write Head
1. Disconnect the magstripe head cable. See “Magstripe Board ISO
(IAT) and JIS (NTT)” on page 6-53.
2. Remove the magstripe rocker assembly (1) by unsnapping from printer.
3. Pull back on retaining clip to release and then push head (2) up from bottom
to remove.
Replacement
1. Replace head and rocker assembly and reconnect cables.
2. Lubricate the assembly as described in “Lubricating the Magnetic Stripe
Assembly” on page 5-16.

Smart Card Options
Smart Card Assembly
1. Remove the flipper assembly as described on page 6-71.
2. Remove the smart card assembly by pulling tabs (1a) out on both sides while
lifting out the smart card assembly (1b).

Smart Card Circuit Board
1. Disconnect USB (1) and power plugs (2).
2. Push tab (3a) down while lifting board (3b) out enough to
release.
3. Lift tab (4a) while lifting board (3b) again to release board.
4. Slide board (5) out from under tab (6) and remove board.

Smart Card Lid Assembly
1. Remove the smart card assembly as described on page 6-56.
2. Push tabs (1a) on both sides to release catches (1b).
3. Lift smart card lid assembly (2) out.

Smart Card Contact Board
1. Disconnect the assembly by pushing the contact mount back and holding it
steady with left index finger (1) while pushing down and out at 2a and 2b
with your thumbs.
2. Separate from contact plug (3).

Smart Card Station Spring
Remove smart card lid assembly as described on page 6-57.
Unhook spring (1) and lift from smart card base assembly.

Smart Card Gate Roller
1. Push smart card guide (1a) back while pushing tab (1b) out and lifting contact
mount (1c) up to release.
2. Slide contact mount (2) back and out on the slots and pegs (3).
3. Remove plug (4) from contact guide.
4. Remove gate roller (5) from guide.

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).

Card Guide
Slide card guide (1) forward until it stops, and lift peg (2) from keyway slot.

Dual Reader Board (Contact/Contactless)
1. Squeeze the snap-tips (1) on the standoffs and lift the reader board (2) just
enough to clear the standoffs.
2. Place a flat screwdriver between the base (3) and reader board, and then
carefully twist the screwdriver to release the adhesive pad (4).
Always use all new adhesive pads when reassembling.

i-Class Read/Write Board
1. Place a flat screwdriver between the base (1) and reader board, and then
carefully twist the screwdriver to release adhesive pads (2).
2. Lift reader (3) off.
Be sure to use all new adhesive pads when reassembling. Place them near the
center of the board.

Duplex Components
Duplex Frame
1. Disconnect cables from tie downs at indicated on page 6-7.
2. Disconnect cables (1) at J13 and J29 on print engine board.
3. Pull out tabs (2a) on both sides while sliding the frame (2b) away from the
main frame.
4. Pull frame (3) away and up to remove.

Duplex Home Sensor
1. Disconnect sensor cable (J5) from duplex circuit board.
2. Push tab (1a) out while lifting duplex circuit board (1b) to clear tab.
3. Slide board (2) out from under tab (3) to remove.
4. Remove flipper home sensor (4).

Duplex Transport and Flipper Motors
1. Disconnect motor cable(s) from connector on duplex board: J7 for Transport
or J3 for Flipper.
2. Push tab (1a) in while rotating motor (1b) in direction shown.
3. Remove motor (2).

Duplex Circuit Board
1. Disconnect cables from duplex circuit board.
2. Feed cable through the frame as indicated in “Cable Routing”
on page 6-4.
3. Push tab (1a) out while lifting duplex circuit board (1b) to clear tab.
4. Slide board (2) out from under tab (3) to remove.

Duplex Backup Idler Roller, Springs
1. Push spring (1a) out from under tab (1b) to release spring.
2. Remove spring (2).
3. Repeat to remove other spring, and remove both backup idler rollers (3).

Flipper Assembly and Transport Gear
1. Hold flipper assembly (1a) firmly while separating it from frame (1b) until
mis-aligning the shaft (1c).
2. Lift flipper assembly (2) by maneuvering it up through the frame assembly.
3. If gear (3) did not fall out, remove it.

Duplex Drive Rollers and Body Gear
1. Remove flipper assembly as described on page 6-71.
2. Push drive roller (1) into larger hole until you hear a hard snap.
3. Remove drive roller (2) from frame (3).
4. Repeat for other drive roller.

Datacard CD Series Card Printers: Service Manual

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Datacard CD Series Card Printers: Service Manual

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Datacard® CD Series Card Printers

Part No. 539944-001, Rev A

Windows and Internet Explorer are registered trademarks of Microsoft

Firefox is a registered trademark of Mozilla.

© 2011 DataCard Corporation. All rights reserved.

Revision Date Description of Changes

A March 2011 First release of this manual.

Notice for Canada

Le présent appareil numérique n'émet pas de bruits radioélectriques dépassant

• Know the location of equipment branch circuit interrupters or circuit breakers

• Use adequate lighting at the equipment.

• Maintain the recommended range of temperature and humidity in equipment

• Do not use this product in an environment containing volatile or flammable

Safe Human Interface

• Use standard electrostatic discharge (ESD) precautions when working on or

• Do not defeat or disconnect safety interlocks on covers.

This chapter provides an introduction to card printer components

About This Manual ___________________________________________________ 1-3

CD Series Card Printers Service Manual 1-1

Designates a procedure that involves electrostatic discharge sensitive

Caution: Indicates a strong cautionary message to avoid serious

Warns the technician to wear safety glasses during the procedure.

• Remove watches, jewelry, and rings before servicing equipment

• Avoid wearing loose clothing when working around moving parts

• Be aware of your surroundings when servicing the equipment

• Ensure that you are properly grounded at all times

• Wear protective eyewear when replacing parts on the system

CD Series Card Printers Service Manual 1-3

• 100-card input tray • Lock option

• 100-card input tray • 100-card output tray option

• Output tray with 25-card capacity and • Lock option

• Smart Card reader/writer • Magnetic stripe options (ISO and JIS)

CD Series Card Printers Service Manual 1-5

CD Series Card Printers Service Manual 1-7

CD Series Card Printers Service Manual 1-9

Head Latch This sensor detects when the swingarm is open.

CD Series Card Printers Service Manual 1-11

Smart Card This switch detects a contact smart card is in position.

Pick Motor This DC motor drives the card picking mechanism.

Transport Motor This stepper motor drives the print engine.

CD Series Card Printers Service Manual 1-13

Light Light Condition Indication

Ribbon Off Ribbon is OK.

Green/Amber Both green and amber lights appear during power-on

Steady Amber Out of ribbon or ribbon is missing.

Blinking Amber Ribbon error.

Card Status Off Card supply is OK.

Steady Green Cleaning card cycle is due.

Green/Amber Both green and amber lights appear during power-on

Steady Amber Card not picked.

Blinking Amber No card in manual position or in the hopper.

User Off Printer power is off.

Blinking Green Printer is busy.

Green/Amber Both green and amber lights appear during power-on

Steady Amber Printing is suspended or paused.

Blinking Amber Error condition.

CD Series Card Printers Service Manual 1-15

Main Menu Option Submenu Item Option

Exit Exit to Main menu.

FW Revision Displays the revision number for the firmware.

Network Status The following options are available on the Network

USB IP Address Displays the USB IP address, if any.

Card Counters The following counters are available: