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FARGO electronic HDP820 Printer User Manual

1. Step Procedure 1 Confirm that the fan operates correctly a Upon power up the fan should run momentarily and shut off b Verify that the fan is plugged into the Main Print Board properly on J67 2 Check the Printhead fans for pinched wires a Inspect the wires that are routed under the top cover and through to the back of the Board to ensure that they are not pinched 3 Verify if the thermal regulator on the Printhead has failed a Remove the Printhead and reseat cable connections b If problem persists replace with a new Printhead as described in the Replacing the Printhead D840854 procedure in Section 5 page 281 4 Ensure that the Printer has received data at the speed that it requires See Communication Errors in Section 2 page 60 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 89 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Printhead Temp Error Message Symptom The Printhead temperature regulator is not functioning properly Step Procedure 1 Reboot the Printer e If the problem persists remove the Printhead and ensure that the Printhead Cables are seated properly e Remove the back cover as needed to verify the Printhead Cable connection to the Main Print Board 2 Replace the Printhead if after checking the Printhead Cable connection at both the Printhead and the Main Print Board the error is still displayed on startup See the Replacing the Pri
2. Good Bad HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 127 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Image washout on Film problems Symptom The Image appears to not be completely printed on Film Step Procedure 1 Verify that the upper and middle Modules are seated properly and are completely locked down 2 Verify if the Printhead pressure is too low a Remove the Printhead See the Replacing the Printhead D840854 procedure in Section 5 page 281 and bend the two metal Springs slightly toward the front of the upper Module b Reinstall the Printhead and print a test card c If registration does not get better remove the Printhead and bend the two metal Springs away from the upper Module slightly d Reinstall the Printhead and print a self test 3 Increase Image Darkness in the LCD a Select Menu from the LCD b Select Setup Printer and then select Image Darkness c Increase in increments of five the Image Darkness through the LCD Setup Menu and print a card 4 Reprint with Fargo cards if printing with non Fargo cards 5 Adjust Printhead Bracket Adjustment Screws Note These can be found on the backside of the Printhead See drawing D840854 c Loosen and adjust the screws so there is equal Spring pressure on each side of the print head d Tighten the screws and reprint the card that is exhibiting the issue 6 Remove the Printhead and reins
3. Full bleed Printing that covers the entire card surface Gamma The degree of contrast of an image or the display of a monitor determined by the slope of a characteristic curve relating optical density to relative log exposure Glossy Matte A smooth polished surface in comparison to a rougher matte surface Fargo matte cards have a surface index Ra of approximately 65 microinches while glossy have a Ra 3 Glossy PVC A card made of PVC with a smooth polished surface Surface roughness of approximately 0 10 micro inches This is required for direct to card dye sublimation printing Graphical Device Interface GDI A Windows standard for protocol between Drivers and applications and the Windows interface An application uses a Driver to rasterize the data in the format necessary for the Printer but also for the Windows interface to execute the print commands Gray Scale A graduation through the various brightness levels from white to black Halftoning A process in Monochrome printing that simulates continuous tone by using changes to the distribution of single dots Increasing the number of dots in a given area increases the darkness even though the individual dots stay the same size HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 Continued on the next page 509 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Term Definition Hard Driv
4. Insert 1 screw HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 161 RESTRICTED USE ONLY Fargo Electronics Inc Attaching the Card Lamination Module continued Step Procedure 16 Insert two 2 screws into the bottom rear of the Card Lamination Module as shown below Continued on the next page Insert 2 screws HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 162 RESTRICTED USE ONLY Fargo Electronics Inc Attaching the Card Lamination Module continued Step Procedure 17 Move the Printer s Release Lever to the Unlocked position and close the Print Station and Transfer Station 18 Installation of the field upgradeable Card Lamination Module is now complete To ensure a successful installation install cards Print Ribbon HDP Film and overlaminate and run the Lamination Self Test color Resin YMCK L 19 Install the LC version of the Printer model s Print Driver Refer to the Lamination tab for Lamination related Printer Driver options See the Using the Lamination tab only with Card Lamination Module procedure in Section 4 on page 238 Note The packaging for the HDP Printer has been designed to accommodate shipping either the Printer only or the fully assembled Printer with Lamination Module After assembling the complete Printer Lamination system use th
5. EXCEPTION LOG We of Error Occurrences XX Example Wrong Print Ribbon Oeeurrences 2 Error Log End CARD STATISTICS cc ex pC xx TC XX SYSTEM UPGRADE Mo sure you to conlinue Yos HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 40min 040 max Current Value x t 99min 90 m Current Value X 1 99 min 00 max Current Value X 25 min 25 max Current Value X 25 min 25 max Current Value X 1 25min 25 max Current Value X 25 min 25 max Current Value X 4 D0 min 990 mex Current Valuo X 00min 00 max Current Value X 2500 min 3500 max Current Value X 99min 489 mak Current Value X Mag Nome tnstatied Smart None installed Prox More installed Magnetic 99 min 99 max Current Value X Print Level oh Lamination Level AO min 10 max Current Value X 99 min 90 max Current Value X o min 99 max RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Printer Setup The Printer parameters found in Setup Printer are preset at the factory and should not need to be changed unless an issue develops If a change to these settings is needed be sure to record the changes on the Default settings sticker located on the back of the Printer Lr Caution These settings are optimized at the factory and will rarely need to be changed Step Procedure 1 Lr Caution Do not alter th
6. HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 247 RESTRICTED USE ONLY Fargo Electronics Inc Cleaning the Cleaning Rollers The Cleaning Rollers remove dust particles from the top and bottom of a blank card as it feeds into the Printer Cleaning these rollers will help prevent card contamination thus allowing for higher quality output The Cleaning Rollers should be cleaned approximately every 250 prints or if the cards start showing bumps speckles or debris on the printed surface Step Procedure 1 Open the Front Access Door of the Printer 2 Depress the Cleaning Roller Lock Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 248 RESTRICTED USE ONLY Fargo Electronics Inc Cleaning the Cleaning Rollers continued Step Procedure 3 Pull the Cleaning Roller Assembly out of the Printer HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 249 RESTRICTED USE ONLY Fargo Electronics Inc Cleaning the Cleaning Rollers continued Step Procedure 4 Clean the rollers with one of the adhesive backed Cleaning Cardss from the Printer Cleaning Kit a Remove the card s adhesive backing paper and slide the card between the rollers until all dust particles are removed b Flip over the Cleaning Cards to clean both the top and bottom Cleaning Rollers Note Alternatively place the a
7. 2 If you would like to try to correct the problem and continue printing with the same card do so by pressing the FORWARD button to advance the card or the BACK button to reverse the card Use these buttons to help free the card from its jam Try not to move the card too far from where it was just before the jam occurred Once the jam is cleared replace media close the Printer and press the RESUME button to resume printing If you would like to remove the jammed card completely do so by using the FORWARD and BACK buttons to manually eject the card Then close the Printer Press the CANCEL button to reset the Printer and cancel all jobs within the Printer s memory In this case you must also cancel and resend the print job from the computer Note For best results cancel the job from the computer first and then press the Printer s CANCEL button If the Printer is equipped with the Card Lamination Module and a card is jammed in this area open the Lamination Module s Top Cover and Lamination Station Push the Module s Cancel or Resume buttons to move the Lamination Module s rollers and clear the card jam e If you only slightly moved the card to clear the jam close the Lamination Module and press its Resume button to try laminating again e If you completely removed the card press the Lamination Module s Cancel button to reset the Lamination Module for the next card The Lamination Module buttons only affect the card in
8. Step Procedure 11 See Print Offset Transfer Tension Transfer TOF Top of Form and Transfer EOF End of Form Alignment procedure in Section 8 page 449 to adjust the Printer through the LCD 12 Verify that the Peel Off Bar and the Ribbon Peel Bar height is correct Note From the front of the HDP Card Printer the Peel Off Bar on the input side See drawing D841085 should be flush with the frame The Ribbon Peel Bar on the output side should have a 3 16 inch 4 5mm gap between the frame and the Ribbon Peel Bar a Remedy the offset printing by raising the bar higher off of the card 0 005 inches by loosening the screws for the Peel Off Bar and carefully raising both sides to the same degree Note The Peel Off Bar assembly should be equidistant at both ends from the frame HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 126 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the poor Image Quality problems Symptom Photos on the cards look pixilated or grainy as shown below Step Procedure 1 Use a high resolution 24 bit color image to always capture an image at a 24 bit color setting at 300 dpi and at the same size that it will be printed on the card as captured either with a scanner or with a digital camera Note If a small or low resolution image is stretched or blown up a pixilated or grainy effect will occur when printing as shown below
9. Component Description Reference Resume Press the Resume button to resume See the Using the Lamination pause operation after an error condition is tab only with the Card button cleared Lamination Module in Section 5 page 238 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 42 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Rejection Card Hopper and Card Output Hopper Card Hopper separate potentially bad cards from a stack of good cards which eject into the Card Output Hopper The Printer will automatically eject cards into this hopper to indicate e There is a printing error laminating error or encoding error e There is a card is left in the Printer after a print job is canceled or the Printer restarted Component Description Reference Rejection The Rejection Card Hopper helps to See the Using the Lamination tab only with the Card Lamination Module in Section 5 page 238 Card Output Hopper Stores up to 100 printed cards 30 mil cards a When the hopper has reached its maximum capacity of cards note that the operation pauses and an Output Hopper Full message appears on the Printer s LCD Display b Remove the stack of cards from the hopper c Press the Lamination Module s Resume button to continue Note If printing onto oversized cards the Card Output Hopper Door should be placed in the open position in order for these larger c
10. Lamination TAB 104 107 Lamination Take Up Encoder Sensor Assembly 327 Lamination not adhering 106 107 Laminator Controls 37 Laminator Temperature Adjustment 47 Laminator Warming 46 LAN Local Area Network 511 Landscape 512 LCD 78 82 113 122 LCD Liquid Crystal Display 512 LCD and Softkey Control Pad 25 LCD Display 20 25 28 71 82 224 LCD Display Messages 50 51 52 53 54 LCD error 76 LCD Firmware 474 LCD Interface Cable 349 355 LCD Menu 444 LCD Menu and Selecting an Option 445 LCD On Line Menu Navigation 444 LCD panel 71 78 82 LCD Setting 83 LCD Setup 122 LED Light Emitting Diode 512 LED Light 20 28 less heat 202 less saturated resin images 202 Lever Unlocked 51 LoCo Low Coercivity 512 Low Coercivity 221 Lower Film Drive 120 Lower Film Sensor 91 92 Lower Film Sensor Assembly 328 lower transfer temperature 180 LPT Port Line Printer Port 512 M Mag Encode Failed 54 Mag encoding 512 Mag stripe 512 Mag Track 512 Mag Verify 512 magnetic card analyzer 462 Magnetic Encoder 76 Magnetic Encoder Head 363 Magnetic encoding area of Printer 78 Fargo Electronics Inc Magnetic Encoding tab 218 magnetic stripe 79 Magnetic Stripe Encoding Modules 219 Magnetic Stripe encoding process 218 Magnetic Stripe verification 224 Magnetic Test 78 82 Magnetic TOF 462 463 Magnetic TOF setting 462 Magnetic Track data
11. RESTRICTED USE ONLY Fargo Electronics Inc Replacing the HDP 800 Series Ribbon Hub 294 Replacing the HDP 800 Series Ribbon Take up Roller Hubs 313 Replacing the HDP 800 Series Film Supply Hub 315 Replacing the Headlift Sensor Assembly D840983 322 Transfer Station Components Replacements 323 Replacing the Film Drive O Rings 140212 323 Replacing the Film Drive Encoder Wheel 2 810492 324 Replacing the Stepper Motor Assembly 840123 325 Replacing the Supply Encoder Sensor Assembly 840135 326 Replacing the Lamination Take Up Encoder Sensor Assembly 840136 327 Replacing the Lower Film Sensor Assembly 840199 328 Replacing the Upper Film Sensor Assembly D841023 329 Replacing the Print Platen Roller D840811 330 Replacing the Transfer Peel Off Bar Assembly D840698 331 Replacing the Transfer Station Assembly D841083 332 Replacing the Lamination Assembly D841085 334 Replacing the Transfer Lift Sensor A000126 336 Replacing the Transfer Lift Motor D840173 337 Base Module Components Replacements 338 Replacing the Drive Belt Platen Roller to Card Feed Roller 220071 338 Replacing the Drive Belt Card Feed Roller to Card Feed Roller 220082 339 Replacing the Stepper Motor Assembly D841045 340 Replacing the Pinch Roller Spring Plate Front Input Side D840865 341 Replacing the Pinch Roller Spring Plate Front Output Si
12. e If using Windows 98Se ME right click on the HDP800 Series Card Printer Icon and select Properties e If using Windows NT 4 0 right click on the HDP800 Series Card Printer and select Document Defaults e f using Windows 2000 XP right click on the HDP800 Series Card Printer and select Printing Preferences b Click on the Image Color tab c Adjust the Dye Sub Intensity to a more negative value OR Correct the Image Darkness in the LCD a Select Menu from the LCD b Select Setup Printer and then select Image Darkness c Adjust the current value to a more negative number 3 Adjust the Ribbon Tension a Select Menu from the LCD b Select Setup Printer and then select Ribbon Tension c Adjust the current value to a more positive number Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 115 RESTRICTED USE ONLY Resolving the Ribbon wrinkle problems continued Fargo Electronics Inc Step Procedure 5 Check the Printhead and Printhead Mounting Bracket for debris and burrs 6 Adjust Printhead Bracket Adjustment Screws Note These can be found on the backside of the Printhead See drawing D840854 a Loosen and adjust the screws so there is equal Spring pressure on each side of the print head b Tighten the screws and reprint the card that is exhibiting the issue Mike Berman Student 3957105 library Code 2439 5
13. Glossary of Terms continued Term Definition UPS Un interruptible Power Supply An AC power supply typically powered by batteries which provides temporary power to the PC or Printer during an interruption of the supply voltage USB Universal Serial Bus A 1 5M sec 12Mbit sec serial communication interface that can support 127 separate devices consisting of 4 wires power ground data in and data out Virtual Memory A technique used by Windows when chip memory is exhausted in which data is written to the hard to hold data temporarily and support Window s operations Wrinkle The appearance in the card image of wavy or arched lines either colored or clear caused by improper film or ribbon tension YMC The designation of colored ribbon by the Panels of color in the order in which they are printed Yellow Y Magenta M Cyan C YMCK The designation of colored ribbon by the Panels of color in the order in which they are printed Yellow Y Magenta M Cyan C Black K YMCKH The designation of colored ribbon by the Panels of color in the order in which they are printed Yellow Y Magenta M Cyan C Black K Heat Seal H YMCKK The designation of colored ribbon by the Panels of color in the order in which they are printed Yellow Y Magenta M Cyan C Black K Black K the second K is for backside black only printing YMCKO The desi
14. HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 HDP820 Dual Sided Card Printer Encoders HDP820 LC Dual Sided Card Printer Encoders e HDP825 Dual Sided Card Printer Encoders HDP825 LC Dual Sided Card Printer Encoders Part Number L000307 RESTRICTED USE ONLY FARGO Electronic Inc HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 property of FARGO Electronics Incorporated Copyright 2002 2003 2004 2005 2006 by FARGO Electronics Incorporated All rights reserved Printed in the United States of America Exclusive permission is granted to authorized resellers of FARGO products to reproduce and distribute this copyrighted document to authorized FARGO customers who have signed a no disclosure agreement regarding the restricted proprietary use of said document The revision number for this document will be updated to reflect changes corrections updates and enhancements to this document Revision Control Date Document Title Number Revision 5 0 1 January 2004 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 These reference documents were thoroughly reviewed to provide FARGO with professional and international standards requirements guidelines and models for our technical training and user documentation At all times the Copyright Protection Notice for each document was adhered to within our FARGO documentation process This reference to other
15. Head Voltage Error 53 Headlift Motor 88 Headlift Motor Assembly 292 Headlift Sensor Assembly 322 Headlight Drive O Rings 285 Heat Seal 180 510 Heat sink 510 Heat Source Off 53 Height Adjustment Thumb Screw 177 HiCo High Coercivity 510 High Coercivity 221 High Coercivity UltraCards 221 high Transfer Temperature or high Transfer Tension 477 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 526 RESTRICTED USE ONLY high coercivity Magnetic Stripes 219 high resolution 24 bit color images 127 holographic type overlaminates 49 Hopper Lift 70 Horizontal adjustment 206 HTML HyperText Markup Language 510 HTTP HyperText Transfer Protocol 510 Humidity 13 I IC Integrated Circuit 510 IC smart cards proximity cards 178 ID Identification 510 ID format 192 ID software applications 227 IEEE 1284 Institute of Electrical and Electronics Engineers 1284 511 I EEE 1284 compliant cable 60 Image 511 Image color tab 190 201 203 Image Color tab 115 117 118 Image Darkness 113 460 Image orientation 205 image placement problems 123 124 125 126 Image Position controls 205 Image Position option 125 image skewed 131 Image Transfer tab 119 121 125 235 image washout on film problems 128 inadequate data cable 60 incomplete transfer is limited to the trailing edge 122 incorrect image darkness problems 113 Initial Heating Proces
16. Karen Atkins Access Level 2 ID 1234478 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 214 RESTRICTED USE ONLY Fargo Electronics Inc Measuring the Area to be positioned on the Card Step Procedure 1 Once the area is sized properly measure the location where this area is to be positioned on the card a Measure from the lower left corner of the card up and over to the lower left corner of where the defined area is to begin b Enter these values into the X and Y boxes as shown below c Note that the card grid lines are spaced at 2 5mm intervals Karen Atkins Access Level 2 ID 1234478 172355 Y 0 2 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 215 RESTRICTED USE ONLY Fargo Electronics Inc Selecting the Print YMC under the K and Print K Only options Step Procedure 1 Use the Defined Area function a Define an area by clicking on the Defined Area UP arrow Note Another 2 x 2 5mm x 5mm area will appear in the lower left hand corner This is the location in which all newly defined areas will first appear Up to 5 areas can be defined e Additional areas cannot be added until the most recently created area has been moved or sized For this reason size and position each area as it is created e Use the Defined Area arrows to navigate back and forth from area to area The active area will always be highlig
17. Use a Cleaning Pad from the Printer Cleaning Kit to wipe the roller clean Press the FORWARD and BACK buttons to move the roller back and forth while cleaning g Replace the printing supplies and close the Print and Transfer Stations after the rollers are clean and completely dry 6 Replace the Printhead See the Replacing the Printhead D840854 procedure in Section 5 page 281 Mike Berman Student 3957105 library Code 2439 554 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 109 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Card surface debris problems Symptom Prints have spots white or colored voids and or dust on them Step Procedure 1 Be sure the cards are clean and stored in a dust free environment A Caution Cards with embedded contaminants in the surface should not be used 2 Clean the inside of the Printer a b C e Open the Print Station and Transfer Station Remove the print ribbon and HDP Film from the Printer Use a can of compressed air to blow out all visible areas of the Printer interior If you do not have a can of compressed air use a cleaning pad from the Printer Cleaning Kit to wipe out all visible areas inside the Printer Remove any debris that may be inside A Caution Be extremely careful not to let any alcohol drip inside the Printer f g Re install the printing supplies Close the Print and Tra
18. 104 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Lam Error Out Error Message continued a b C Step Procedure 3 Check the Laminate Ribbon Clutch to determine if it is too loose a Remove the back cover b Use a 7 16 wrench to tighten the nut on the end of the Encoder wheel by turn 4 Test the Encoder Sensor D870198 Remove the back cover Using a Digital voltmeter connect the negative lead to ground Connect the positive lead to Pin 4 of J13 e f blocked the voltage should read 4 9 to 5 5 VDC e f unblocked the Sensor should read 0 15 to 0 18 VDC If the voltages do not read correctly the Sensor should be replaced HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 105 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Lamination not adhering to the card surface problem Symptom The Lamination will not transfer to the card or is easily peeled off the card Step Procedure 1 Ensure the Card quality by verifying that these requirements are met a Requirement 1 That the Printer does print onto any card with a clean level and polished PVC surface Note Although the Printer is equipped with card cleaning rollers it is very important to always print onto cards specifically designed for direct to card dye sublimation printing to ensure proper print quality Requirement 2 That suitable cards display a polished
19. 140212 O Ring 1 024 Belt O Rings Film 1 00 Compound 23811 Drive 220071 Belt 65 GRV 080P 1 8 Belt Card Drive 9 62 Width 220082 Belt 105 GRV 080P Belt Card Drive 9 23 1 8 Width Belt2 760286 Pulley Ribbon Motor Pulley Motor 1 17 760287 Pulley Gear Pulley Gear 0 78 Combination Combination 760288 Gear Ribbon Idler Gear Idler 3 71 760289 Gear Ribbon Drive Gear Ribbon Drive 2 47 760330 Gear Headlift Gear Card 1 19 Transport 760401 Gear Idler Gear Cleaning Idler 2 24 Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 480 RESTRICTED USE ONLY HDP8xx Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 Fargo Electronics Inc Category Part Part Description Alternate Part MSRP List Number Description Price Belts and 810266 Gear Card Gear Card 0 72 Gears Transport Drive Transport Drive 810271 Gear Card Feed Gear Card Feed 0 66 Shaft Flipper D841032 Gear 72 X36 Tooth Gear Compound 3 50 Gear F000018 Belt 104 GRV Belt 104 MXL 11 31 080P 1 8 Width back side F000063 O Ring 1 022 Belt O Ring 0 40 COMPOUND 5747 F000092 Belt FHT 1 220 Belt Stepper 7 09 Tooth Motor F000093 Belt 136T FHT 1X Belt N2 Stepper 5 27 4MM Motor F000094 Belt 163T FHT 1X Belt Stepper 5 40 4MM Motor F000094 Belt 163T FHT 1X Belt C2 Stepper 5 40 4MM Motor F000111 Belt
20. 5 Close the Print and Transfer Stations Cleaning outside the Printer Step Procedure 1 The Printer has a durable casing that should retain its luster and appearance for many years Clean it only with a Cleaning Pad from the Printer Cleaning Kit A Caution Do not use cleaning solvents of any kind or spray the cabinet with a cleaner HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 246 RESTRICTED USE ONLY Fargo Electronics Inc Cleaning the Printhead Clean the printhead every time the Print Ribbon is changed to maintain consistent print quality as instructed below This procedure should also be performed approximately every 400 prints in order to maintain consistent print quality A Caution Never use a sharp tool or abrasive object of any kind to clean the Printhead It will damage the Printhead Watches rings bracelets and other jewelry can damage the Printhead if accidentally bumped against it For best results remove such items before touching any internal components of Printer Step Procedure 1 Remove watches rings bracelets and other jewelry 2 Open the Print Station 3 Use a Printhead Cleaning Pen from the Printer Cleaning Kit to firmly wipe back and forth across the surface of the Printhead 4 Close the Print Station once the Printhead is completely dry Printhead
21. 53 RESTRICTED USE ONLY Reviewing LCD Messages continued Fargo Electronics Inc Message Cause Solution Mag Encode The magnetic stripe was not encoded See the Resolving the Failed Failed properly Magnetic Encode Error Message procedure in Section 2 page 77 Multiple Two or more cards fed from the Card See the Resolving the Card Cards Fed Hopper Feeding problem in Section 2 page 65 No ENC There is no response from the Encoder See the Resolving the No ENC Response control Module Response Error Message procedure in Section 2 page 76 No MAG You are trying to send encoding data See the Resolving the No Encoder but the Printer is not configured with Magnetic Encoder Error this Encoder type Message procedure in Section 2 page 76 No Prox You are trying to send encoding data See the Resolving the No Prox Encoder but the Printer is not configured with Encoder Error Message this Encoder type procedure in Section 2 page 83 No SMART You are trying to send encoding data See the Resolving the Failed Encoder but the Printer is not configured with Smart Encode Error Message this Encoder type procedure in Section 2 page 84 Output The output stacker is full of cards Remove cards from the Output Hopper Full empty the output stacker to avoid a Hopper and press OK to jam continue Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 54 RESTR
22. C Print E Only HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 210 RESTRICTED USE ONLY Fargo Electronics Inc Selecting the Defined Area s with the K Panel Resin tab Step Procedure 1 Select the Defined Area s option to print the resin black K Panel for all black found only in an area or areas defined as shown below CR 80 Card Size f Front C f inches B mm Defined Ares dh Direction Card Travels Through Printer Lizleka Print All Black With E Panel Full Card W Defined Areas Undefined Area s f Print YMC Under K t Print amp Only HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 211 RESTRICTED USE ONLY Fargo Electronics Inc Selecting the Undefined Area s with the K Panel Resin tab Step Procedure 1 Select the Undefined Area s option to print the resin black K Panel for all black found only in the space outside the areas defined as shown below CR 80 Card Size f Front C 1 600 X 0 400 f inches mm Defined Area Ba 4h Direction Card Travels Through Printer Delete Print All Black With E Panel Full Card Defined Areals AS 0 0 SERTER Print YME Under K C Print K Only HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 212 RESTRICTED USE ONLY Fargo Electronics Inc Defining the Area to activate the Card Grid Step Procedure 1 Select on the ap
23. HDP820 HDP820 LC Magnetic and Smart Card Module Replacement 414 Replacing the Magnetic Smart Card Module 418 Section 7 Packing the HDP800 Series Card Printer 437 Section 8 Board Level Diagnostics 438 Board Errors 438 Resolving the EE Memory Error 438 Resolving the EE Checksum Error 438 Resolving the DRAM Memory Error 439 Resolving the RAM Memory Error 439 Resolving the FPGA Error 439 Sensor Testing 440 Reviewing the Sensor Location and Voltages 441 Reviewing the Sensor Layout on Ribbon Sensor array 442 Reviewing the Sensor Location and Voltages for the Lamination Module 443 Section 9 LCD On Line Menu Navigation 444 Entering the LCD Menu and selecting an Option 444 Selecting from the HDP800 Series Menu Option Structure Tree 446 Reviewing the Printer Setup 447 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 7 RESTRICTED USE ONLY Fargo Electronics Inc Preparing to Adjust the Print Offset Transfer TOF and Transfer EOF 449 Aligning the Print Offset 450 Setting the Transfer TOF 452 Setting the Transfer EOF 454 Setting the Transfer EOF 455 Adjusting the Transfer Tension 456 Adjusting the Film Drive 457 Adjusting the Ribbon Tension 457 Adjusting the Ribbon Drive 458 Adjusting the Transfer Temperature 458 Setting the Flattener Temperature 459 Setting the Printhead Resistance 459 Adjusting the Image Darkness 460 C
24. Lamination Drive Hubs Note The smaller Lamination Drive Hub closest to the front of the Lamination Module is Spring loaded b Use the end of the supply roll with the black core plug to push this hub in when inserting the overlaminate roll Note Make certain the overlaminate material is fed from beneath the roll as shown HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 141 RESTRICTED USE ONLY Fargo Electronics Inc Loading the Overlaminate continued Step Procedure 5 a Place the take up end of the roll in between the two black Lamination Drive Hubs located on the far left hand side of the Lamination Module s interior b Load the take up end of the roll just as you loaded the supply end in step 4 Note When loaded properly the overlaminate material should feed underneath both ends of the overlaminate roll 6 Close the Lamination Module Note When you start to print the Lamination Drive Hubs will automatically engage the overlaminate core notches A Caution Do not reverse the overlaminate roll Damage may occur to the Lamination roller HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 142 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Card Lamination Module The HDP800 Series Card Printer supports the attachment of an optional Card Lamination Module This Module can be ordered pre installed on the P
25. PVC core 106 PVC laminate 33 Queue 516 R Radio frequency interference 60 RAM Random Access Memory 516 RAM Memory Error 56 439 Rasterize 516 Reading Access Card 58 Ready Printer Open Screens 26 Realigning Film 56 Rear Transfer Cover 275 Reboot 516 Receiving encoding data 76 recorded magnetic data 225 ReFilm Drive O Rings 323 Registration 516 registration problems 129 130 regulator 89 Regulatory Compliances 11 Reinstall Printhead 129 Release Lever 23 273 274 275 284 290 Remove Back cover 278 Remove Card Input Hopper cover 277 Remove Card Output Hopper cover 277 Removing Print Station cover 273 Repair by taping ribbon 85 Replace Fan Assembly 282 Replace Head Force Spring 283 Replace Lamination Board 91 Replace Print Board 91 Replace Printhead 128 130 Replace Ribbon Deflector 284 replace Sensor 75 replace the motor 100 Replacing Headlift Sensor Assembly 88 Replacing Main Board 90 Replacing Printhead 281 Fargo Electronics Inc Replacing the Headlift Motor Assembly 88 Replacing Transfer Lift Motor 99 Replacing Transfer Lift Switch 99 reseat cable 89 reset the Printer 100 Resident Font 516 Resin 516 resin black K Panel 211 212 213 216 Resin Black Panel 32 resin dither 191 Resin Heat slide 202 resin images 202 Resin Thermal Transfer 17 Resolution 517 Resolving card feeding problem 63 64 65 66 67 Resolving card j
26. Supply Frequency 15 Supply Voltage 15 Surface mount 519 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 532 RESTRICTED USE ONLY surface roughness 180 switch box 61 63 Switch box 519 Switch Box 519 System Check Screens 25 system Firmware 55 System Requirements 15 System Upgrade 467 System Upgrade option 471 T TAC 519 Tape adhesion Test 181 183 Tape Test 207 Target Temperature 46 Technical Specifications 12 Temp file 519 Temperature Adjustment 37 Temperature Timeout 56 Temperature Timeout problem 99 test image correctly positioned 453 Testing Memory 56 Test print 519 Thermal Transfer Film 48 Thermal Transfer Film overlaminates 49 Thermistor 519 Thermocouple 520 Thermocouple Control C111 97 Thermocouple wire 333 thicker cards 180 thinner cards 180 Through hole 520 Timeout 520 to buffer to hold 197 198 TOF Top of Form 520 TOF Sensor 75 top bottom Cleaning Rollers 67 108 111 250 total card area 214 Track 520 Track Information 227 track number 1 2 or 3 227 Transfer Cooling 56 Transfer Cooling Error LCD indication 97 Transfer Cooling message 97 Transfer Count 134 Fargo Electronics Inc Transfer Dwell Time Temperature 207 Transfer EOF 454 455 Transfer EOF value 454 Transfer Film 91 Transfer Film Drive errors 91 Transfer Lift 56 Transfer Lift Motor 99 337 Transfer Lift Motor problem
27. messages before performing an operation preceded by this symbol To prevent equipment or media damage observe all established Electrostatic Discharge ESD procedures while handling cables in or near the Circuit Board and Printhead Assemblies To prevent equipment or media damage always wear an appropriate personal grounding device e g a high quality wrist strap grounded to avoid potential damage To prevent equipment or media damage always remove the Ribbon and Cards from the Printer before making any repairs unless otherwise specified To prevent equipment or media damage take jewelry off of fingers and hands as well as thoroughly clean hands to remove oil and debris before working on the Printer HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 245 RESTRICTED USE ONLY Fargo Electronics Inc Cleaning inside the Printer Step Procedure 1 Open the Print Station and Transfer Station 2 Remove the Print Ribbon and HDP Film from the Printer 3 If you have a can of compressed air blow out all visible areas of the Printer interior Note Remove any debris that may be inside OR If you do not have a can of compressed air use a cleaning pad from the Printer Cleaning Kit to wipe out all visible areas inside the Printer Note Remove any debris that may be inside Lr Caution Be extremely careful not to let any alcohol drip inside the Printer 4 Re install the printing supplies
28. of Card 463 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Flipper Offset Step Procedure 1 Select MENU Setup Printer and Flipper Offset 2 Change the setting in small increments if the card is not feeding correctly Note A negative adjustment will lower the side of the Flipper Table closest to the Exit Hopper 3 Press the Select button to save the value Adjusting the Lamination Flipper Offset Step Procedure 1 Select MENU Setup Printer and Flipper Offset 2 Change the setting in small increments if the card is not feeding correctly Note A negative adjustment will lower the side of the Flipper Table closest to the Exit Hopper 3 Press the Select button to save the value HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 464 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the LAM TOF and EOF Step Procedure 1 Applies only if the Printer is equipped with the Card Lamination Module e Use this control to align the PolyGuard Overlaminate patch on the card Decrease the Lamination TOF value to move the overlaminate patch more toward the leading edge of the card e Increase the Lamination TOF value to move the overlaminate patch more toward the trailing edge of the card The numbers being entered for the settings are in Pixels The number of Pixels is equal to the measurement in inches times 300 or the measurement
29. x Magnetic Encoding Lamination K Panel Resin Card Device Options Image Colar Image Transter Ribbon Type AICI Full Color Resin Black Film Type cer O RS Algebraic Mone Resin Dither Algebraic Monitor Color Watching HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 190 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting for the Resin Dither Select the appropriate dither method according to the type of image to be printed Note This option only affects those objects printed on the backside of a card with the resin black Panel of a YMCK or YMCKK Print Ribbon Step Procedure 1 Select Optimized for Photo when printing photo quality images with resin OR Select Optimized for Graphics when printing lower quality images e g clipart logos etc with resin HDPS20 LC Card Printer Printing Preferences E ajx Magnetic Encoding Lamination E Panel Resin Card Device Options Image Color Image Transter Ribbon Type YECHA Full Color 2 Resin Black x Fimtye a OOO H Color Matching Morito S A Resin Dither M Print Anth HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 191 RESTRICTED USE ONLY Fargo Electronics Inc Using the Print Both Sides option Use this option to automatically print on both the front and backside of a card Step Procedure 1 Select this option in conjunction with any appl
30. 070048 Sensor up ITM TUP 840141 Assembly Sensor Sensor Card Feed 20 48 070049 Sensor Card Path Card PSN 840199 Assembly Ribbon Sensor Lower Film 105 16 Sensor Array LAM Sensor 840263 Thermocouple Sensor 72 80 Kapton Thermocouple Lamination Roller A000126 Assembly PCB S3 Sensor Transfer 25 86 Sensor 2 Lift Sensor D840526 Thermocouple Sensor 69 94 Kapton Thermocouple flattener D840624 Assembly Sensor Sensor Card Feed 21 78 E000002 Sensor Card Fed Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 492 RESTRICTED USE ONLY HDP8xx Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 Fargo Electronics Inc OPT PRN Sensor Category Part Part Description Alternate Part MSRP List Number Description Price Sensor D840625 Assembly Sensor Sensor Card Feed 21 78 E000002 Sensor Flipper Table Card FTB D840982 Assembly Sensor Sensor Ribbon 24 31 070048 Sensor Rib Encoder Spy D840983 Assembly Sensor Sensor Headlift 24 31 070048 Sensor position PRN PSN D841023 Assembly Slotted Sensor Upper Film 116 42 FARGO ELECTRONICS INCORPORATED 2003 FARGO Electronics Incorporated FARGO is a registered trademark of FARGO Electronics Incorporated Prices and specifications are subject to change without notice Address Phone FAX L00
31. 106 GRV 08 P Belt Magnetic and 7 15 60DEG 1 8 Smart Card F000139 Belt 221 GRV 080P Belt Hopper Travel 5 39 1 8W HDP 825 ONLY F000158 O Ring 103 X Belt O Ring 1 17 1 063 SH A 80 Printhead F000158 O Ring 103 X Belt O Ring 1 17 1 063 SH A 80 Lamination Motor Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 481 RESTRICTED USE ONLY HDP8xx Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 Fargo Electronics Inc Category Part Part Description Alternate Part MSRP List Number Description Price Boards 140311 Assembly Pro L Board Smart Guard 124 58 SMART LOCK Assembly Board 140403 Assembly Board Board LCD Display 283 53 User Interface 140403 Assembly Board Board User 283 53 User Interface interface A000271 Assembly PCB Board Main Print 0 00 Main HDP LC 5200 CPU A000294 Assembly HDP and Board Assembly 113 69 SII Magnetics HDP and SII Board Magnetic D841136 HDP820 PROG Board Lam Board 1 160 00 LAM Board 140402 Cables 130069 Power Cord Cord Europe 7 48 European 6 Foot 24000111 Assembly Cable Cable Smart Guard 10 02 Ribbon SMART LOCK 840176 Assembly Cable Cable Flipper 38 87 FLEX CT HDR Brown HDR Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 482 RES
32. 140407 364 Power Assembly Components Replacements 365 Replacing the Power Switch 120011 365 Replacing the Power Cord Receptacle 130067 366 Replacing the Main Print Board A000271 367 Replacing the Lamination Board 140402 368 Replacing the Power Supply 150240 369 Output Stacker Components Replacements 370 Replacing the Output Stacker D841079 370 Replacing the Stacker Full Sensor 140407 371 Replacing the Stacker Lift Motor 840130 372 Card Lamination Module Component Replacements 373 Replacing the Lamination Module Board Cover D870151 373 Replacing the Lamination Module Main Cover D870159 374 Replacing the Lamination Module Main Board A000250 375 Replacing the Lamination Module Arm Assembly D870153 376 Replacing the Lamination Module Card Flipper Table Assembly D870091 377 Replacing the Card Position Sensor Assembly D870186 379 Replacing the Lamination Module Flipper Position Sensor D870188 380 Replacing the Lamination Module Overlaminate Encoder Sensor D870189 381 Replacing the Lamination Module Ribbon ID Sensor 820593 382 Replacing the Lamination Module Overlaminate Sensor D870241 383 Replacing the Lamination Module Hopper Sensor Assembly D870228 384 Replacing the Lamination Module Platen Motor D870218 386 Replacing the Lamination Module Flipper Table Motor D870217 388 Replacing the HDP820 LC HDP825 LC Lamination Lid Hinge Bracket 390 Adjusting the HDP820 LC HDP825 LC Lamination Heat Shield Adjustment ___ 408
33. 236 Position Feeler Gauge 177 Position magnetic data 462 positive negative image placement values 206 potentiometer 129 Potentiometer 515 Potentiometer on Sensor Board 91 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 529 RESTRICTED USE ONLY Power Cord Receptacle 366 Power Port 22 Power Supply 150240 369 Power Switch 22 365 prevents magnetic encoding 223 Print All Black With K Panel 210 Print and Transfer Stations 26 Print Area 14 Print Back Side First option 194 Print back side only 195 print both sides 192 193 Print Both Sides option 193 195 Print Data 54 Print Driver 515 Print Job 515 Print K Only option 216 Print Length 233 Print Module 349 Print Offset 449 450 451 Print Offset value 451 Print Offset Transfer TOF and Transfer EOF 449 450 456 Print Platen Roller 330 print ribbon 110 Print Ribbon 55 246 Print Ribbon Low 55 Print Ribbon Options 15 Print Ribbon Out 55 Print ribbon problem 81 86 Print Ribbon replacement 87 Print Ribbons 32 Print Server 515 Print Speed 15 Print Speed Batch Mode 15 Print Station 20 108 247 273 276 282 286 290 292 Print Station Cover 273 287 322 Print Status Screen 27 Print Stepper Motor 269 Print Test Image 78 82 132 Print Test Image Setup Printer Show Error Count Show Card Count and System Upgrade 445 print the first page of a two page document 194
34. 76 Resolving the No Magnetic Encoder Error Message 76 Resolving the Failed Magnetic Encode Error Message 77 Removing the Card jam in the Printer s Magnetic Encoding Area 78 Resolving the Printer being unable to read Encoded Magnetic track Data problem 79 Resolving the magnetic stripe Data being printed on a Card problem 80 E card Encoding Errors 81 Resolving the Job Mismatch error 81 Removing the Card jam in the Printer s Smart Card Encoding Area 82 Resolving the No Prox Encoder Error Message 83 Resolving the No Smart Encoder Error Message 83 Resolving the Failed Smart Encode Error Message 84 Printing Process Errors 85 Resolving the Ribbon Alignment Error Message 85 Resolving the Print Ribbon Jam 86 Resolving the Print Ribbon Error Message 86 Resolving the Print Ribbon Out Error Message 87 Resolving the Wrong Print Ribbon Error Message 87 Resolving the Unknown Ribbon Type Error Message 88 Resolving the Headlift Error Message 88 Resolving the Printer pausing between Panels problem 89 Resolving the Printhead Temp Error Message 90 Resolving the Printer Open Error Message 90 Transfer Process Errors 91 Resolving the Upper and Lower Film errors 91 Resolving the Film Sensor errors 93 Resolving the Transfer Cooling error 97 Resolving the Card Jam Error Message 98 Resolving the Temperature Timeout Error Message 99 Resolving the Transfer Lift Error Message 99 Resolving the Output Stacker errors 100 Card Lamination Errors 101 Resolving the Overlamina
35. Color Image Transter Magnetic Encoding Lamination K Panel Resin Ventication Encoding Mode So JIS f Auto Eject 1st Error i Manual Eject Each Error Coercryity Fetes A e High Co Low Co oi 2 Ie a Track Selection i Track 1 C Track2 f Track 3 Enable MLE Support HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 222 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Enable MLE Support checkbox Multi Language Extension MLE support in Windows XP can cause text strings to be broken up into fragments This fragmentation of the text string prevents magnetic encoding Step Procedure 1 Check this box to allow the Driver to process the fragmented text HDP825 LC Card Printer Printing Preferences _ x Card Device Options Image Color Image Transfer Magnetic Encoding Lamination K Panel Resin r Encoding Mode Verhication te isg JIS I f Auto Eject 1st Error S C Manual Eject Each Error Coerciity Retes P HighCo C Low Co a Magnetic Track Selection i Tracki Track2 Track 3 Enable MLE Support HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 223 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Verification options Use this option which instructs the Printer to verify that all magnetic data has been correctly encoded on each card Note With either of these optio
36. Default Temperature Reviewing the Laminator Temperature Adjustment Reviewing the Overlaminates Reviewing the Thermal Transfer Film and PolyGuard Overlaminates Reviewing the CR 90 or CR 100 Patch Size Reviewing the Overlaminate Design Section 2 General Troubleshooting LCD SmartGuard Messages Reviewing LCD Messages Reviewing SmartGuard Error and Status Messages Communications Errors Resolving the Communication Errors Firmware Errors Resolving the Upgrade Failed error Card Feeding Errors Resolving the Card Feeding problem HDP820 820 LC Resolving the Card Feeding Errors HDP825 825 LC Resolving the stalled Cards on or at the Feed Rollers Resolving the jammed Cards on the Flipper Table Resolving the Flipper Alignment Error Message Resolving the Cards being fed improperly off the Flipper Table HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 10 10 11 11 12 16 17 25 31 32 33 34 35 36 37 39 40 41 42 43 44 45 46 47 48 48 49 49 50 50 58 60 60 63 63 65 65 68 71 71 72 173 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Card Jam Error Message 74 Resolving the Card Jam Lam Error Message 75 Magnetic Encoding Errors 76 Resolving the No ENC Response Error Message
37. Defined Area s Undefined Areals Print YMC Under K Print K Only Cancel Appi Help HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 217 RESTRICTED USE ONLY Fargo Electronics Inc Using the Magnetic Encoding tab Use these options only if the Printer has an optional Magnetic Stripe Encoding Module installed Step Procedure 1 Select the Magnetic Encoding tab to display options for controlling the Magnetic Stripe encoding process Note The following describes these options and the Printer s magnetic encoding process HDP825 LC Card Printer Printing Preferences Card Device Options Image Color Image Transfer Magnetic Encoding Lamination K Panel Resin m Encoding Mode Verification CSI Auto Eject 1st Error Manual Eject Each Error gt Coercivity eg HighCo Low Co Retries 2 r Magnetic Track Selection Track1 Track2 Track3 Enable MLE Support L r Magnetic Track Options Bit Density r Character Size m ASCII Offset C 75 BPI C 5Bits NULL 128 BPI 7 Bits SPACE 210 BPI 8Bits ZERO LAC Generation p Character Parity C NoLRC No Parity Even Parity Even Parity Odd Parity Odd Parity Default M Shift Data Left Cancel Apply Help Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 218 RESTRICTED USE ONLY Fargo El
38. Direction Card Travels Through Printer Transter Dwell Time 2 0 seconds inch Transfer Temperature 175 0 Centigrade Flattener Temperature 75 0 Centigrade Default Cancel Apply Help HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 204 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Image Position controls Use the Image Position controls to position the image on a card to be adjusted Step Procedure 1 Adjust the Image Position values by clicking on the Vertical and Horizontal adjustment arrows e These values ensure that the Cards always remain in the same position as they travel through the Printer regardless of image orientation e The Card Illustration shown in the Image Position box will flip and rotate according to the selection of Portrait Landscape or Rotate 180 Degrees e The outline around the illustration will always remain in the same Landscape orientation Continued on the next page e T LLE MaL AULI E a es HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 205 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Image Position controls continued The display below represents how the printed image will move in relation to the fixed card position as positive and negative image placement values are entered Step Procedure 2 Use the Vertical adjustmen
39. HDP825 825 LC e CR 80 3 375 L x 2 125 W 85 6mm L x 54mm W Accepted Card 030 in 30 mil to 070 in 70 mil 762mm to 1 778mm 30 mil Thickness maximum for CR 100 size cards 030 to 040 762mm to 1 02mm if laminating with HDP800 Series LC thicker cards are allowed to pass through the Lamination Module if you choose to print only Accepted HID Proximity Cards MIFARE Contactless Smart Cards and Contact Electronic Card types Smart Cards Accepted Card Compositions ABS PVC PET and PETG Colors Up to 16 7 million colors and 256 shades per Pixel Card Capacity HDP820 HDP820 LC 250 cards 030 762mm auto or manual feed HDP825 HDP825 LC 200 cards 030 762mm auto or manual feed Dimensions e HDP820 825 15 H x 26 1 W x 14 D 381mm H x 663mm W x 356mmD e HDP820 LC 825 LC 15 H x 34 75 W x 14 D 381mm H x 883mm W x 356mmD e LC Module 14 2 H x 13 W x 10 D 362mm H x 330mm W x 254mmD HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 12 RESTRICTED USE ONLY Fargo Electronics Inc Technical Specifications continued Term Description Display User friendly SmartScreen LCD Control Panel LED display on Card Lamination Module Encoding Options e ISO Magnetic Stripe Encoding Module dual high and low coercivity Tracks 1 2 and 3 e JIS Il Magnetic Stripe Encoding Module e E card Docking Statio
40. ID Card Printer Recommended Spare Parts List Effective Date January 2004 Fargo Electronics Inc Category Part Part Description Alternate Part MSRP List Number Description Price Motors D870183 Assembly Motor LC Assembly Motor 0 00 Headlift LC Headilift D870187 Assembly Motor LC Assembly Motor 0 00 Take up LC Take up D870217 Assembly Motor Assembly Motor 83 52 LAM FLIP LAM FLIP D870218 Assembly Motor Assembly Motor 83 52 LAM Platen LAM Platen Rollers 810264 Roller Ribbon Roller Ribbon 10 08 Guide Guide 820516 Roller Platen Pulley Roller Platen Pulley 45 31 84031411 Roller Card Full Roller Card Full 48 69 Width Width D870090 Roller Card FLIP Roller Card FLIP 0 00 D870163 Roller CR 100 Roller CR100 0 00 Lamination Lamination D870211 Assembly LAM Assembly LAM 0 00 Roller Roller D880039 Roller Pinch Output Roller Pinch Output 30 88 D880050 Roller Card Flattener Roller Card 0 00 Flattener D880117 Roller Card Feed Roller Card Feed 19 44 C25 PRO Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 499 RESTRICTED USE ONLY Fargo Electronics Inc HDP8xx LAM Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 Category Part Part Description Alternate Part MSRP List Number Description Price Sensors D870186 Assembly
41. Indicates there is not an adequate Add cards to the input hopper and supply of cards in the Card Input press Resume to continue printing Hopper Aligning If this appears as a prompt the If this appears as an error see the Film HDP Film is self aligning to the the Resolving the Film Sensor proper position for printing errors procedure in Section 2 page 93 Aligning If this appears as a prompt the print If this appears as an error see the Ribbon ribbon is self aligning to the proper Resolving the Ribbon Alignment position for printing Error Message procedure in Section 2 page 85 Card Jam A card is jammed in the Transfer See the Resolving the Card Jam Station or card flipping area of the Error Message procedure in Section Printer 2 page 74 Card Jam A card is jammed in the card See the Resolving the jammed Flipper flipping area of the Printer Cards on the Flipper Table procedure in Section 2 page 71 Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 50 RESTRICTED USE ONLY Reviewing LCD Messages continued Fargo Electronics Inc Message Cause Solution Card Jam A card is jammed in the magnetic See the Removing the Card jam in Mag encoding area of the Printer the Printer s Magnetic Encoding Area in Section 2 page 82 Card Jam A card is jammed in the smart card See the Removing the Card jam in Smart encoding area of the Printe
42. Lamination Module continued Step Procedure 7 Remove the one 1 screw which fastens the Card Output Bin to the Baseplate and lift the bin up and off of the Printer Continued on the next page Remove 1 screw HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 156 RESTRICTED USE ONLY Fargo Electronics Inc Attaching the Card Lamination Module continued Step Procedure 8 In all eight 8 screws the Card Output Hopper s main enclosure and the Card Output Bin should now be removed from the Printer Note Set these items aside 9 Set the Card Lamination Module just to the left of the Printer and at a slight angle as shown Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 157 RESTRICTED USE ONLY Fargo Electronics Inc Attaching the Card Lamination Module continued Step Procedure 10 a Connect the Lamination Module s Power Cable to the Printer s Power Port Note Both are labeled with a red Power label b Push firmly to ensure both are securely connected Note The port and cable are keyed for one way installation Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 158 RESTRICTED USE ONLY Fargo Electronics Inc Attaching the Card Lamination Module continued Step Procedure 11 Connect the Lamination Module s C
43. Low Coercivity encodes at 300 Oe LPT Port Line Printer Port The system abbreviation for a PC s parallel Printer port Mag encoding The process of orienting successive magnetic bits to produce a serial data string Mag stripe An area of the card with an applied or impregnated ferrous material that may hold encoded data through a Series of prescribed polarity changes Mag Track An area of a magnetic strip running the length of the card with a given width and position constitutes a track This is the area dedicated to one data string restricted to specific rules of format ISO standards specify three Magnetic Tracks on the back of a card The JIS standard specifies one track on the front Mag Verify A process to confirm proper magnetic encoding After encoding the information is read off back and compared to the intended string Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 512 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Term Definition MB Megabyte A unit of storage that equals 1 048 576 bytes Memory A generic term for any device that stores digital information using magnetic media or digital chip storage device Menu A descriptive list of headings above nested functions that aid navigation to a specific operation These are found in computer applications with the heading at
44. PVC surface free of fingerprints dust or any other types of embedded contaminants Note In addition cards must have a completely smooth level surface in order for the Printer to achieve consistent color coverage Requirement 3 That certain types of Proximity cards with an uneven surface which can inhibit consistent color transfer are identified Note Likewise some smart card chips are raised slightly above the cards surface which also results in poor color transfer Requirement 4 That only Fargo approved HDP Laminate is used in the Printer Approved Laminate part numbers and descriptions are available on the HDP800 Series LC Price List Recommendation That high quality blank cards e g a factory approved card stock called UltraCard are in use e UltraCard stock has a glossy PVC laminate on top and bottom and is optically inspected to provide the cleanest most scratch and debris reduced cards possible e UltraCard stock which has a PVC core and offers medium card durability UltraCard III stock has a 40 polyester core and offers high durability e Both types of UltraCards produce printed images with a glossy photo quality finish For the flattest possible cards when laminating it is recommended use of UltraCard III card stock Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 106 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Lamination not
45. Printer Encoders Service Manual Rev 5 0 171 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Card Stacker Output Guide continued Step Procedure 3 Close the Card Output Hopper Door Note To make sure the cards remain neatly stacked in the Card Output Hopper always keep the hopper door closed during printing HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 172 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Internal Card Guide Adjust the Printer s Internal Card Guide to the proper card size prior to printing to ensure consistent card feeding throughout the printing process If you do not set this guide prior to printing you could experience card jams Step Procedure 1 Open the Print and Transfer Stations 2 Locate the Internal Card Guide and the Card Size Adjustment Knob Continued on the next page Internal Card Guide Card Size Adjustment Knob a A i IE FHG HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 173 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Internal Card Guide continued Step Procedure 3 Pull the Internal Card Guide toward the front of the Printer until it stops Continued on the next page a lt n 2 Lift UP on Card Size 3 Rotate Adjustment Knob Adjustment Knob to CR 80 80 or 100 1 Pull Card Guide Toward oo Front
46. Printhead up until the Headlift Sensor is activated All stop 8 The Ribbon Drives and Film Ribbon Drive advance until the Print Ribbon Encoder sees acceleration at release Note The Ribbon Encoders are active during this step 9 The Ribbon Drives move until the Print Ribbon Position Sensor finds the next panel All Motors stop Note The Ribbon Encoder is active during this step 10 The Film ribbon drive turns ON until the images portion of the Film is positioned before the Printhead using the Film Alignment Sensor All stop Note The Ribbon Encoder is active during this step 11 The Headlift Motor engages moving printhead down until the Headlift Sensor is activated All stop 12 Ribbon Drive Film Ribbon Drive and Stepper all turn ON and the Printhead burns image data until the image data is depleted All stop Note The Ribbon Encoders are active during this step 13 The Headlift Motor engages moving the Printhead up until the Headlift Sensor is activated All stop 14 The Ribbon Drive and Film Ribbon Drive engage until print ribbon encoder sees acceleration at release Note The Ribbon Encoders are active during this step 15 Repeat Steps 9 to 14 for the appropriate number of color heat seal panels Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 viii RESTRICTED USE ONLY FARGO Electronic Inc Reviewing HDP 800 Series Card Printer Sequence of Oper
47. Resin Dither Optimized for Graphics IV Print Both Si ides Print in Single Card Mode Split 1 Set of Ribbon Panels J Link Card to Print Job Print Back Side First Disable Printing J Print Back Side Only Rotate Front 180 Degrees Rotate Back 180 Degrees Cancel Apply Help HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 187 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Ribbon Type Use the Ribbon Type dropdown menu to match ribbon type Step Procedure 1 Adjust to match the Ribbon Type selection with the ribbon type that is loaded in the Printer e YMC Yellow Magenta Cyan OR YMCK Yellow Magenta Cyan Resin Black OR e YMCKK Yellow Magenta Cyan Resin Black Resin Black OR e YMCKH Yellow Magenta Cyan Resin Black Heat Seal Magnetic Encoding Lamination E Panel Resin Card Device Options Image Color Image Transter Ribbon Type Oa Full ColorResin Black Film Type a Full ColorResin Black Tal Full Color Resin Black Color Matching YMCA Full Color Resin Black Heat Seal Pean Dither Optimized for Graphics HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 188 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Film Type Use the Ribbon Type dropdown menu to match ribbon type Step Procedure 1 Adjust to match the Film Type selection with the film type that is loaded in th
48. Rev 5 0 535
49. Sensor LC Sensor Assembly 35 56 Card POSN LC Card POSN D870188 Assembly Board Sensor Assembly 19 82 Flipper Sensor LC Board Flipper Sensor LC D870189 Assembly Slotted Sensor Assembly 51 94 Sensor Mount Slotted Mount D870193 Assembly Board Sensor Assembly 18 40 LED LC Board LED LC D870198 Assembly Optical Sensor Assembly 0 00 Encoder Sensor LC Optical Encoder LC D870219 Assembly Sensor Sensor Assembly 0 00 070048 LAM Lift _070048 LAM Lift D870220 Assembly Sensor Sensor Assembly 0 00 070048 Arm Open _070048 Arm_ Open Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 500 RESTRICTED USE ONLY HDP8xx LAM Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 Fargo Electronics Inc ELECTRONICS INCORPORATED 2003 FARGO Electronics Incorporated FARGO is a registered trademark of FARGO Electronics Incorporated Prices and specifications are subject to change without notice Address Phone FAX L000467 Rev 030224 6533 Flying Cloud Drive Eden Prairie MN 55344 U S A 952 941 9470 952 941 7836 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 Category Part Part Description Alternate Part MSRP List Number Description Price Sensors D870221 Assembly Film Sensor Assembly 0 00 Sensor LC Film Sens
50. User Interface Board Assembly 280 Using Image Transfer tab 119 y Verification 224 Vertical adjustment 206 Vertical Horizontal adjustment arrows 205 Virtual Memory 521 visible damage 108 W Weight 15 Windows 2000 XP 87 104 107 113 115 117 118 119 121 123 125 Fargo Electronics Inc Windows 98Se ME 87 104 107 113 115 117 118 119 121 123 125 Windows NT 4 0 87 104 107 113 115 117 118 119 121 123 125 wires not pinched 89 Wrinkle 521 Writing Access Card 59 wrong print ribbon 87 Wrong Print Ribbon 57 X X Y boxes 215 Y Yellow Y Magenta M Cyan C ribbon Panels 216 Yellow Magenta and Cyan 200 201 202 YMC 188 521 YMC YMCK or YMCKK Print Ribbon 237 YMCK 188 521 YMCK or YMCKK Print Ribbon 191 YMCK YMCKK Print Ribbons 193 YMCKH 188 521 YMCKH Panel ribbon 180 YMCKH ribbon 183 YMCKK 188 521 YMCKO 521 YMCKOK 521 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 534 RESTRICTED USE ONLY Fargo Electronics Inc Appendix A Engineering Drawings These drawings are attached to this document in its PDF form for specified Users ONLY Appendix B Technical Updates These technical updates have already been incorporated into this service document Appendix C Miscellaneous There is no miscellaneous information added to this service document at this time HDP 800 Series Card Printer Encoders Service Manual
51. as the Printhead may be damaged if exposed to static electrical discharges To avoid potential damage always wear an appropriate personal grounding device such as a wrist strap with integral resistor connected to an ESD ground At a minimum make positive contact with the bare metal chassis of the Printer with the hand prior to touching any internal electrical components HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 244 RESTRICTED USE ONLY Fargo Electronics Inc Safety Messages review carefully Symbol Critical Instructions for Safety purposes A Danger Failure to follow these installation guidelines can result in death or serious injury Information that raises potential safety issues is indicated by a warning symbol as shown to the below To prevent personal injury refer to the following safety messages before performing an operation preceded by this symbol To prevent personal injury always remove the power cord prior to performing repair procedures unless otherwise specified To prevent personal injury make sure only qualified personnel perform these procedures A Caution This device is electrostatically sensitive It may be damaged if exposed to static electricity discharges Information that raises potential electrostatic safety issues is indicated by a warning symbol as shown to the below To prevent equipment or media damage refer to the following safety
52. c If the film is not between 5 and 15mm from the ribbon drive side of the transfer station replace the film with a new roll using the Ribbon Telescopic process 6 Ensure that the ribbon is not stuck to the film a Open the top cover b Verify that the ribbon is not stuck to the transfer film c Ifthe ribbon is stuck to the transfer film increase the ribbon tension in increments of 5 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 92 RESTRICTED USE ONLY Resolving the Film Sensor errors Fargo Electronics Inc Step Procedure 1 Check that all LCD settings are set as follows e Film Drive 0 e Ribbon Drive 0 e Transfer Tension 5 e Ribbon Tension 5 Technician Note 1 Transfer tension can be set higher than 5 if it is observed that the Film Take up Motor delays at the beginning of Lamination Technician Note 2 Ribbon tension can be set higher than 5 if it is observed that the Ribbon is sticking to the Film during printing 2 a oe base Film Drive Idler Roller D840867 moves freely see picture HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 Verify this roller spins 93 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Film Sensor errors continued Step Procedure 3 Check for cracked Film Drive Hubs D840952 Note A cracked Film Drive hub will not allow the film to be moved at the appropriate speed re
53. cards are loaded properly with the magnetic stripe facing down and towards the back of the Printer Verify that the card is encoded with magnetic data by using a magnetic imager or developer solution Use WordPad a Windows 95 98 ME NT 2000 XP word processing program in the Accessories Program Group a b c d e f Open the program and type 1 JULIEANDERSON 1234567890 Select File gt Page Setup and click on the Printer button Ensure that the HDP800 Series Card Printer is selected and click OK Change all the margin settings to zero 0 and click OK Select File gt Print on the Menu Bar Go to File on Menu Bar and select Print Note The Printer should then feed a card into the Encoder and magnetically encode it Ensure that the coercivity of the cards matches the setting in the Driver Compare the settings for the card reader to the settings in the Driver Ensure that the magnetic stripe on the card is free of scratches or voids HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 79 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the magnetic stripe Data being printed on a Card problem Step Procedure 1 Confirm that the application is formatting the magnetic string correctly See the Sending the Track Information procedure in Section 3 page 227 2 Use WordPad a Windows 95 98 ME NT 2000 XP word processing program in the Accessories Progr
54. documents does not imply that FARGO is an ISO certified company at this time e ANSI ISO ASQ Q9001 2000 American National Standard sub title Quality Management Systems Requirements published by the American Society of Quality Quality Press P O Box 3005 Milwaukee Wisconsin 53201 3005 e The ASQ ISO 9000 2000 Handbook editors Charles A Cianfrani Joseph J Tsiakals and John E West Second Edition published by the American Society of Quality Quality Press 600 N Plankinton Avenue Milwaukee Wisconsin 53203 e Juran s Quality Handbook editors Joseph M Juran and A Blanton Godfrey Fifth Edition McGraw Hill Any questions regarding changes corrections updates or enhancements to this document should be forwarded to FARGO Electronics Incorporated Support Services 6533 Flying Cloud Drive Eden Prairie MN 55344 USA 952 941 9470 800 459 5636 FAX 952 941 7836 www fargo com E mail sales fargo com HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 i RESTRICTED USE ONLY Reviewing the HDP800 Series Printers Overview table FARGO Electronic Inc Sided Card Printer Encoders HDP800 Series Input Card Accepted Encoding Lamination Hoppers Capacity Card Size Modules Module HDP820 Dual Sided 1 250 CR 80 Optional Optional Card Printer Encoders CR 90 amp CR 100 HDP820 LC Dual 1 250 CR 80 Optional Included Sided Card CR 90 amp Printer En
55. fill the space to the edge of the card as shown on the next page b Use a magnifying device with a built in measuring scale to measure the distance from the edge of the card to the Start Sentinel in the data as shown on the next page 3 If the Start Sentinel is too far from the leading edge of the card reduce or make negative the Magnetic TOF setting needs OR If the Start Sentinel is too close to the leading edge of the card increase or make positive the Magnetic TOF setting needs 4 Select MENU Setup Printer and Magnetic TOF 5 Adjust the setting by the amount determined by the following formula e 0 293 inches Represents measured SS distance inches x 300 steps per in OR e 7 4mm Represents measured SS distance millimeter x 11 8 steps per mm Example 0 293 0 284 x 300 2 7 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 462 RESTRICTED USE ONLY Setting the Magnetic TOF Fargo Electronics Inc Step Procedure 7 Press SELECT to save the value 8 Test the position of the Start Sentinel by magnetically encoding a card and checking as described in Step 1 in this same procedure 9 Repeat Steps 1 to 6 until the Magnetic TOF is correct Trailing Edge of Card 293 744mm UNTO Ea EA a aa a a AA T AN Magnetic Track Data E HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 Leading Edge
56. for the Printer to begin printing HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 23 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components Access Card Slot to Parallel Interface Port continued Refer to the previous table Printhead LED Light LCD Display Scroll Buttons Card Input Hopper Print Station leE Card Output T i 5 Hopper 4 ff Softkey Buttons pp a4 ah mi N2 Se thy pan Access Film Tension _ Card Slot Knobs Front Access Door Card Thickness Adjustment Knob Transfer Station _ Card Cleaning Assembly Release Lever 4 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 24 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components LCD and Softkey Control Pad The Printer provides a four line eighty 80 character LCD Displays that can communicate helpful information about the Printer s operation e The top three lines of the LCD Display will always be used to communicate print status error messages and menu options e The bottom line of the LCD Display will always be used to communicate the current function of the Printer s softkey buttons This section describes how the LCD Display and Softkey Control Pad work together Component Description Softkey The Printer has three soft
57. formatting magnetic string 80 81 Forward Back soft key buttons 131 FPGA 52 FPGA Field Programmable Gate Array 509 FPGA error 439 FPGA Load Fail 52 FPGA Timeout 53 Front Access Door 20 67 108 111 248 251 273 274 276 277 282 287 Front Transfer Cover 274 Full bleed 509 Full Card option 210 Functional Specifications 16 G Gamma 509 Gas Spring 347 Gear Card Transport 2 346 General tab 61 Glossy PVC 509 Glossy Matte 509 Glossy PVC or Matte PVC options 207 Graphical Device Interface GDI 509 Gray Scale 509 Gray Align YMC 460 Gray Align YMCK 132 Fargo Electronics Inc H Halftoning 509 Hard Drive 510 hard drive space adequate or inadequate 62 HDP High Definition Printing 510 HDP Card Matte PVC Card Type option 208 HDP Cards Matte PVC H Panel ribbon 180 HDP Cards Matte PVC non H Panel ribbon 180 HDP Film 52 56 109 112 129 207 255 HDP Film creased or wrinkled on printed card 119 120 HDP Film Options 13 HDP Film particles 183 HDP Film Storage Temperature 13 HDP Film transfer parameters 178 HDP film wrinkle problems 119 120 HDP Lamination Board 270 333 HDP Lamination Module Board Cable Connections Reference 272 HDP Main Board A000080 269 HDP ribbon 88 HDP710 Gray Align YMC K for HDP800 Series 132 HDP800 Series Card Printer 437 Head 510 Head Force Spring 283 Head Lift 53 Head Resistance Error 53
58. handling cables in or near the Circuit Board and Printhead Assemblies To prevent equipment or media damage always wear an appropriate personal grounding device e g a high quality wrist strap grounded to avoid potential damage To prevent equipment or media damage always remove the Ribbon and Cards from the Printer before making any repairs unless otherwise specified To prevent equipment or media damage take jewelry off of fingers and hands as well as thoroughly clean hands to remove oil and debris before working on the Printer HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 164 RESTRICTED USE ONLY Fargo Electronics Inc IMPORTANT Fargo Card Printers require highly specialized Print Ribbons to function properly To maximize Printer life reliability printed card quality and durability you must use only Fargo Certified Supplies For this reason your Fargo warranty is void where not prohibited by law if you use non Fargo Certified Supplies To order additional materials please contact your authorized reseller Adjusting the Card Size The Printer is initially configured to automatically feed and print standard CR 80 sized cards Note When loading cards which vary from this standard size or the standard 30 mil thickness it is necessary to make simple adjustments to the Printer e Wider Cards If loading wider cards into the Printer adjust the Card Input Guide Card Output Guide and Internal C
59. in mm times 11 8 For example 0 100 inches or 2 54mm equals 30 increments on the LCD Once adjusted this value will be stored in the Lamination Module Note This adjustment can also be made more easily through the Printer Driver but it will not be stored in the Lamination Module Rear of Printer F Card Output Card Input Side of Printer gt Side of Printer Leading Edge Trailing Edge of Card of Card Direction card travels through printer Front of Printer HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 465 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Lamination Sensor Calibration Step Procedure 1 Applies only if the Printer is equipped with the Card Lamination Module Note This setting reports the current Lamination Sensor calibration setting as dictated by the Printer Driver s Sensor calibration procedure In most cases this will not need to be changed Adjusting the Lamination Temperature Setting Step Procedure 1 Applies only if the Printer is equipped with the Card Lamination Module Use this setting to change the nominal setting of the Lamination roller Note In most cases this will not need to be changed as more direct control of the Lamination roller can be achieved through the Printer Driver Show the Error Count Use the Show the Error Count tool to a troubleshoot the Printer o mai
60. inch sec in This may be adjusted in the Driver to ensure adhesion and card flatness Dye Migration The diffusion of dye out of the card surface and into another receptive surface such as a vinyl pouch card holder resulting in a faded image Dye Sublimation Also called dye diffusion thermal transfer it is the process of heating a dye suspended in a cellulous substrate until the dye can flow diffusing into the dye receptive surface of the card or InTM This produces the image in the surface of the card E card An abbreviation for electronic card A generic term used to reference any card with built in electronic devices such as smart cards or prox cards E card Docking Station The device in the Printer that accepts smart cards with an ISO smart card contact station This allows the user to write to the smart card chip with a standard RS 232 interface in the back of the Printer or with the optional built in Encoder Edge to Edge Refers to the maximum printable area on a card resulting in printed cards with virtually no border ECP Mode Enhanced Capabilities Port Mode A type of parallel port mode developed by Microsoft to increase the port throughput and improve performance EE Memory An abbreviation for EEPROM EEPROM Electrically Erasable Programmable Read Only Memory A microchip based non volatile memory storage device that can be rewritten in the field The chip can hold
61. inches f mm Print width 2 204 Frint Length 3 452 Card Type UltraCards Glossy PYE HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 233 RESTRICTED USE ONLY Fargo Electronics Inc Selecting the Card Type Select the appropriate card type according to the composition of the card stock Step Procedure 1 Select UltraCards Glossy PVC if using Fargo UltraCard stock or any other similar card stock OR Select HDP Cards Matte PVC if using Fargo HDP Card stock or any other similar card stock Note The Printer Driver uses this information to automatically determine the proper Dwell Time and temperature for the image transfer process Lr Caution If the appropriate option is not selected the wrong Dwell Time and temperature may be used during the image transfer process which may result in poor adhesion of the HDP Film or warping of the card Continued on the next page Magnetic Encoding Lamination E Panel Resin Card Device Options Image Color Image Transfer Card Size CR 60 i inches mm Print Width 2 204 Frint Length 3 452 UltraCards G UltraCards Glozsy FYC HOP Cards M atte FYC Custom 1 Custom 2 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 234 RESTRICTED USE ONLY Fargo Electronics Inc Selecting the Card Type continued Step Procedure 2 If using a card stock other than those listed use the Cust
62. is available only in the READY PRINTER OPEN screens Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 26 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components LCD and Softkey Control Pad continued Component Description Print Status Screen During operation the LCD will indicate the current Print Status by showing you the area of the Printer that is active It does this by displaying the following icons on the second line FDR Indicates the Feeder Station is feeding a blank card into the Printer ENC Indicates the Encode Station is encoding a card appears only if you are using a Printer with an optional built in Encoding Module PRT Indicates the Print Station is printing onto the HDP film TFR Indicates the Transfer Station is transferring an image to a blank card LAM indicates the Lamination Station is applying an overlaminate to a card appears only if using a Printer equipped with the optional Card Lamination Module See Section 3 Card Lamination Module on page 136 Since the Printer is capable of performing several of these functions simultaneously one or all of these icons may appear at once depending on if you are printing just one card or a batch of cards The Print Status screen always displays Cancel in the lower left and Pause in the lower right Continued on the next page HDP 800 Series Card Printer Encoders Servic
63. may be a negative value 7 Adjust the Print Offset value 8 Press SELECT to save the value 9 Print a test card as described in step 1 10 Repeat Steps 1 to 9 until the test image is correctly positioned as shown below in the display 11 Follow these procedures for further adjustments a Decrease the Print Offset value to move the printed image toward the leading edge of the card b Increase the Print Offset value to move the printed image toward the trailing edge of the card c Remember that 30 Pixels will move the image 0 100 in or 3 84mm HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 451 RESTRICTED USE ONLY Fargo Electronics Inc Setting the Transfer TOF This procedure positions the HDP Film correctly on the leading edge of the card Refer to the Preparing to adjust the Print Offset Transfer TOF and Transfer EOF procedure in Section 8 page 449 for proper sequence Step Procedure 1 Choose MENU Print Test Image and Gray Align YMC to print a test card 2 Examine the test card e The Inner Alignment arrows should appear at the edge of the leading edge e The Outer Alignment arrows should not appear on the card but are shown here for clarity If the test card does not look like the display below go to step 5 to adjust the Transfer TOF Inner Alignment Arrows Outer Alignment Arrows ae Ce gt lt Trailing Edge of Card o
64. new values as the Printer adapts its operational parameters Encoder smart card An electro mechanical interface to transfer data from the PC to a chip or Magnetic Stripe built into the card HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 Continued on the next page 507 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Term Definition Encoder wheel An electromechanical device attached to a shaft that detects the change in rotational position incremented to count ticks per revolution The Printer s Encoder wheel both detects motion and measures the amount of rotation in the movement of the ribbon Engine A generic term for a collection of systems and mechanisms that is dedicated to executing a specific function A Printer that also laminates would have both a print engine and a Lamination engine EOF End Of Form The trailing edge of the card detected to indicate when the Printer should stop printing EPP Enhanced Parallel Port A type of parallel port mode developed by Intel to increase the port throughput EPROM Electronically Programmable Read Only Memory A microchip based non volatile memory storage device that can not be rewritten in the field Firmware for many Fargo Printers is stored on these chips and so a change of the chip is necessary for an upgrade Escape sequence A string or control character
65. of We d HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 174 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Internal Card Guide continued Step Procedure 4 While holding the guide forward lift the Card Size Adjustment Knob up and rotate it to the desired CR 80 CR 90 or CR 100 position 5 Release the Internal Card Guide Note If you adjusted to the CR 90 or CR 100 position the Internal Card Guide will now rest against the Card Size Adjustment Knob as shown in the above illustration This allows the Printer to consistently feed and print onto the wider card stock Card Guide Held in CR 90 Position a f HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 175 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Card Thickness Knob When loading thicker or thinner cards it is important that the Card Thickness Adjustment Knob be set accordingly to ensure the Printer feeds only one card at a time Note If the Printer is equipped with the Card Lamination Module only cards with a thickness ranging from 30 mil to 40 mil can be laminated Thicker cards will however be allowed to pass through the Lamination Module if you choose to print only Step Procedure 1 Open the Printer s Front Access Door and locate the Card Thickness Adjustment Knob 2 Rotate this knob clockwise to the setting that matches the thickness of the cards
66. on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 152 RESTRICTED USE ONLY Fargo Electronics Inc Attaching the Card Lamination Module continued Step Procedure 4 Remove the three 3 screws fastening the Card Output Hopper s main enclosure to the Printer Continued on the next page Remove 3 screws HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 153 RESTRICTED USE ONLY Fargo Electronics Inc Attaching the Card Lamination Module continued Step Procedure 5 Remove the four 4 black screws fastening the Card Output Hopper s main enclosure to the black Baseplate Continued on the next page Remove 4 screws HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 154 RESTRICTED USE ONLY Fargo Electronics Inc Attaching the Card Lamination Module continued Step Procedure Remove the Card Output Hopper s main enclosure by lifting it up and off of the Printer Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 155 RESTRICTED USE ONLY Fargo Electronics Inc Attaching the Card
67. over from the beginning Should the Printer Encoder encounter another Upper Film error on the same job the Printer Encoder then displays the Film Error message with the error code and provides the User with the Cancel and Resume options Pressing Resume directs the Printer Encoder to again attempt to reprint the image from scratch The Cancel key will reboot the unit Improvement No 3 prevention of circular Film errors Another improvement to this type of error handling is the prevention of circular Film errors When the User presses the Resume key in previous versions of the Firmware the Printer Encoder often displayed another Film Error message shortly after Resume was pressed Press Resume after an Upper Film error to direct the Printer Encoder to realign the Film and reprint the job Technician Note These Upper and Lower Film errors and their auto recovery attempts are logged in the LCD Error Count as Unique Film errors Improvement No 4 auto Film realignment Another improvement to the Film handling is the addition of an auto Film realignment feature Should the Printer Encoder experience an error while aligning the Film most likely following a boot up or Cover close it will automatically attempt to realign the Film Technician Note As with Upper Film errors if another error is encountered during the alignment phase then the error is posted to the LCD screen Pressing Resume attempts to align the Film again Pressi
68. perpendicular to the card feed path c If the card falls off the Flipper Table when rotated flip the Flipper Table over and inspect the U Shaped Spring 810480 that holds the white tensioning roller in place d Either replace the U shaped Spring or remove and attempt to bend the arms of the Spring down to provide more tension 3 Verify Card Thickness a Ensure that the card stock that is being used conforms to the accepted card thickness specification Note Cards should be between 0 030 and 0 070 762mm to 1 778mm 4 Test the Flipper Home Sensor 140407 a Remove the screws from the rear cover b Tilt the back cover outwards from the Printer c Using a digital voltmeter connect the negative lead to its ground d Connect the positive lead to Pin 4 of J58 on the Lamination Board e f covered the voltage should read approximately 9 VDC e f uncovered the Sensor should read 3 0 to 3 3 VDC HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 73 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Card Jam Error Message Symptom If a card becomes jammed inside the Printer the LCD Display will indicate approximately where it is jammed At this point you can either try to correct the problem and continue printing with the same card or remove the card completely and start the print job over Step Procedure 1 Leave the power ON and open the Print and Transfer Stations
69. proper location Note The wall of the card hopper should be within 030 75mm of the stack of cards HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 65 RESTRICTED USE ONLY Fargo Electronics Inc Resolving a Card Feeding problem HDP820 820 LC continued Step Procedure 3 When loading cards ensure that Card Thickness Adjustment Knob is properly set to ensure that the Printer feeds in only one card at a time a Open the Front Access Door b Locate the Card Thickness Adjustment Knob c Adjust this knob to the setting that matches the card thickness For fine scale changes see the Fine Tuning the Card Separator Adjustment Assembly D840995 procedure in Section 3 page 165 Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 66 RESTRICTED USE ONLY Fargo Electronics Inc Resolving a Card Feeding problem HDP820 820 LC continued Step Procedure 4 Clean the Cleaning Rollers a b c d Open the Front Access Door of the Printer Depress the Cleaning Roller Lock Pull the Cleaning Roller Assembly out of the Printer Clean the rollers with one of the adhesive backed Cleaning Cards from the Printer Cleaning Kit Remove the card s adhesive backing paper and slide the card between the rollers until all dust particles are removed Flip over the Cleaning Card to clean both the top and bottom Clean
70. section and into the output hopper based on steps from a known position All stop 32 The Heater and Thermocouple are maintained at a set temperature at all times when the Printer is ON The cooling fan is ON when the Printer is ON 33 The Stacker Lift Motor engages until the Stacker Lift Sensor is activated 34 The Stacker Full Sensor checks for presence of cards HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 RESTRICTED USE ONLY FARGO Electronic Inc Reviewing the HDP 800 Series Card Printer Encoders Boot up Sequence Step Process 1 The Card feed stepper turns ON to check for a card on the Flipper table 2 The Lam Headlift turns until the head up position is returned from the Headlift Sensor 3 The Film transfer take up Motor turns ON to take up any slack in the dancer and runs until the Dancer Down Sensor is activated 4 The Print Headlift turns until head up position is returned from Headlift Sensor 5 The Print Ribbon moves forward until it finds the yellow panel pauses advances to magenta then backs up to yellow the Ribbon Sensor detects marks on the ribbon 6 The Transfer Ribbon advances forward two panels from supply advances until the Print Film Sensor senses 2 marks on the Film 7 The Transfer Ribbon advances forward one panel onto take up advances until the Transfer Film Sensor senses 1 mark on the Film 8 The Transfer Ribbon a
71. simultaneously and you would like to cancel both the print and Lamination jobs press the Printer s CANCEL softkey button Note This will cancel all jobs in the Printer Any card currently laminating will finish and eject The Lamination Module s Cancel button cancels only the Lamination job the Card Lamination Module in Section 5 page 238 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 Continued on the next page 41 RESTRICTED USE ONLY Reviewing the Resume pause button Fargo Electronics Inc If an error occurs the Lamination Module s LED will flash and the Printer s LCD will report the specific error If this happens correct the error and press the Lamination Module s Resume button to continue printing Press this button to pause the Lamination Module during normal operation Note The Lamination Module will always finish its current task before pausing If this button is pressed while a card is being laminated the Lamination Module will pause only after the current card has finished laminating and the Lamination Module has reached a safe stopping point If the Printer is paused the LED Light will flash slowly and will return to solid when operation is resumed Note With the Lamination Station open the Pause button can also be used to manually rotate the feed rollers backward This is helpful when cleaning the rollers or when clearing jammed media
72. tab only with the Card Display the Printer s LCD Display to communicate Lamination Module in Section interaction status message such as when an error 5 page 238 occurs or when it is time to replace the overlaminate material If a Lamination error does occur the Lamination Module s LED will flash and an attention level message will appear on the Printer s LCD Display Note Since it is an ATTENTION level message it will not interrupt printing a Correct the error b Press OK to clear the LCD s ATTENTION message c Press the Lamination Module s Resume button to resume operation or its Cancel button to cancel the current Lamination job and accept the next Note If canceled the canceled card will eject into the Rejection Card Hopper Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 45 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Module s Programmed Default Temperature temperature Target Temperature Ifa print job is sent while the Lamination Module is heating up the Printer s LCD Display will read Laminator Warming This will alternate with LAM Temp current target which shows the current temperature of the Lamination Roller and the target temperature it is trying to reach Note This indicates that the Lamination roller is heating to its preset temperature Initial Heating Process The initial heating proces
73. the Printer Continued on the next page Card Input Feed Rollers HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 252 RESTRICTED USE ONLY Fargo Electronics Inc Cleaning the Card Feed Rollers additional Feed Rollers continued Steps Procedure 2 Use a Cleaning Pad from the Printer Cleaning Kit to wipe the rollers clean Note Use fingertips to move the rollers back and forth while cleaning 3 Open the Front Access Door and then open the Print Station and Transfer Station of the Printer If using a Printer with a Card Lamination Module attached open the Lamination Module s Top Cover and Lamination Station Continued on the next page Card Input Feed Roller HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 253 RESTRICTED USE ONLY Fargo Electronics Inc Cleaning the Card Feed Rollers additional Feed Rollers continued Steps Procedure 4 Inside the Front Access Door locate the single Card Input Feed Roller Use the Cleaning Pad to wipe the roller clean c Press the Forward and Back buttons to move the roller back and forth while cleaning 5 Locate the four Card Feed Rollers that reside just beneath the Print and Transfer Stations Continued on the next page Card Feed Rollers HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 254 RESTRICTED USE ONLY Fargo Electronics Inc Cleaning the Card Fee
74. the card 2 Inspect the Card Feed Roller Motors for proper operation a Leave the power ON and open the Print and Transfer Stations b Press the FORWARD button to advance the card or the BACK button to reverse the card Use these buttons to move the card through the Encoder 3 Ensure that the cards are feeding into the Encoding Module properly a Reset power on the Printer to clear any error messages b Open the Front Access Door c Select the Menu from the LCD d Select the Print Test Image from the menu e Select the Magnetic Test from the menu f Acard is then fed from the input hopper onto the Flipper Table and rotated into the Encoding Module If the card appears to jam against the components of the encoding assembly the Flipper Offset may need to be adjusted 4 Adjust the Flipper Offset a Select Menu on the LCD Display b Select Setup Printer and Flipper Offset c Change the setting on small increments Note A negative adjustment will lower the side of the Flipper Table closest to the Exit Hopper d Press Select to save the new value HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 82 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the No Prox Encoder Error Message Symptom The Printer is receiving encoding data but the Printer is not configured with this Encoder type Step Procedure 1 Verify that the LCD Settings are correct a Press Select on the LCD b Select S
75. the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 513 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Term Definition Oversized Cards Oversized cards are used for more efficient visual identification and are available in many non standard sizes The most popular sizes are CR 90 3 63 x 2 37 92mm x 60mm and CR 100 3 88 x 2 63 98 5mm x 67mm Overlaminate Protective clear or holographic material to increase security and durability applied over the printed surface with a hot roller Parallel A method of data transfer in which serial data is divided into sections and sent simultaneously down parallel wires to speed transfer rate Parallel port A communication socket on a device that allows for parallel data transfer PC Personal Computer A stand alone programmable electronic device that can store retrieve and process data consisting of a CPU mouse keyBoard and monitor PCB Printed Circuit Board A solid multi layered plate on which electronic elements are attached either through the Board or on the surface Peel The removal of a film or ribbon from a card surface at a perpendicular angle to ensure proper transfer then separation from the card surface Peel Off A bar on the Lamination section that holds the film at the correct position and provides proper peel angle Peripheral Any device that is attache
76. the optimum position is found Note Be sure the Internal Card Guide always remains parallel to the card path and that the screws loosened in step 1 are retightened after each adjustment JAN E A gt N 010 25mm cR100 space i CR90 Va rN e Internal Card Guide a ic aaa HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 151 RESTRICTED USE ONLY Fargo Electronics Inc Attaching the Card Lamination Module The Card Lamination Module can be attached as a field upgradeable option Note This can typically be done in 30 minutes or less and with no other tools than a Phillips screw Driver This section applies only if you are installing the field upgradeable Card Lamination Module onto a Printer Note The Printer model must be capable of accepting this Module as not all Printer models are compatible with this field upgradeable option HDP800 Series Printers with a serial number greater than A2360028 are compatible with the Card Lamination Module Step Procedure 1 Remove the Card Lamination Module from its packaging 2 Disconnect the power cable from the Printer 3 Open the Printer s Print Station and Transfer Station Note Leave these open for the entire procedure until you are instructed to close them Continued
77. the top of a subset of like functions They are also on the Printer LCD control Panel Monochrome An image composed of a single color Network A Series of computers connected by data transfer cable for communication and sharing of functions and peripherals Oersted Oe The unit of magnetic field strength named after Dutch scientist Hans Christian Oersted who found the science of electromagnetism Offset The prescribed distance between a reference point and the target point The offset in card printing may refer to the position of the image relative to the leading edge or the distance of the start of magnetic encoding from the leading edge of the card O Ring A rubber ring used as a belt in several media driving applications OS Operating The instructions installed on the computer hard drive that run the System computer s operations and applications The Driver used for any given OS will differ from other platforms The correct version Driver must be loaded for the Printer to interface with the OS and the application to print Output Any product of the Printer including card image encoded data and Lamination Output hopper The portion of the Printer that accepts the completed cards Overlay A resin like substance that is transferred by the printhead to the card surface over a printed dye image to prevent image fading increase abrasion durability and prevent dye migration Continued on
78. to find troubleshooting removal and replacement procedures The section titles are always labeled according to their function for consistent usage Cross Referencing hyper linked You can use the cross referencing links to quickly locate an error message or a procedure Comprehensive Index hyper linked You can use the Comprehensive Index to quickly locate information on the HDP 800 Series card Printer relating to a specification a procedural step a window or screen a component a term a qualifier or a related feature to this Printer HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 RESTRICTED USE ONLY FARGO Electronic Inc Safety Messages review carefully Symbol Critical Instructions for Safety purposes Danger A Failure to follow these installation guidelines can result in death or serious injury Information that raises potential safety issues is indicated by a warning symbol as shown to the below To prevent personal injury refer to the following safety messages before performing an operation preceded by this symbol To prevent personal injury always remove the power cord prior to performing repair procedures unless otherwise specified To prevent personal injury make sure only qualified personnel perform these procedures Caution A This device is electrostatically sensitive It may be damaged if exposed to static electricity disc
79. until the gauge or the paper on top of the card just touches the clear rubber e If the gap above the card is too small the card will not feed e If the gap above the card is too large multiple cards may feed After completing this adjustment be sure to test it for efficiency levels Feed a card with a few other cards into the hopper Place a full stack of cards in the Card Input Hopper and feed a few cards Continue to adjust the Card Separator Adjustment Assembly as needed HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 177 RESTRICTED USE ONLY Fargo Electronics Inc Printing on Alternate Card stocks Selecting the Right Cards and optimize the HDP Print Process In order to optimize the HDP Card Printer s capabilities for cards with hard to print surfaces we recommend evaluating the card stock selection before installation of the Printer The variability in cards based on e Different surface textures and different sources of raw materials This may require different HDP Film transfer parameters e Varied methods of assembling IC smart cards and proximity cards These particular adhesives used to glue a smart chip to a plastic card may react differently to a Lamination roller s pressure and temperature e Cleanliness of card stock The HDP process does not eliminate the need to use clean card stock The best looking card always starts with the cleanest card surface Dirt and debris on a card c
80. with a serialized number e The Card Output Stacker also holds a maximum of 250 30 mil cards When the Card Output Stacker reaches this maximum capacity the Printer will pause operation and the LCD will alert you by displaying OUTPUT HOPPER FULL Note To make sure the cards remain neatly stacked in the Card Output Hopper always keep the hopper door closed during printing Both the Card Input Hopper and the Card Output Stacker are initially configured to automatically feed and print standard CR 80 sized cards Technician Note 1 The HDP820 Printer is also capable of printing onto CR 90 and CR 100 sized cards Technician Note 2 The Optional Output stacker is not compatible with the Card Lamination Module HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 36 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components Lamination Roller A A Danger The Printers Lamination Roller can reach temperatures exceeding 350 degree F 175 C Use extreme caution when operating the Laminator Never touch the Lamination Roller unless the Printer Power has been turned off for at least 20 to 30 minutes Type Description Controls Both the Printer itself and the Printer s software Driver control the built in laminator Temperature To change the temperature of the laminator adjust its temperature Adjustment through the Lamination tab within the Printer Driver setup window Once adjusted
81. work cycle e The Lamination Count is the total number laminated cards that the Printer has produced System Upgrade Firmware Upgrade This option is used to upgrade the Printer Firmware Step Procedure 1 Upgrade by selecting SYSTEM UPGRADE The LCD will prompt Are you sure you want to continue 2 Select YES to begin the System Upgrade select NO to return to the READY screen Note See Appendix A Firmware Update for detailed instructions for upgrading the system Firmware on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 467 RESTRICTED USE ONLY Fargo Electronics Inc Section 10 Firmware Updates The purpose of this section is to provide the User with information on the internal software or Firmware which controls all aspects of the Printer s operation New Firmware versions may be released containing enhancements such as improved reliability added features or better print quality New Firmware updates can be downloaded from the Internet and loaded into the Printer through its parallel interface port no chip replacement is needed Refer to the instructions in this Section to download and install Firmware updates Firmware Updater Application Program The Firmware Updater application program is the software required to send Firmware updates from the computer to the Printer To download and install the Firmware Updater from this site refer to the fo
82. 0 Series Card Printer Encoders Service Manual Rev 5 0 236 RESTRICTED USE ONLY Fargo Electronics Inc Clicking on the About button Click this About button to open a dialog box containing the copyright and version information about this Printer Driver software s HDP820 LC Card Printer Printing Preferences Magnetic Encoding Lamination K Panel Resin Card Device Options Image Color Image Transfer m Card Size cR 20 z inches mm Print Width 2 204 H Print Length 3 452 r Card Type UltraCards Glossy P C m Orientation Portrait C Landscape L m Copies 1 aad Test Print About Cancel Apply Help HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 237 RESTRICTED USE ONLY Fargo Electronics Inc Using the Lamination tab only with Card Lamination Module Use this option to control specific Printer functions The Lamination Tab appears only if the Printer is equipped with the Card Lamination Module These options allow you to control the Printer s Lamination process HDP820 LC Card Printer Printing Preferences Card Device Options Image Color Image Transfer Magnetic Encoding Lamination K Panel Resin m Lamination Position Horizontal E ajel lt Direction Card Travels Through Printer m Lamination Side Lamination Type No Lamination iz Lamination Transfer Dwell Time 2 2 seconds inch Tr
83. 00 Series Card Printer Icon and select Properties e If using Windows NT 4 0 right click on the HDP800 Series Card Printer and select Document Defaults e If using Windows 2000 XP right click on the HDP800 Series Card Printer and select Printing Preferences b Click on the Image Color tab c Adjust the Resin Heat to a more negative value OR Correct the Image Darkness in the LCD a Select Menu from the LCD b Select Setup Printer and then select Image Darkness c Adjust the current value to a more negative number HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 118 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the HDP Film wrinkle problems Symptom HDP Film is creased or wrinkled on the printed card Note HDP Film wrinkle will appear clear or look as though the entire image is wrinkled Alternately ribbon wrinkle will appear as assorted colors Step Procedure 1 a Ensure that the HDP film is aligned with the red alignment arrows on the Transfer station b If it is not aligned properly it may be necessary to replace the roll of Film or cut and reattach the Film to the Take up Spool 2 Decrease Transfer Temperature setting within the Image Transfer tab of the Printer Driver a Open the Printer control panel from the computer e If using Windows 98Se ME right click on the HDP800 Series Card Printer Icon and select Properties e If using Windows NT 4 0 right
84. 0144 Cover Top LAM Cover HDP 8XX 159 00 Cover Top LAM D870149 Cover Access Cover Base Plate 0 00 Cover Access D870151 Cover Plate Board Cover HDP LAM 97 50 Board Cover D870159 Assembly HDP LAM Cover HDP Lam 0 00 Covers Main Cover D870212 Assembly Base Cover Base Plate 0 00 Plate LAM LAM Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 496 RESTRICTED USE ONLY HDP8xx LAM Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 Fargo Electronics Inc Category Part Part Description Alternate Part MSRP List Number Description Price Misc Hardware 140083 Foot Rubber Bumper Rubber Foot bumper 1 04 150094 Spring EXT 125 x Tension Spring 2 28 875 x 014 150141 Spring COMP Flipper Spring 0 84 480Dx 750L x 036 760293 Hub Ribbon Right Hub Ribbon Right 0 65 760294 Hub Ribbon Left Hub Ribbon Left 0 66 810455 Spring Thermocouple Spring Thermocouple 2 22 810480 Spring Card Idler Spring Card Idler 1 54 810492 Encoder Wheel Encoder Wheel 12 81 DO00186 Spacer Inverter Spacer for Clutch 1 95 Friction D840777 Label Hot Label Hot 0 00 D850189 Latch Hook Latch Hook 2 48 D850190 Pulley Main O80MXL Pulley Main O80MXL 1 50 Pitch 24T Pitch D850244 Flag Sensor S2 Headlift Flag 2 22 D870091 Assembly Card Assembly Card 321 62 Flipper Flipper D870133 Plate Gua
85. 0468 Rev 030224 6533 Flying Cloud Drive Eden Prairie MN 55344 U S A 952 941 9470 952 941 7836 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 493 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing Spare Parts List for Card Lamination Module HDP8xx LAM Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 For current pricing see http www fargopartner com support_services Category Part Part Description Alternate Part MSRP List Number Description Price Belts and Gears 140212 O Ring 1 024 Belt Drive 0 Ring 1 00 Compound 23811 760286 Pulley Ribbon Motor Pulley Ribbon Motor 1 17 760287 Pulley Gear Pulley Gear 0 78 Combination Combination 760288 Gear Ribbon Idler Gear Idler 3 71 760289 Gear Ribbon Drive Gear Ribbon Drive 2 47 810265 Gear Platen Card Gear Platen Card Drive 0 91 Drive 810266 Gear Card Transport Gear Card Transport 0 72 Drive Drive 840288 Pulley Press 15 GRV Pulley Flipper 0 00 MXL D870142 Pulley 54 GRV MXL Pulley Stepper 54 GRV 0 00 MXL F000003 Belt 6 OGRV 080P Belt 60 Groove 080P_ 9 23 1 8 Width 1 8 width F000018 Belt 104GRV 080P Belt 104 GRV 080P 11 31 1 8 Width 1 8 Width Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 494 RESTRICTED USE ONLY HDP8xx LAM Series ID Card Printer Recomme
86. 11 current print jobs canceled 98 Cursor 505 Custom 1 Custom 2 options 179 235 custom Image Transfer settings 179 customization options 222 D Dancer Rollers 123 Darkness 505 Data for magnetic stripe printed on card 80 81 Data Input 51 Data Timeout 51 DB 9 505 DC Direct Current 505 DC Motor 505 decrease the Print Offset setting 455 Fargo Electronics Inc Decrease Increase the Print Offset value 451 Default 505 Default button 203 Defined Area s check box 213 Defined Area s option 211 Deflector 284 Defrag 505 Delete Card Data 58 Device Option tab 87 113 digital voltmeter 72 73 Dimensions 12 DIP switches Dual In line Package Switches 505 Direct to Card DTC Printing 506 direct to card printing 178 disable printing 199 disabled SmartGuard Security Feature 59 Disconnect motors 91 disk cleanup utility 62 Display 13 Dither 506 dither method 191 DMA Direct Memory Access 504 Dongle 506 Dot 506 Dot pitch 506 Download 506 DPI Dot Per Inch 506 DRAM Dynamic Random Access Memory 506 DRAM Memory Error 51 439 Drive Belt Card Feed Roller to Card Feed Roller 339 Drive Belt Platen Roller to Card Feed Roller 338 Drive Hubs 101 Drive Pulley Back 2 345 Driver 506 Driver Settings extreme 97 DTC ribbon 88 dual sided card 193 Duplex Printing 506 dust particles 108 dwell temperature 235 Dwell Tim
87. 227 Magnetic Track Options 222 Magnetic Track Selection 221 Magnetic Track Selection option 221 Main Firmware 471 473 Main Firmware LCD Firmware 471 Main Print Board 89 90 367 438 Manual Eject Each Error option 224 manual eject mode 224 matte finished cards 180 Maximum Accepted Card Length Range 14 Maximum Accepted Card Width Range 14 maximum value 206 MB Megabyte 513 Measuring area positioned on card 215 Media 512 Memory 513 Memory 14 Menu 513 MENU button 444 Menu option 26 MENU Print Test Image and Gray Align YMC 450 452 457 MENU Setup Printer and Encoder Settings 461 mistakenly verified card 224 Module and LCD Display interaction 45 Module and Printer interaction 44 Module s Programmed Default Temperature 46 Monochrome 192 513 more heat 202 Motor operation 85 Motor Operation 72 Multi Language Extension MLE 223 Multimeter 85 88 97 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 528 RESTRICTED USE ONLY Multiple Cards Fed 54 multiple messages 29 N Network 513 new Platen Roller 330 new Platen Roller Assembly 330 New Temperature Setting 37 New Temperature Settings 47 new value 82 No ENC Response 54 No MAG Encoder 54 No Magnetic Encoder 76 No Prox Encoder 54 No Smart Encoder 83 No SMART Encoder 54 O obstruction 72 Oersted Oe 513 Off 28 Offset 513 Open Printer or transfer s
88. 3 in 64mm to 67mm Maximum Accepted Card Length Range 3 375 in to 3 88 in 85 6mm to 98 5mm Memory 8 MB RAM expandable to 32 MB RAM Operating 65 F to 80 F 18 C to 27 C Temperature Options The options are the 32MB RAM Upgrade Kit Printer Cleaning Kit External Print Server Windows only required for stand alone networking of printer encoders Card Lamination Module and USB to Parallel Interface Cable Windows 98 Me 2000 XP only Output Hopper Card Capacity 100 cards 030 762mm 250 cards with optional Card Output Stacker Overlaminate Options HDP800 Series LC only All overlaminates are available in either clear holographic globe design or custom holographic design They can also be optimized for use with smart cards and Magnetic Stripes PolyGuard available in CR 80 CR 90 and CR 100 patch sizes Here are the options e Thermal Transfer Overlaminate 25 mil thick 500 prints e PolyGuard Overlaminate 6 mil thick 250 prints e PolyGuard Overlaminate 1 0 mil thick 125 prints Print Area Over the edge on all accepted standard card sizes YMCKH ribbon required for over the edge printing on CR 100 cards Print Method HDP Dye Sublimation Resin Thermal Transfer Printing Method HDP Dye Sublimation Resin Thermal Transfer Printing Resolution Up to 16 7 million colors and 256 shades per Pixel Continued on the next page HDP 800 Series
89. 41023 is out of calibration See the Reviewing the Transfer Station Components photograph to see the location of the Upper Film Sensor on page 265 a Position the Transfer Film so that the clear portion is between the slotted optical Sensor b Turn the potentiometer on the Sensor Board with a small slotted screwdriver until the LED on the Board turns ON c Back the potentiometer off until the LED just turns OFF 3 Verify if a wire has broken off the Ribbon Drive Motor D840980 a Verify that both motors are connected to J66 on the Lamination Board b Disconnect the motors Note 9 VDC battery connected to the motor leads should make it turn c If the motors do turn verify the wire connections at the motor and replace or solder those connections as needed 4 Verify if the Print or Lamination Boards has failed a Replace the Print Board See Replacing the Main Print Board A000271 procedure in Section 5 page 367 for instructions b Replace the Lamination Board See the Replacing the Lamination Board 140402 procedure in Section 5 page 368 Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 91 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Upper and Lower Film errors continued Step Procedure 5 Verify Film placement on the core a Remove the transfer film from the Printer b Ensure that the film is straight on the core
90. 510 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Term Definition IEEE 1284 Institute of Electrical and Electronics Engineers 1284 A standard method of signaling for a bi directional parallel interface on personal computers To ensure proper Printer communications and image output Fargo recommends a parallel interface cable that complies with this specification Image A collection of pictures or graphical elements that compose the visual features on a card Also refers to the digital representation Input Any data or material being transferred to the Printer Input hopper The area of the Printer that stores the blank cards ready to print Intermediate Transfer A thin flexible material coated with a resin material into which the Media InTM dye is transferred from the ribbon by the printhead The film is then transferred to the card surface by the hot Lamination roller ISO For the Greek iso meaning the same Used to represent data from the International Organization for Standardization JIS II Japanese Industrial Standard The standard for encoding to a Magnetic Stripe provided by the Japan Standards Association The single track is as wide as ISO tracks 1 and 2 combined and in the same approximate location as those tracks but on the front of the card The coercivity level is 600 Oe K Panel An area of a multicolored ribbon e g YMCK that co
91. 54 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 116 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the excessive Resin Printing problems Symptom Black resin text and barcodes appear smeared or too thick Step Procedure 1 Reduce the Resin Heat setting within the Image Color tab of the Printer Driver a Open the Printer control panel from the computer e If using Windows 98Se ME right click on the HDP800 Series Card Printer Icon and select Properties e If using Windows NT 4 0 right click on the HDP800 Series Card Printer and select Document Defaults e If using Windows 2000 XP right click on the HDP800 Series Card Printer and select Printing Preferences b Click on the Image Color tab c Adjust the Resin Heat to a more negative value OR Correct the Image Darkness in the LCD a Select Menu from the LCD b Select Setup Printer and then select Image Darkness c Adjust the current value to a more negative number HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 117 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the incomplete Resin Printing problems Symptom Black resin text and barcodes appear faded or too light Step Procedure 1 Reduce the Resin Heat setting within the Image Color tab of the Printer Driver a Open the Printer control panel from the computer e If using Windows 98Se ME right click on the HDP8
92. 69 E 93 46 70 F 94 A 47 71 G 95 Bs 48 0 72 H 49 1 73 50 2 74 J 51 3 75 K 52 4 76 L 53 5 77 M 54 6 78 N 55 7 79 O HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 229 RESTRICTED USE ONLY Fargo Electronics Inc Using the Card tab Use this option to control specific Printer functions HDPS20 LC Card Printer Printing Preferences Magnetic Encoding Lamination E Panel Resin Card Device Options Image Color Image Transfer Card Size f inches C mm Print width 2 204 Print Length 3 452 Card Type LltraCards Glossy PWE Orientation Portrait C Landscape Copies 1 weal Test Print About Cancel Apply Help HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 230 RESTRICTED USE ONLY Fargo Electronics Inc Selecting the Card Size from CR 80 CR 90 or CR 100 Step Procedure 1 Select the appropriate card size option from three 3 standard card sizes e CR 80 OR e CR 90 OR e CR 100 OR e One 1 custom size is available see Step 2 on the next page Note The dimensions of the total print area for each card size will appear in the Print Width and Print Length boxes These print area dimensions are 04 1mm larger than the actual card size This is so the Printer can overprint images to ensure they will appear Edge to Edge when transferred to the card For this reason when designi
93. 800 Series Card Printer Encoders Service Manual Rev 5 0 195 RESTRICTED USE ONLY Fargo Electronics Inc Using the Rotate Front 180 Degrees or Rotate Back 180 Degrees options Use this option to change the position of the printed image in relation to the set location of a card s Magnetic Stripe or smart chip Step Procedure 1 Select the Rotate Front 180 Degrees option to rotate the image on the front of the card by 180 degrees when printed OR Select the Rotate Back 180 Degrees option to rotate the image on the back of the card by 180 degrees when printed HDPS25 LC Card Printer Printing Preferences 2x Magnetic Encoding Lamination k Panel Resin Card Device Options Image Color Image Transter Ribbon Type MEE Full Color Resin Black a Film Type kar Bf Color Matching a Resin Dither Uptirged for Graphics T lw Print Both Sides Print in Single Card Made Split 1 Set of Ribbon Panels T Link Card to Print Job Print Back Side First T Disable Printing IY Rotate Front 180 Degrees IY Rotate Back 180 Degrees HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 196 RESTRICTED USE ONLY Fargo Electronics Inc Using the Print in Single Card Mode option Use this option to force the Printer s memory to buffer or to hold only one print job at a time Step Procedure 1 Select this option only when printing to multiple Printers sharing print job
94. 800 Series Card Printer Encoders Service Manual Rev 5 0 55 RESTRICTED USE ONLY Reviewing LCD Messages continued Fargo Electronics Inc Message Cause Solution Realigning Indicates the Printer is aligning the No action required Film HDP Film to the proper position for printing Usually occurs after the Printer has finished a print job Smart Encode Failed The card s smart chip was not encoded properly See the Resolving the Failed Smart Encode Error Message procedure in Section 2 page 84 Starting Self test Indicates the self test print is preparing to print See the Printing a Test Image procedure in Section 2 page 132 Temperature The Transfer Roller is unable to reach See Resolving the Temperature Timeout the optimum temperature Timeout Error Message procedure in Section 2 page 99 Testing Indicates the Printer s memory is See Printer Components LCD Memory being tested and Softkey Control Pad in Section 1 page 25 Transfer The Printer s Transfer Roller is cooling See the Resolving the Transfer Cooling to the proper temperature Cooling Error procedure in Section 2 page 97 Transfer Lift The Printer was unable to raise or lower the transfer roller See Resolving the Transfer Lift Error Message procedure in Section 2 page 99 Transfer Timeout The Printer was unable to complete image transfer See Transfer Process Errors in Sec
95. 99 Transfer Lift Switch 336 Transfer Module 334 349 Transfer Peel Off Bar Assembly 331 Transfer Platen Roller 109 112 transfer problems 121 Transfer Roller unable to reach optimum temperature 99 Transfer Station 27 82 110 274 Transfer Station Assembly 332 333 Transfer Temperature 119 458 Transfer Tension 122 456 Transfer Tension set too low 122 Transfer Timeout 56 Transfer TOF 452 453 Transfer TOF value 452 Transfer TOF Transfer EOF 449 Transfer Warming 57 transferred HDP Film 181 troubleshoot the Printer 478 Troubleshooting 50 520 TrueType TT 520 TrueType black text and TrueType barcodes 209 TU V EMC 11 TUV GS 11 UL 11 UltraCard 520 UltraCard III 520 UltraCard stock 33 106 UltraCards Glossy PVC 181 234 UltraCards Glossy PVC H Panel ribbon 180 UltraCards Glossy PVC non H Panel ribbon 180 Unable To Feed Card 57 unable to read encoded data 76 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 533 RESTRICTED USE ONLY unblocked Sensor 75 105 Undefined Area s K Panel Resin tab 212 Undefined Area s option 212 Unknown Ribbon Type 57 Update 520 Update Failed 57 Update file 470 Update Firmware Now 57 Upgrade Failed or Upgrade Firmware Now on 473 Upgrade Successful 474 Upper Film Sensor Assembly 329 UPPER MIDDLE Modules 125 UPS Un interruptible Power Supply 521 USB Universal Serial Bus 521
96. Card Printer Encoders Service Manual Rev 5 0 14 RESTRICTED USE ONLY Fargo Electronics Inc Technical Specifications continued Term Description Print Ribbon e Full color YMC 700 prints Options e Full color with resin black YMCK 250 or 500 prints e Full color with two resin black Panels YMCKK 400 prints e Full color with resin black and heat seal Panel for difficult to print surfaces YMCKH 400 prints extra wide for over the edge printing on CR 100 cards All HDP ribbons utilize Fargo s exclusive RibbonTraq system for maximum print quality performance reliability and ease of use Print Speed Batch Mode e 35 seconds per card 112 cards per hour YMC with transfer e 38 seconds per card 94 cards per hour YMCK with transfer e 66 seconds per card 54 cards per hour YMCKK with transfer e 40 seconds per card 90 cards per hour YMCK Lamination e 72 seconds per card 50 cards per hour YMCKK Lamination Resolution 300 dpi 11 8 dots mm Software Drivers Windows 95 98 ME NT 2000 XP Supply Voltage 100 to 240 VAC 3 75A Supply Frequency 50 Hz 60 Hz System Requirements IBM PC or compatible Windows 95 98 ME NT 2000 XP Pentium class 133 MHz computer with 32 MB of RAM or higher 200 MB free hard disk space or higher and ECP parallel port with DMA access Warranty Printer One year optional Extended Warranty Program U S only Printhead Lifet
97. Cleaning Kit to wipe the roller clean Locate the Transfer Platen Roller as shown below 0929 5 Use a Cleaning Pad from the Printer Cleaning Kit to wipe the roller clean Press the FORWARD and BACK buttons to move the roller back and forth while cleaning g Replace the printing supplies and close the Print and Transfer Stations after the rollers are clean and completely dry Mike Berman Student 3957105 library Code 2439 554 ed HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 112 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the incorrect Image Darkness problems Symptom Printed cards are too dark or too light Step Procedure 1 Run a self test from the Printer a Select Menu from the LCD b Select Print Test Image from the menu c Select Gray Align Self test from the Menu d If the Self test card does not appear to have the same darkness issues continue to step 2 Adjusting the Dye sub intensity e If the self test card does appear to have the same darkness issues continue to step 3 Adjusting the image darkness 2 Adjust the Dye Sub Intensity setting within the Image Color tab of the Printer Driver a Open the Printer control panel from the computer e If using Windows 98Se ME right click on the HDP800 Series Card Printer Icon and select Properties e If using Windows NT 4 0 right click on the HDP800 Series Card Printer and select
98. Description Price Misc D850253 Assembly Input Tray Assembly Input 0 00 Hardware 02 2 Tray 2 HDP 825 ONLY D850254 Assembly Cleaning Assembly 34 95 Cartridge Cleaning Cartridge HDP 825 ONLY D880153 Roller DELRIN AF Roller Card Idler 4 22 Card Idler D880153 Roller DELRIN AF Roller Encoder 4 22 Card Idler Pinch Idler Brown Roller Motors 840123 Assembly Motor Stepper 114 53 Motor_E000062_Motor Motor STP PRN 840124 Assembly Motor Motor Flipper 193 25 Flipper Table 840130 Assembly Motor Motor Stacker Lift 0 00 150285 Motor OHP Lift A000124 Assembly PCB S3 DC Motor Hopper 17 56 Motor D840980 Assembly Motor Motor Headlift 18 72 A000124 Motor Rib Assembly D840980 Assembly Motor Motor Ribbon 18 72 A000124 Motor Rib Supply Assembly Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 488 RESTRICTED USE ONLY HDP8xx Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 Fargo Electronics Inc Category Part Part Description Alternate Part MSRP List Number Description Price Motors D840980 Assembly Motor Motor Ribbon 18 72 A000124 Motor Rib Take Up Assembly D841045 Assembly Stepper Motor Lamination 132 02 Base MOD Stepper D841073 Assembly Motor Motor Lamination 16 38 A000124 LAM Lift Roller D841081 Assembly Motor Motor Card Fe
99. Document Defaults e If using Windows 2000 XP right click on the HDP800 Series Card Printer and select Printing Preferences b Click on the Image Color tab c If the image is too light adjust the Dye Sub Intensity to a more positive value d Ifthe Image is too dark adjust the Dye Sub Intensity to a more negative value OR Correct the Image Darkness in the LCD a Select Menu from the LCD b Select Setup Printer and then select Image Darkness c If the image is too light adjust the current value to a more positive number d If the Image is too dark adjust the current value to a more negative number Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 113 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the incorrect Image Darkness problems continued Mike Berman Student 3957105 library Code 2439 554 Mike Berman Student 3957105 library Code 2439 554 ph HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 114 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Ribbon wrinkle problems Symptom Printed cards have off colored lines or streaks on them Step Procedure 1 Confirm that the Printer is using the most current Driver from http www fargo com 2 Adjust the Dye Sub Intensity setting within the Image Color tab of the Printer Driver a Open the Printer control panel from the computer
100. ESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Term Definition Cache A type of memory buffer to store data temporarily used to hold information that is most often exchanged between controller and peripheral to expedite data transfer Calibrating A procedure to adjust an electro mechanical device so that it operates within established parameters Cleaning Roller High tack rollers positioned just after the input hopper to lift debris off the card as it rolls over it A clean card surface improves print quality CD Compact Disc A 4 75 inch 12 cm optical disk that stores data written too and read from using a laser DMA Direct Memory Access Channels designated within the Windows operating environment that are used for dedicated high speed communication between the PC and the Printer port Centronics A parallel communications interface that has become the standard for connections to Printers designed by the Centronics Corp Coercivity The property of a Magnetic Stripe that indicates the amount of force needed before magnetic saturation measured in Oersted Oe color matching The process of adjusting color hue saturation and brightness to duplicate a desired color An algorithm within the Driver which adjusts the color balance and provides output with the desired color automates this process Compressed air Air stored in a tank or produced by an a
101. ESTRICTED USE ONLY Fargo Electronics Inc Selecting the Sensors button and Defaults button Step Procedure 1 Select the Lamination Tab s Sensors button to display options for calibrating the Card Lamination Module s Lamination Sensor The Lamination Sensor is what detects the start of each PolyGuard patch throughout the roll This Sensor may occasionally need to be recalibrated e If the Lamination Module seems to skip PolyGuard patches or wind the PolyGuard roll until the Lamination Module s LED flashes recalibrate the Lamination Sensor according to the instructions given the in the Calibration window e Be sure the Printer is powered ON and that the Lamination Module s Top Cover and Lamination Station are closed when calibrating Note This Sensor is not used if applying Thermal Transfer Film overlaminate 2 x Caid Device OpY 19 a a Image Transfer Magnetic Encoding Lamination K Panel Resin Lamination Position Calibration Lamination Sensor Calibration To calbrale the lamination sensor remove the lamination media and close the piinter s top cover Then click on the send button Help The printer s LED wil indicala when calibration is complete SEND Tianser Dwel Time 22 saconds inch Tianster Temperaure 125 5 Centigrade Default OK Cancel Apply Help HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 243 RESTRICTED USE ONLY Fargo El
102. ElectroStatic Discharge 508 Ethernet 508 Exception Log 466 excessive resin printing problems 117 118 Extended Capabilities Port ECP 31 external device interference 61 F factory default settings Default button 207 Failed magnetic encode 77 Failed Smart Encode 84 Fan Assembly 282 Fargo Technical Support 478 Fargo Technical Support via the Web 478 FCC 11 feed card into Encoder magnetically encode 80 81 Feeder Station 27 Field Separator FS 227 Film 508 Film Drive adjustment 457 Film Drive Motor 129 Film Low 53 Film mark from Film Sensor 91 Film Out 52 Film Sensing 52 Film Tension 120 Film Tension Knobs 19 Film tracking sideways 131 Film transfers 458 Film upper lower 52 Firmware 508 Firmware file link 470 Firmware Updater Application Program 468 469 Firmware Updater dialog 471 Firmware Updater window 471 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 525 RESTRICTED USE ONLY Firmware Updates 469 470 473 474 Firmware Upgrade 467 Firmware Upgrades 476 477 Flash Memory 509 flashing 477 Flashing GREEN 28 Flattener Temperature 208 459 Flattener Time out 53 Flipper align 52 Flipper Home Sensor 72 73 Flipper Offset 78 82 Flipper Table 82 Flipper Table Home Sensor 72 Flipper Table Home Sensor Cable 352 Flipper Table Position Motor 359 Flipper Table Sensor Board Assembly 350 351 352 Font 509
103. Flipper Home J42 4 Lam Covered lt 9 Uncovered 3 0 3 3 Sensor Mod Card Position J35 4 Lam Unblocked 17 9 Blocked 3 0 3 3 Sensor Mod Hopper Full J65 4 Lam Covered lt 9 Uncovered 3 0 3 3 Sensor Mod Roller Lift J36 4 Lam Unblocked 17 9 Blocked 3 0 3 3 Sensor Mod Lamination J40 4 Lam Unblocked 17 9 Blocked 3 0 3 3 Arm open Mod Sensor Ribbon ID J2 3 Lam Present 02 Not present 70 Sensor Mod Ribbon J38 4 Lam Unblocked 17 9 Blocked 3 0 3 3 Encoder Mod Sensor HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 443 RESTRICTED USE ONLY Fargo Electronics Inc Section 9 LCD On Line Menu Navigation The purpose of this section to provide the User with specific procedures for LCD On Line Menu Navigation Test Image Printing and Printer Setup for the HDP 820 Card Printer Entering the LCD Menu and selecting an Option The MENU option is above the center softkey button as shown below This allows you to access several test setup and reporting functions The Selecting from the Menu Option Tree Structure in Section 8 page 446 shows the available menu options A description of each option and its function is included on the pages following the on line menu Step Procedure 1 Press the MENU button to bring up the SELECT FUNCTION screen appears as shown here Ready HDP820 MENU SELECT FUNCTION Print Test Image Set
104. Forward button to advance the card or the Back button to reverse the card b Try not to move the card too far from where it was just before the jam occurred c Once the jam is cleared close the Printer and press the Resume button to resume printing 2 Remove the jammed card from the Printer by leaving the power ON and opening the Print Station and Transfer Station a b Use the Forward and Back buttons to manually eject the card Close the Printer Note The LCD Display will then display a prompt to either press the Resume button or the Cancel button Press the Cancel button to reboot the Printer Cancel all jobs from the Printer memory Note All current print jobs will be canceled and will need to be resent from the computer HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 98 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Temperature Timeout Error Message Step Procedure 1 Run a self test from the Printer a Select Menu from the LCD b Select Print Test Image from the menu c Select Gray Align Self test from the Menu If no error occurs the Transfer Temperature settings in Driver may be too high or too low See the Adjusting the Image Transfer tab procedure in Section 3 page 204 for instructions on how to adjust the transfer settings 2 Resolve the Transfer Roller not being able to reach the optimum temperature a Turn the Printer OFF and ON to reset and try re
105. Guard Security Feature this is the slot in which a SmartGuard Access Card is inserted Card Input Load blank cards into this hopper Hopper Card Output Stores printed cards Hopper Card Works in conjunction with the Printer to apply a variety of different Lamination overlaminates to printed cards providing increased card durability and Module security The Module has its own LED indicator light and control buttons so it can be operated separately from the Printer Note When printing a batch of cards the Printer can be encoding and printing one card while the Lamination Module laminates another card See Section 3 _ Card Lamination Module on page 136 Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 17 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components Access Card Slot to Parallel Interface Port continued Component Description Card Output Guide If the Printer is equipped with an optional Card Output Stacker adjust the stacker s Card Output Guide to the proper card size prior to printing as shown below Note This will ensure consistent card ejecting and stacking CR30 30 700 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 18 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components Access Card Slot to Parallel Interface Port continued Component Description Film Tens
106. ICTED USE ONLY Reviewing LCD Messages continued Fargo Electronics Inc Message Cause Solution Pause Indicates the Printer is paused See Printer Components LCD and Softkey Control Pad in Section 1 page 25 Print Data The print data sent to the Printer is See Communication Errors in corrupt or has been interrupted Section 2 page 60 Print Ribbon The print ribbon is not installed properly See the Resolving the Print or has run out jammed broken or been Ribbon Error Message damaged procedure in Section 2 page 86 Print Ribbon The print ribbon will soon run out Pause the current print job and Low replace the ribbon Print Ribbon The print ribbon has run out See Resolving the Print Ribbon Out Out Error Message in Section 2 page 87 Print The Printer was unable to complete the See Communication Errors in Timeout print process Section 2 page 60 Printer Open You are trying to print with the Print See the Resolving the Printer and or Transfer Station open Open Error Message procedure in Section 2 page 90 Printhead The Printhead temperature regulator is See the Resolving the Printhead Temp not functioning properly Temp Error Message procedure in Section 2 page 90 Program The system Firmware has detected an See Communication Errors in Exception error while attempting to process the Section 2 page 60 current print job Continued on the next page HDP
107. January 2004 Fargo Electronics Inc Category Part Part Description Alternate Part MSRP List Number Description Price Sensors 140404 Assembly Board Sensor Ribbon 36 73 Ribbon Sensor Assembly 140407 Assembly Sensor Sensor Ribbon 12 35 Board Board Assembly 140407 Assembly Sensor Sensor Module 12 35 Board close 140407 Assembly Sensor Sensor Output 12 35 Board Stacker 140407 Assembly Sensor Sensor Flip home 12 35 Board 140407 Assembly Sensor Sensor Dancer high 12 35 Board and low 140407 Assembly Sensor Sensor Top Cover 12 35 Board Sensor 140407 Assembly Sensor Sensor Cards low 12 35 Board 140407 Assembly Sensor Sensor Magnetic 12 35 Board E Card TOF 140500 Assembly Board Sensor Assembly 18 00 Laminator Film Board Laminator Sensor Film 840108 Assembly Ribbon Sensor Ribbon 131 95 Sensor Array Sensor with bracket 840135 Assembly Sensor Sensor Film Supply 24 31 070048 Sensor ITM Spy Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 491 RESTRICTED USE ONLY HDP8xx Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 Fargo Electronics Inc Category Part Part Description Alternate Part MSRP List Number Description Price Sensors 840136 Assembly Sensor Sensor Film Take 24 31
108. K L Self Test 135 Section 3 Card Lamination Module 136 Safety Messages review carefully 136 Opening the Card Lamination Module 137 Loading the Overlaminate 140 Adjusting the Card Lamination Module 143 Adjusting the Card Flattener 143 Adjusting the Card Guide Rail 145 Adjusting the Internal Card Guide 149 Attaching the Card Lamination Module 152 Section 4 Printer Adjustments 164 Safety Messages review carefully 164 Adjusting the Card Size 165 Adjusting the Card Input Guide 166 Adjusting the Card Stacker Output Guide 170 Adjusting the Internal Card Guide 173 Adjusting the Card Thickness Knob 176 Fine Tuning the Card Separator Adjustment Assembly D840995 177 Printing on Alternate Card stocks 178 Selecting the Right Cards and optimize the HDP Print Process 178 Selecting the Appropriate HDP Printer Driver settings 179 Conducting the Tape Adhesion Test 181 Printer Driver Options 184 Installing Printer Driver Updates 184 Setting Up the Printer Driver 186 Setting up Windows 98SE Windows Millennium 186 Setting up Windows NT Windows 2000 Windows XP 186 Using the Device Options tab 187 Adjusting the Ribbon Type 188 Adjusting the Film Type 189 Adjusting for the color matching 190 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 3 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting for the Resin Dither Using the Print Both Sides option Using the Split 1 Set of Ribbon Panels option Using the Print Back Side First optio
109. Lift Motor a Disconnect the cable connector b Connect a 9 Volt battery to the wires c Replace the motor if it does not turn d Replace the Lam Board as needed if the motor does turn See the Replacing the Lamination Board 140402 procedure in Section 5 page 368 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 100 RESTRICTED USE ONLY Fargo Electronics Inc Card Lamination Errors Resolving the Overlaminate Jam Symptom This section only applies if the Printer is equipped with an optional Card Lamination Module If the overlaminate becomes stuck to the card or jammed inside the Printer the LCD Display will indicate that it is jammed Step Procedure 1 Leave the power ON and open the Top Cover and Lamination Station 2 Remove the Take Up core the side with used overlaminate on it from in between the two black Drive Hubs 3 Steadily pull the overlaminate free from where it is jammed If it is stuck to the card pull the overlaminate off the card e Jammed or Wrapped If it is jammed or wrapped around the rollers press and hold down the Lamination Module s Resume button while gently pulling on the overlaminate Lr Caution Do not jerk the overlaminate to free it since this will increase the chance of breaking it e Broken If it does happen to break remove and tape the broken end of the supply roll directly onto the take up roll Then wind a few inches worth of ov
110. Note If you do not find a setting for the exact card thickness set the adjustment knob to the setting closest to the thickness of the cards The adjustment knob controls the position of the Printer s internal Card Separator which is designed to accommodate a range of card thicknesses surrounding the given card thickness settings Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 176 RESTRICTED USE ONLY Fargo Electronics Inc Fine Tuning the Card Separator Adjustment Assembly D840995 See Drawing D841087 The height of the Card Input Guide may need to be fine tuned to accommodate a specific card thickness The example given below describes adjusting the Card Input Guide for a 30 mil card Tools Needed e 005 in Feeler Gauge Or a single sheet of paper e Card of appropriate thickness Step Procedure 1 Place the card in the Card Input Hopper with the trailing edge of the card over the center line of the outside Feed Roller Position the Feeler Gauge or sheet of paper on top of the card and just under the Card Separator Adjust the Card Thickness Adjustment Knob a b Locate the Card Thickness Adjustment Knob Adjust this knob to the setting that most closely matches the thickness of the card Adjust the Card Separator Adjustment Assembly D840995 a oa o DF Move the Height Adjustment Thumb Screw up and down
111. Off 0 00 LAM Bar Assembly D840769 Assembly Fan Fan Lamination 35 30 150315 Fan ITM Module Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 485 RESTRICTED USE ONLY HDP8xx Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 Fargo Electronics Inc Category Part Part Description Alternate Part MSRP List Number Description Price Misc D840848 Support Magnetic Support Magnetic 7 74 Hardware Head Damper Head Damper D840865 Spring Wing Front Side Input 4 48 Stainless Pinch Springs D840865 Spring Wing Back Side Output 4 48 Stainless Pinch Springs D840865 Spring Wing Back Side Input 4 48 Stainless Pinch Springs D840865 Spring Wing Front Side Output 4 48 Stainless Pinch Springs D840909 Card Weight Card Weight 23 34 D840952 Assembly Ribbon Hub plain 8 77 Hub D840952 Assembly Ribbon Hub Drive plain 8 77 Hub D840985 Assembly Fan Side Fan 60 20 150322 Fan Side D840986 Assembly Fan Printhead Fan 42 64 150313 Fan Top D840995 Assembly Input Card Separator 122 00 Separator Adjust Assembly D841010 Assembly Fan Fan 46 93 150322 Base Fan D841079 Assembly Stacker Output Stacker 0 00 820 Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 486 RESTRICTED USE ONLY HDP8xx Series ID Card Printer Recommende
112. Print Timeout 55 Fargo Electronics Inc Print Width 233 Print YMC Under K and Print K Only options 216 Print YMC Under K Print K Only options 216 Print Transfer Stations 67 71 78 90 255 256 257 printed image 206 printed text and barcodes 216 Printer 447 448 Printer cannot align flipper 72 Printer cannot align the flipper 73 Printer cannot read encoded data 79 Printer Cleaning Kit 67 108 109 111 247 250 256 257 Printer Components 17 18 19 20 Printer Driver 57 Printer Driver setup 207 Printer mat 89 Printer Open 55 Printer pausing between panels 89 Printer Setup 281 Printer s Firmware 471 Printer s memory full 197 198 Printer s memory to buffer 198 Printhead 20 283 516 Printhead 281 Printhead Cables 90 Printhead cleaning 247 Printhead Cleaning Pen 247 Printhead Fan 89 Printhead NO raise lower 88 Printhead pressure too low 128 Printhead Resistance 459 Printhead Resistance option 281 Printhead Temp 55 printhead temperature malfunctioning 90 Printhead temperature regulator 90 Printhead Printhead Mounting Bracket 116 128 Printing Method 14 Printing Process Errors 85 86 Printing Resolution 14 Program Exception 55 Proper Settings 179 Prox Card Encoder 516 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 530 RESTRICTED USE ONLY Prox Setting 83 Proximity cards 106 Pulley Gear Combo 285 286 PVC 516
113. Printer is upgraded to include an Encoder e Mag None or Installed e Smart None or Installed e Prox None or Installed Step Procedure 1 Select MENU Setup Printer and Encoder Settings 2 Change the desired option as needed Example Adding a Mag Encoder change MAG from None to Installed 3 Press SELECT to save the value HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 461 RESTRICTED USE ONLY Fargo Electronics Inc Setting the Magnetic TOF Use this setting to position the magnetic data at the correct distance from the leading edge of the card e The Magnetic TOF is the distance from the edge of the card to the Start Sentinel SS e The Start Sentinel marks the beginning of the encoded data Note According to the magnetic recording standard ISO 7811 the correct Start Sentinel distance is 0 293 inches 0 020 inches 7 44 mm 0 51 mm from the leading edge of the card Step Procedure 1 a Measure this distance by making the data visible using a magnetic viewer or developer solution b Alternatively use a magnetic card analyzer to measure the Start Sentinel distance 2 a Use a magnetic viewer or developer solution or spray to make the magnetic data visible in order to identify the Start Sentinel as the first set of magnetic lines or first one bit which are visibly closer together than the large number of evenly spaced lines or leading zero bits that
114. Printer s Ready LED flashes Step Procedure 1 Check that the proper Over Laminate type is installed according to the Lamination Type option selected in the Printer Driver a Open the Printer control panel from the Computer e If using Windows 98Se ME right click on the HDP800 Series Card Printer Icon and select Properties e f using Windows NT 4 0 right click on the HDP800 Series Card Printer and select Document Defaults e If using Windows 2000 XP right click on the HDP800 Series Card Printer and select Printing Preferences b Click on the Lamination tab c Ensure that the Lamination Type selected matches the Lamination type installed in the Printer 2 Calibrate the Lamination Sensor a Reset the Printer to clear any Error Messages by removing Power and reapplying it b Open the Printer control panel from the Computer e If using Windows 98Se ME right click on the HDP800 Series Card Printer Icon and select Properties e f using Windows NT 4 0 right click on the HDP800 Series Card Printer and select Document Defaults e If using Windows 2000 XP right click on the HDP800 Series Card Printer and select Printing Preferences Click the Lamination tab Click on the Sensors button Remove the Laminate ribbon and close the top cover O29 2 9 Click on the Send button for a Lamination Sensor Calibration Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0
115. TRICTED USE ONLY HDP8xx Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 Fargo Electronics Inc Category Part Part Description Alternate Part MSRP List Number Description Price Covers 840167 Assembly Input Cover Card Input 1 293 44 Covers hopper 840169 Assembly Output Cover Left output 460 07 Covers 840260 Cover LAM Roller Cover Lam black 4 42 plastic 840361 Cover Top Tower Cover Top 159 06 840362 Cover Mid Tower Cover Mid Tower 121 42 840363 Cover Base Tower Cover Base Tower 133 70 D840839 Input Cover Main Cover Right no 512 00 doors input D841221 Cover Rear Access Cover Rear HDP 0 00 NO LOUVER Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 483 RESTRICTED USE ONLY HDP8xx Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 Fargo Electronics Inc Category Part Part Description Alternate Part MSRP List Number Description Price Misc Hardware 120011 Switch ON OFF Switch ON OFF 5 66 2600 11E 2600 11E 130063 Power Cord Black Cord Domestic 8 58 130067 Filter A C Line RT Power Cord 25 61 Angle Receptacle 130200 Magnetic Catch Magnetic Door 2 56 Catch Used with 130201 130201 Magnetic Latch Magnetic Latch 0 60 Plate Plate Used with 130200 150074 Spring COMP Flipp
116. The Inner Alignment Arrows should appear at the trailing edge and the Outer Alignment Arrows should not appear on the card b If the test card does not look like the color bars YMC display See the Reviewing the Color Bars YMC Self Test in Section 2 page 133 Go to Step 7 below to adjust the Transfer EOF 3 Record the Transfer EOF value on the test card last printed 4 Select MENU Setup Printer and Transfer EOF 5 Measure the distance from the trailing edge of the card to the trailing edge of the image transfer 6 Calculate the Transfer EOF value for inches or mm e Inches 24 Measurement x 300 e Millimeters 24 Measurement x 11 8 Example Inches 24 050 x 300 105 7 Adjust the Transfer EOF value e Decrease the Transfer EOF value to move the end of the transferred image toward the leading edge of the card e Increase the Transfer EOF value to move the end of the transferred image toward the trailing edge of the card Remember 30 Pixels will move the transferred image 0 100 in 3 84mm 8 Press SELECT to save the value HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 454 RESTRICTED USE ONLY Fargo Electronics Inc Setting the Transfer EOF Step Procedure 9 Print a test card as described in step 1 10 a Repeat steps 1 to 9 until the test image is correctly positioned If the inner alignment arrows are not printing on the card but are just off the edge decrease the P
117. Upper and Lower Film error The xxx is a three digit code that is different for each Film error Technician Note When off site Technicians contact Fargo Technical Support with a Film Upper xxx error they can now provide our in house Technicians with a unique error code for a more precise exchange of information The Printer Encoder now decides when it can and cannot recover from Upper Film errors For example if an image has already been transferred to a card during a batch job and the User encounters an Upper Film error the Printer Encoder displays the error without the Resume option Canceling the print job is the best recovery method and the User must cancel the job from the PC and re send the job when the Printer Encoder is ready Technician Note Additionally the Printer Encoder will not allow the User to resume from an Upper Film error if the job is no longer resident in the unit s memory Improvement No 2 auto recovery Another improvement to this type of error handling is auto recovery Since the Printer Encoder can determine which Upper Film errors are recoverable and which are not it can automatically decide to reprint an image For example if the Printer Encoder encounters an unexpected Upper Film error while it is printing it will attempt to reprint the image Technician Note The reprinting process includes the abandonment of the current section of Film queuing the next fresh Film Panel and starting the job
118. Y Fargo Electronics Inc Reviewing the Card Count Self Test Step Procedure 1 Use this card to view counts for Card Count CC Pass Count PC Transfer Count TC and Lamination Count LC e The Card Count is the total number of cards the Printer has produced Pass Count is the total number of print passes made by the Printhead Note A pass is measured each time a single ribbon panel is printed or passes beneath the Printhead e The Transfer Count is the total number of times the Printer transfers an image to a card Reviewing the Magnetic Test option Step Procedure 1 Use this option only applies if a Magnetic Encoding Module is installed in the Printer Note The Printer will feed encode and eject a card Be sure to have high coercivity cards installed when running this test HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 134 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Lamination Color Resin YMCK L Self Test Step Procedure 1 Use this card to determine Lamination Placement and confirm that a the image colors are properly reproduced and b the Resin Panel is printing properly Note The Image consists of twelve spot colors YMC and RGB as well as gray density bars and thin resin lines HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 135 RESTRICTED USE ONLY Fargo Electronics Inc Sec
119. adhering to the card surface problem cont Step Procedure 2 Check the Lamination Temperature a mp acp S Open the Printer Control Panel from the Computer e f using Windows 98Se ME right click on the HDP800 Series LC Card Printer Icon and select Properties e If using Windows NT 4 0 right click on the HDP800 Series LC Card Printer and select Document Defaults e If using Windows 2000 XP right click on the HDP800 Series LC Card Printer and select Printing Preferences Click on the Lamination tab Increase the Lamination Temperature by 5 degrees Click on the OK button Print and Laminate a card from the software Continue to adjust the Lamination Temperature until the Lamination adheres completely and cannot be peeled off Adjust as needed the card flattener if increased temperature is causing the cards to bow HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 107 RESTRICTED USE ONLY Fargo Electronics Inc Diagnosing the Image Problems Resolving the Pixel failure problems Symptom A thin line or scratch travels the entire length of the card Step Procedure 1 Check the card stock for scratches Replace the cards as needed 2 Examine the Printhead for visible damage 3 Clean the Printhead a Remove watches rings bracelets and other jewelry b Open the Print Station c Use a Printhead Cleaning Pen from the Printer Cleaning Kit to fi
120. am 98 Resolving Laminator Cooling Error 99 Resume button 85 88 Retainer Clip 288 Retaining Ring 285 289 354 retries 224 RFI Radio Frequency Interference 517 RGB 133 RGB Red Green Blue 517 Ribbon 517 Ribbon cable 517 Ribbon Clutch 105 Ribbon Deflector 284 Ribbon Drive adjustment 458 Ribbon Drive O Ring 286 Ribbon jammed 85 ribbon Panels 193 Ribbon Peel Bar 126 Ribbon Sensor 85 88 440 Ribbon Sensor Array Assembly 289 Ribbon Sensor Assembly 287 Ribbon Supply Encoder Sensor Assembly 293 Ribbon Supply Motor Assembly 290 Ribbon Take Up Motor Assembly 291 Ribbon Tension 129 Ribbon Tension adjustment 457 Ribbon Transfer Roller 289 ribbon type 87 88 188 189 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 531 RESTRICTED USE ONLY Ribbon Type setting 87 ribbon wrinkle problems 115 116 Ribbon Cards 164 245 259 RibbonTraq 517 RibbonTraq mark 85 88 RibbonTraq marks 440 Right Cards 178 Right Cards HDP Print Process 178 RMA number 517 Roller 517 rotate front by 180 Degrees 196 rotates image 196 RS 232 517 S safety issues 136 164 245 259 Safety Standards 11 Saturation 517 Save this Program to Disk 470 Scroll Buttons 21 second K Panel 193 second parallel port into 61 SELECT FUNCTION screen 444 Select Printer button 471 474 Select Update File button 471 474 self test 61 Self test 518 Sending Upd
121. am Group a Open the program and type 1 JULIEANDERSON 1234567890 b Select File gt Page Setup and click on the Printer button c Ensure that the HDP800 Series Card Printer is selected and click OK d Change all the margin settings to zero 0 and click OK e Select File gt Print on the Menu Bar f Go to File on Menu Bar and select Print Note The Printer should then feed a card into the Encoder and magnetically encode it HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 80 RESTRICTED USE ONLY Fargo Electronics Inc E card Encoding Errors Resolving the Job Mismatch error Symptom The Job Mismatch error is displayed on the LCD while running a batch print job with E card Encoding Step Procedure 1 Cancel the current print job 2 Remove any cards that are still in the Printer 3 Visually check the last card that was printed properly 4 Restart the print job using the last successfully printed card as a reference for where to start HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 81 RESTRICTED USE ONLY Fargo Electronics Inc Removing the Card jam in the Printer s Smart Card Encoding Area Symptom A card is jammed in the smart card encoding area of the Printer Step Procedure 1 Clear the jammed card a Open the Print and Transfer Station b Use the arrows on the LCD panel to move the card forward or backward to free
122. an show up as blemishes on the card surface and may reduce the life of the image itself HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 178 RESTRICTED USE ONLY Fargo Electronics Inc Selecting the Appropriate HDP Printer Driver settings Fargo offers two types of PVC cards glossy UltraCard cards and matte finished HDP PVC Cards Defaults The HDP Printer Driver software has default Transfer Temperature Dwell Time and Flattener Temperature settings that deliver the best transfer for these card types These defaults automatically configure based on the card type ribbon type and whether printing single or dual sided Note The default Dwell Time of the HDP820 and HDP820 LC Printer Drivers has been changed or modified from two 2 seconds per inch to three 3 seconds per inch in order to improve adhesion and media handling capabilities as well as to reduce printer errors Card Type Selection Before printing if using these standard Fargo card types check to make sure that the appropriate card type option selected from the Card tab of the HDP Printer Driver Proper Settings It is very important to note that not all card types will be accommodated by these default settings In some cases experimentation may be needed to find the proper settings For the cases where custom settings are required the Printer Driver s Card Type option also includes Custom 1 and Custom 2 options Settings These settings allow de
123. and select Printing Preferences b Click on the Card tab c Ensure that the proper card size is selected Note An incorrect card size selection can cause the image to be placed improperly on the card Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 123 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Image Placement problems continued Step Procedure 6 Confirm that the card is feeding straight into the Print section a Check to ensure that the Card Size Knob in the base Module is set to the proper card size if it is not feeding straight into the Print section Continued on the next page Mike Berman Student 3957105 library Code 2439 554 Mike Berman Student 3957105 library Code 2439 554 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 124 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Image Placement problems continued Step Procedure 7 Confirm that the Flattener is not impeding the card a Manually feed a card into the Printer using the Forward and Back buttons on the display Note The card should move freely under the Flattener b If the card is hitting the Flattener adjust the width of the Flattener Guides by loosening the two 2 screws that hold the Flattener c Re tighten the two 2 screws after the Flattener Guides have been adjusted 8 Verify that the u
124. and to adjust certain menu options Transfer Station Transfers printed images and the HDP film to blank cards Print Station Transfer Station Unlock Release Lever to open Print and Transfer Stations HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 21 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components Access Card Slot to Parallel Interface Port continued Component Description Card Thickness Adjustment Knob Adjusts the Printer to feed varying card thicknesses Card Cleaning Assembly Automatically cleans cards for higher print quality Note Clean this assembly after every 250 cards or as needed Power Switch Turns the Printer power ON and OFF Power Port Connect to the included power cord Parallel Interface Port Connect to a Windows PC with a parallel cable See below Parallel Interface Port HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 22 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components Access Card Slot to Parallel Interface Port continued Component Description Release Lever Locks and unlocks the Print and Transfer Stations so they can be opened and closed Note This lever must be in its locked position in order
125. ansfer Temperature 125 5 Centigrade Default Cancel Apply Help HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 238 RESTRICTED USE ONLY Selecting the Lamination Position Fargo Electronics Inc Step Procedure overlaminate requires adjustment arrows enter a positive number 1 The Lamination Position control allows you to adjust the horizontal position of the PolyGuard Overlaminate This control functions in the exact same fashion as the Image Position controls except only the horizontal position of the e To adjust the Lamination position click on the Horizontal adjustment e To move the overlaminate more toward the card output side of the Printer e To move the overlaminate more toward the card input side of the Printer enter a negative number Note The adjustment arrows point in the direction the patch will move on the card The maximum value for the Horizontal adjustment is 100 Pixels 10 Pixels about 03 8mm e To adjust the Vertical placement of the PolyGuard Overlaminate click g HDPS20 LC Card Printer Printing Preferences Card Device Options Image Color Magnetic Encoding Lamination Lamination Position Direction Card Travels Through Printer HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 Continued on the next page Image Transter K Panel Resin Horizontal 239 RESTRICTED USE ONLY Fargo Electro
126. anster Ribbon Type YEGE Full Color Resin Black T Film Type tea o Color Matching laleraico ssi Pesin Dither Uptinmzed tor Graphics Iv Print Both Sides Print in Single Card Mode T Split 1 Set of Ribbon Panels T Link Card to Print Job T Disable Printing Print Back Side Orly Rotate Front 180 Degrees Rotate Back 180 Degrees HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 194 RESTRICTED USE ONLY Fargo Electronics Inc Using the Print on Back Side Only option Use this option to print only onto the backside of cards Step Procedure 1 Select this option to print only onto the backside of preprinted cards that must have their Magnetic Stripe or smart card chip encoded Note Load the cards in the usual fashion e When this option is selected the Print Both Sides option is automatically disabled e When attempting to print a two page document if Print Back Side Only is selected the first page of the document will print on the backside of the card e The second page of the document will then be printed on the back of a second card Ribbon Type YEER Full Color Resin Black Film Type cer i lt sC Color Matching Algebras 0 Resin Dither Optimized for Graphics Print Both Sides Print in Single Card Mode Split 1 Set of Ribbon Panels T Link Card to Print Job Print Back Side First Disable Printing Rotate Back 180 Degrees HDP
127. ard Smudging is typically caused by low Transfer Temperature or low Transfer Tension a Ifa smudge is on the leading edge of the card increase the Transfer Tension b Verify that the Take up Motor turns without delay when the Lamination begins c Ifthe Motor delays increase the Transfer Tension d Adjust the Transfer Temperature according to the acceptable variation e Adjust the Driver settings to increase the Transfer Dwell Time e For chipping of the card image follow this procedure Note Chipping is characterized by areas of incomplete transfer or voids in the card image a Check the Printhead alignment b Lower the Transfer Tension if chipping is on the leading edge c Increase the Transfer Temperature according to the acceptable variation d Adjust the Driver settings to increase the Transfer Dwell Time If you have any questions please feel free to contact Fargo Electronics Support Services at 952 941 9470 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 477 RESTRICTED USE ONLY Fargo Electronics Inc Section 11 Fargo Technical Support The purpose of this section to provide the User with an efficient step by step procedure to be used when contacting Fargo Technical Support as needed for the HDP 820 Card Printer Contacting Fargo Technical Support Step Procedure 1 Read the suggested Sections of the Technical Service and Maintenance Manual in order to troubleshoot the Card P
128. ard Guide e Thicker or Thinner Cards If loading thicker or thinner cards into the Printer adjust the Card Thickness Adjustment Knob HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 165 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Card Input Guide When loading cards it is important that the Card Input Guide rests securely against the stack of cards to ensure consistent feeding Step Procedure 1 Before moving the Card Input Guide loosen the guides Locking Knob Note To do this open the Front Access Door and loosen the Locking Knob by turning it counter clockwise Continued on the next page Card Input Guide Locking Knob SCE ooo Oe a A a a a a HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 166 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Card Input Guide continued Step Procedure 2 Open the Card Input Hopper Door and locate the Card Input Guide closest to the front of the Printer Continued on the next page Card Input Guide HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 167 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Card Input Guide continued Step Procedure 3 Adjust this guide is adjustable and move it slightly to the left or right Push the Card Input Guide out of the way and insert a stack of at least 100 cards Continued on the ne
129. ard Slot HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 30 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components Centronics Type Parallel Interface The Card Printer is equipped with a standard 8 bit centronics type parallel interface port Note This communication port is the means through which the Printer receives data from the computer This section describes the pin assignments and signal specifications for this port e The Centronics type parallel interface is a widely used Printer interface due to its standardization throughout the PC industry e The Printer s parallel interface connector is a standard 36 pin Amp type with two metal wire retaining clips and is ECP Extended Capabilities Port compatible Note It mates with a standard bi directional PC to Printer parallel cable For best results keep the interface cable to under 6 feet in length WIRE DIAGRAM ee 1i 1 as eee E ees Ca 3 3 E Dew e oT 5 J 5 A 6 6 o 88 ee a a ae os t 5 9 9 E oF 0 E E 5 E ee ee eee eee eH ae ae ee a Cn T n Coa o a CO o as 14A PNA Oa o ae ee a shel She HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 31 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components Print Ribbons The Card Printer utilizes both dye sublimation and or resin thermal transfer methods to print images directly onto blan
130. ards to eject properly See the Using the Lamination tab only with the Card Lamination Module in Section 5 page 238 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 43 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Module and Printer interaction durability and security The Lamination Module features its own LED indicator light and control buttons so it can conveniently be operated separately from the Printer Note This means that when printing a batch of cards for example the Printer can be encoding and printing one card while the Lamination Module laminates another card for maximum efficiency In fact you can even open the Lamination Module to replace the overlaminate while the Printer is printing or encoding and vice versa Term Description Reference Module The Card Lamination Module works in See the Using the Lamination and conjunction with the Printer to apply a tab only with the Card Printer variety of different overlaminates to Lamination Module in Section interaction printed cards providing increased card 5 page 238 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 44 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Module and LCD Display interaction Term Description Reference Module For ease of operation the Card See the Using the Lamination and LCD Lamination Module works in tandem with
131. ary files on the computer can cause communications errors Access temporary files by following this process e Search for all folders called TEMP Once found clear out the contents of the folders e Use a disk cleanup utility such as Disk Cleanup found in the System Tools folder of the Start menu or use a third party application e If using Windows 98Se ME 2000 XP run the system utility Disk Defragmenter found in the Accessories folder of the Start Menu Printing from a network Note Some network configurations can cause communications issues with the Printer a Disconnect the Printer from the network jack b Directly connect the Printer to a parallel port on a computer to determine if the network is the source of communications problems HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 62 RESTRICTED USE ONLY Fargo Electronics Inc Firmware Errors Resolving the Upgrade Failed error Symptom An Upgrade Failed error is displayed on the LCD during the upgrade process Step Procedure 1 Determine if there is interference from an external device a Do not use an A B switch box dongle key or other peripheral in line with the parallel cable b If using a switch box dongle key or other peripheral remove it while testing communication between the computer and the Printer c If needed replace the switch box dongle key or other peripheral once it is determined that the ca
132. ate to Printer dialog 473 474 Sensor 518 Sensor 443 Sensor Assembly 361 Sensor Board 287 Sensor Location and Voltages 440 Sensor Location Voltage 441 Sensor Testing 90 440 Serial interface 518 Setting the Printhead 281 setup options 60 Setup Printer 71 78 SETUP EXE file 469 Shift Data Left option 225 Show Error Count 466 SIMM 518 Simplex 518 Slide Lock 69 Fargo Electronics Inc Smart Card 518 smart chip 178 Smart Encode Failed 56 Smart Setting 83 SmartGuard 518 SmartGuard Access Card 58 59 SmartGuard card 58 SmartGuard data 58 SmartGuard Disabled 59 SmartGuard Enabled 59 SmartGuard PCB Assembly 279 SmartGuard Ribbon Cable 279 SmartGuard 518 SmartShield 518 smudging 477 Softkey Buttons 20 25 Software 518 Software Drivers 15 Software Drivers 13 Solid GREEN 28 Spare Single Dir Driver 269 special precautions 164 245 259 Split 1 Ribbon Panels 193 Split 1 Set Ribbon Panels 193 Spooler 518 Spooling 519 SS Start Sentinel 519 SS distance inches 462 SS distance millimeter 462 SS ES FS 227 Stacker 519 Stacker Full Sensor 140407 371 Stacker Lift Motor 100 Stacker Lift Motor 840130 372 Start Sentinel 463 Start Sentinel SS 227 462 Start Sentinel distance 462 Starting Self test 56 static build up 70 Stepper Motor 519 Stepper Motor Assembly 325 340 String 519 Supply Encoder Sensor Assembly 326
133. ation Module Selecting the Lamination Position Selecting the Lamination Side Selecting the Lamination Type Adjusting the Transfer Dwell Time and Transfer Temperature Selecting the Sensors button and Defaults button HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 191 192 193 194 195 196 197 198 199 200 204 205 207 208 209 210 211 212 213 214 215 216 218 219 221 222 223 224 225 226 227 228 229 230 231 233 234 236 236 237 238 239 240 241 242 242 RESTRICTED USE ONLY Fargo Electronics Inc Selecting the Sensors button and Defaults button Section 5 Cleaning Using the Required Supplies Safety Messages review carefully Cleaning inside the Printer Cleaning outside the Printer Cleaning the Printhead Cleaning the Cleaning Rollers Cleaning the Card Feed Rollers Cleaning the Platen Rollers Section 6 Parts Replacement Safety Messages review carefully Reviewing the Printer Components Reviewing the Input Hopper Components Reviewing the Print Module Components Reviewing the Transfer Station Components Reviewing the Base Module Components Reviewing the Base Module Components HDP Main Board Cable Connections Reference HDP Lamination Board Cable Connections Reference HDP Lamination Module Board Cable Connections Reference Cover Removal P
134. ations continued Step Process 16 The Ribbon Drives turn ON to advance the printed portion of the Film to a position near the heated lam Roller using the Lamination Film Alignment Sensor The Ribbon Drive stays ON for a certain number of additional clicks after turns OFF to create a slack region between the Printer and Laminator sections All stop Note Ribbon encoders and dancer zero position switch are active during this step 17 The Ribbon Drive is used with the Lamination Film Alignment Sensor to locate the printed Film more precisely under the hot Roller All stop 18 This is simultaneous to Steps 1 to 17 and then Steps 19 to 24 will occur 19 The DC Motor and Stepper Motor turn ON and run until a card is seen by the card Sensor which will cause the Card Input Motor to stop The Stepper will continue to run a certain number of steps to position the card on the Flipper Table All stop Card Low Sensor will check for cards in Input Hopper 20 Stepper will turn ON causing the Flipper to turn to the magnetic angular position The Flag Sensor and counted steps are used to determine the angular position All stop 21 Stepper will engage to drive the card past the Mag Card Sensor and the Mag Head 22 Stepper engages to drive the card to a centered position on the Flipper Table using the Mag Card Sensor and a step count All stop 23 Stepper will turn ON causing the Flipper to turn t
135. can National Standards Institute 502 Appropriate HDP Printer Driver Settings 179 AS400 502 ASCII American Standard Code for Information Interchange 502 Fargo Electronics Inc AT 502 Attaching the Card Lamination Module 160 Attention screen 29 Auto Eject 1st Error option 224 auto eject option 224 auto Film realignment 476 Automatic Reset 47 auto recovery 476 B Black 502 Back cover 278 Barcodes 503 Base Module 348 349 Base Module cover 276 Batch print 503 batch printing 224 Battery Back up 503 Bi directional 503 BIOS Basic Input Output System 503 Bit 503 Bit map 503 black graphics 210 black text or barcodes 210 blank access card 58 blocked voltage 75 105 Board 503 Boot up 503 Buffer 503 buffer single card 198 C Cable 503 Cache 504 Calibrate TAB 103 104 Calibrating 504 cam lobe 128 Cancel button 28 Cancel soft key 224 canceling all print jobs 28 Card blocked in Transfer Station 98 Card blocked restricted in Transfer Station 98 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 522 RESTRICTED USE ONLY Card Capacity 12 Card Cleaning Assembly 22 Card Cleaning Cartridge 68 Card Count 134 Card Design 33 Card Detection Sensor 75 Card Feed Gear 3 355 Card Feed Motor Assembly 360 Card Feed Roller Motors 67 71 78 82 Card Feed Sensor 362 Card Feed Shaft Gear on the Cleaning Roller Assembly 356 Ca
136. cation only when the dongle is installed Typically it works as a pass through device and is connected in serial to the parallel cable Dot The smallest unit of an image that the Printer is able to produce The smaller the dot see dot pitch the sharper the image Dot pitch A measurement of image sharpness denoting the width of the dots that makes up a Pixel The smaller the pitch the sharper the image Download The transfer of a data file from one device to the other over a network or cable typically from the Internet to a PC DPI Dot Per Inch A measurement of the Printer resolution indicating how many dots a Printer can produce in a linear inch DRAM Dynamic Random Access Memory A microchip based volatile memory storage device The Printer uses this to buffer a print job transferred from the PC until the Printer controller is able to process the packet Driver Software utility installed in Windows that interfaces an application to rasterize image data and include command codes so the Printer can process the file Duplex Printing Printing on the front and the back of the card Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 506 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Term Definition Dwell Time The speed at which the card moves across the lam roller measured in seconds
137. ce Options Image Color Image Transfer t Contrast 0 Gamma Ma 0 Yelow Balance 32 Magenta Balance 220 Cyan Balance 34 aeii BNE 0 Resin Heat K t Default HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 202 RESTRICTED USE ONLY Fargo Electronics Inc Using the Image color tab continued Step Procedure 5 Return all options to their factory settings by clicking on the Default button ef HDP820 LC Card Printer Printing Preferences Magnetic Encoding anuni K Panel Resin Cad Device Options Image Color Image Transfer Contrast j 0 Gamma 0 Yelow Balance 32 Magenta Balance 22 CyanBalance E E 34 Dye Sub Intenst 777mm 0 YMC 1 tat T 1 Resin Heat K j 0 Default t t t t t t OK Cancel Apply Help Cancel ew Hee HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 203 RESTRICTED USE ONLY Fargo Electronics Inc Using the Image Transfer tab Use this tab to adjust the Image Position Transfer Dwell Time Transfer Temperature and Flattener Temperature ef HDP820 LC Card Printer Printing Preferences ij 2x Magnetic Encoding Lamination K Panel Resin Card Device Options Image Color Image Transfer Image Position Vertical q Horizontal MERATINININAN as Ay 4 g
138. cement errors Symptom The PolyGuard Overlaminate is not centered horizontally on the card Step Procedure 1 Adjust the Lamination TOF a Select MENU Setup Printer and Lamination TOF b Trailing Edge Adjustment Adjust the current value to a more positive number to move the Lamination closer to the trailing edge c Leading Edge Adjustment Adjust the current value to a more negative number to move the Lamination closer to the leading edge of the card d Press OK to save the new value 2 Calibrate the Lamination Sensor a c d e Reset the Printer to clear any Error Messages by removing Power and reapplying it Open the Printer control panel from the Computer e f using Windows 98Se ME right click on the HDP800 Series Card Printer Icon and select Properties e If using Windows NT 4 0 right click on the HDP800 Series Card Printer and select Document Defaults e If using Windows 2000 XP right click on the HDP800 Series Card Printer and select Printing Preferences Click the Lamination tab Click on the Sensors button Remove the Laminate ribbon and close the top cover Click on the Send button for a Lamination Sensor Calibration HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 103 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Lam Error Out Error Message Symptom The Printer seems to skip PolyGuard overlaminate patches or simply wind the overlaminate until the
139. chanical adjustment can be made Note This adjustment is described below Step Procedure 1 Open the Lamination Module s Top Cover and Lamination Station 2 a Feed a blank card into the Module by inserting it through the output hopper and reverse feeding it by pressing the Lamination Module s Resume button b Manually position the card so its edge is flush with the Card Guide Rail Continued on the next page Card Guide Rail Screws p i L i Blank Card Card Flipping Mechanism HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 145 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Card Guide Rail continued Step Procedure 3 Slightly loosen the two screws which fasten the Card Guide Rail to the Printer s main chassis 4 If the PolyGuard patch is being placed more toward a card s top edge as shown move the Card Guide Rail slightly toward the rear of the Printer opposite the direction you would like the patch to move Contin
140. ck Side Orly D Rotate Front 180 Degrees iY Aotate Back 180 Degrees HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 199 RESTRICTED USE ONLY Fargo Electronics Inc Using the Image color tab Use this tab to adjust color properties Step Procedure 1 Select the Algebraic color matching option see the Device Options tab shown below to control the Contrast and Gamma of the printed image as well as the individual color balance of Yellow Magenta and Cyan see Image color tab shown below Magnetic Encoding Lamination K Panel Resin Card Device Options Image Color Image Transfer Ribbon Type YMORE Full Color 2 Resin Black Film Type cer Ff Color Matching JAlebraic tsti s sS YS Nome Resin Dither Eranti Monitor Magnetic Encoding Lamination K Panel Resin Card Device Options Image Color Image Transfer Contrast m Ez Gamma mmm E 0 Yellow Balance a maar Seams t Magenta Balance 2 2 4 Cyan Balance HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 200 RESTRICTED USE ONLY Fargo Electronics Inc Using the Image color tab continued Step Procedure 2 Select the None or Monitor option see the Device Options tab shown below to only display the Dye Sub Intensity and Resin Heat sliders 3 Control the overall darkness and lightness of the dye sub printed image by adjusting the Dye Sub Int
141. click Exit on the Sending Update to Printer dialog screen Press the Printer s EXIT button When prompted turn the Printer power OFF for a few seconds and then back ON to complete the update process As the Printer restarts you will see the new Firmware version appear on the LCD e If the upgrade was not successful the LCD will display Upgrade Failed or Upgrade Firmware Now on boot up e f you receive this message try updating the Firmware again Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 474 RESTRICTED USE ONLY Fargo Electronics Inc Updating the LCD Firmware continued Firmware Updater ersion 3 0 6 Download Update File Select Update File Send Update File Firmware Updater xj i The print spocler ts sending Firmware update data to your printer Please refer to the LOD display on your printer For update completion ratification HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 475 RESTRICTED USE ONLY Fargo Electronics Inc Firmware Upgrades as of 10 07 03 Reference Technical Update No 53 dated 02 27 2003 These Firmware Upgrades are for the HDP720 V2 2 x and HDP820 820 LC V2 0 2 Card Printer Encoders Improvement No 1 unique error codes Upper and Lower Film errors are now displayed with unique error codes In both Firmware versions the message is Film Upper xxx A unique code is mapped to every possible
142. click on the HDP800 Series Card Printer and select Document Defaults e If using Windows 2000 XP right click on the HDP800 Series Card Printer and select Printing Preferences b Click on the Image Transfer tab c Adjust the Transfer Temperature to a more negative value OR Decrease the Transfer Temperature through the LCD a Select Menu from the LCD b Select Setup Printer and then select Transfer Temp c In increments of one lower the Transfer Temp through the LCD Setup Menu and print a card 3 Verify that the Centerplate Cover D841069 in aligned properly Open the Print and Transfer stations Ensure that the Centerplate Cover is straight in the card path and is not skewed Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 119 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the HDP Film wrinkle problems continued Step Procedure 4 Adjust the Film Tension a b C Select Menu from the LCD Select Setup Printer and then select Film Tension In increments of one lower the Film Tension through the LCD Setup Menu and print a card e f after several adjustments the film wrinkle appears worse return the Film Tension to its original setting and adjust the Film Tension up at increments of one e If there is still no change after the fourth adjustment after having made changes to the Film Tension by a total of 4 points g
143. coders CR 100 HDP825 Dual Sided 2 200 CR 80 Optional Optional Card Printer Encoders HDP825 LC Dual 2 200 CR 80 Optional Included HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 RESTRICTED USE ONLY FARGO Electronic Inc How to use the manual The HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 is designed to provide installers and technicians with quick efficient lookup of related procedures components and terms The manual can be used effectively either in soft or hard copy depending on the preference of the installer or technician Manual Description Sequence of Operations Glossary of Terms and Technical Functional Specifications hyper linked You can go directly to the Sequence of Operations Glossary of Terms Technical Specifications and Functional Specifications to learn how to use the processes procedures functions and windows for the HDP 800 Series Card Printer Encoders within concise correlative tables Table of Contents hyper linked You can use the Table of Contents to quickly locate an error message a procedure the index or an appendix Troubleshooting Replacement Removal Diagnostic and Navigation Procedures in hyper linked Sections You can go directly to Specifications General Troubleshooting Printer Adjustments Parts Replacement Printer Packing Board Level Diagnostics LCD On Line Menu Navigation and Firmware Updates
144. cross the surface of the card pressing out all air bubbles with a fingertip b Remove the tape by smoothly and rapidly approximately 2 inches second 50mm sec pulling it up at a perpendicular 90 degree angle to the card Note The IPC recommends a minimum of three tests for each card type evaluation Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 181 RESTRICTED USE ONLY Fargo Electronics Inc Conducting the Tape adhesion Test continued Continued on the next page Significant transfer to tape FARGO l D Gard Printers Very slight Absolutely NO transfer to tape HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 182 RESTRICTED USE ONLY Fargo Electronics Inc Conducting the Tape adhesion Test continued Step Procedure 4 Visually examine the card and the strip of tape pulled from the card to see if any portion of the HDP Film was removed from the card If any residue e g oil or grease from fingertips is present on the card surface the evaluation results may be affected If the printed transferred HDP Film particles a pull away from the card and b adhere to the tape this indicates that inadequate adhesion of the HDP Film to the card Increased heat and Dwell Times are necessary to resolve this problem Samples 1 2 and 3 show a representation of the adhesion level you can expect Result 1 Sample 1 shows a sig
145. ct MENU Setup Printer and Printhead Resistance 3 a Input the Printhead Setting Number Note The Printhead Resistance setting in the LCD Setup changes in increments of 50 b To select the proper resistance value choose the setting that is closest to the value on the Printhead 4 Press the Select button to save the value HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 459 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Image Darkness Step Procedure 1 Choose MENU Print Test Image and Gray Align YMC to print a test card 2 Examine the test card 3 Select MENU Setup Printer and Image Darkness 4 Record the Image Darkness value on the test card last printed 5 Enter a negative value to lighten the printed image OR Input a positive value to darken the printed image Note Be sure to make adjustments in small increments of 4 to avoid over adjusting this setting A Caution The ribbon may jam or break if the setting is too high 6 Press SELECT to save the value 7 Print a test card as described in Step 1 8 Repeat Steps 1 to 7 until the image darkness is correct HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 460 RESTRICTED USE ONLY Fargo Electronics Inc Changing the Encoder Settings Make this selection to modify the Encoder settings These settings would need to be changed a if the Print Board is replaced or b if the
146. d Checksum Error procedure in Section 7 page 438 Ejecting The system Firmware has detected a See Card Feeding Errors in Used Card card already in the Printer and is Section 2 page 65 ejecting it Film lower The HDP Film is not installed If this appears as an error see the Film upper properly or has run out jammed the Resolving the Film Sensor PP broken or been damaged errors procedure in Section 2 page 93 Film Out The HDP Film has run out Install If this appears as an error see the new Film and press RESUME to the Resolving the Film Sensor continue errors procedure in Section 2 page 93 Film Sensing The Printer was unable to sense the If this appears as an error see the HDP Film properly while printing the Resolving the Film Sensor errors procedure in Section 2 page 93 Flipper Unable to align flipper See the Resolving the Flipper Alignment Alignment Error Message procedure in Section 2 page 72 FPGA An unexpected hardware error has See the Resolving the FPGA Error occurred procedure in Section 8 page 439 FPGA Load Indicates an unexpected hardware See the Resolving the FPGA Error Fail error has occurred procedure in Section 8 page 439 Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 52 RESTRICTED USE ONLY Reviewing LCD Messages continued Fargo Electronics Inc Message Cause Solution Film Low The HDP Film will soon run out If th
147. d 3 0 3 3 Sensor Transfer Lift J65 12 2 Lam Unblocked 9 Blocked 3 0 3 3 Sensor Lower Dancer J62 8 Lam Covered 9 Uncovered 3 0 3 3 Sensor Upper Dancer J62 12 Lam Covered 9 Uncovered 3 0 3 3 Sensor HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 Continued on the next page RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Sensor Location and Voltages continued Sensor Location Pin Board Low Range VDC High Range VDC Ribbon J65 3 Print Covered 9 Uncovered 3 5 5 0 Sensor 5 Ribbon J65 5 Print Covered 9 Uncovered 3 5 5 0 Sensor 4 Ribbon J65 11 Print Covered 9 Uncovered 3 5 5 0 Sensor 3 Ribbon J65 7 Print Covered 9 Uncovered 3 5 5 0 Sensor 2 Ribbon J65 9 Print Covered 9 Uncovered 3 5 5 0 Sensor 1 Latch Open J69 4 Lam Covered 9 Uncovered 3 0 3 3 Sensor Printer Open J64 12 Print Covered 9 Uncovered 3 0 3 3 Sensor Stacker Full J63 12 Lam Covered 9 Uncovered 3 0 3 3 Sensor Stacker H83 8 Lam Unblocked 9 Blocked 3 8 3 5 Position Reviewing the Sensor Layout on Ribbon Sensor array 5 4 B 2 1 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 442 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Sensor Location and Voltages for the Lamination Module Sensor Location Pin Board Low Range VDC High Range VDC
148. d Rollers additional Feed Rollers continued Steps Procedure 6 Use the Cleaning Pad to wipe each of the rollers clean Note Press the Forward and Back buttons to move the rollers back and forth while cleaning If using a Printer with a Card Lamination Module attached wipe all visible rollers within the Lamination Module as well 7 After all rollers are clean and completely dry reload the cards and close all areas of the Printer HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 255 RESTRICTED USE ONLY Fargo Electronics Inc Cleaning the Platen Rollers Step Procedure 1 Leave the Printer power ON and open the Print and Transfer Stations If using a Printer with a Card Lamination Module attached also open the Lamination Module s Top Cover and Lamination Station 2 Remove the Print Ribbon and HDP Film 3 Locate the Print Platen Roller as shown below 4 Use a Cleaning Pad from the Printer Cleaning Kit to wipe the roller clean Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 256 RESTRICTED USE ONLY Fargo Electronics Inc Cleaning the Platen Rollers continued Step Procedure 5 Locate the Transfer Platen Roller as shown below 6 Use a Cleaning Pad from the Printer Cleaning Kit to wipe the roller clean Press the Forward and Back buttons to move the roller back and forth whi
149. d Spare Parts List Effective Date January 2004 Fargo Electronics Inc Category Part Part Description Alternate Part MSRP List Number Description Price Misc D841082 Assembly Base Base Module 2 197 59 Hardware Print Frame 820 Complete Module D841083 Assembly Base Mid Module 2 616 58 Mid Frame 820 Complete Module D841084 Assembly Base Top Module 1 682 72 Top Frame 820 Compete Module D841085 Assembly Lamination Module 1 108 77 Lamination 820 complete unit D841087 Assembly Input Input Module 1 566 76 820 Complete Module D841100 Assembly Supply Supply Pack 34 84 HDP 820 D841103 Sleeve Module Gas Spring Sleeve 12 80 Close D841105 Assembly Card Motor Card Feed 0 00 Feed Assembly D841152 Hub Ribbon Driven Hub Drive ribbon 0 85 Driven notched D841158 Shaft Ribbon Driven Shaft Ribbon Drive 15 40 D850190 Pulley Main Pulley Main Base 1 50 O80MXL Pitch 24T Print Frame D850244 Flag Sensor S2 Headlift Flag 2 22 D850253 Assembly Input Assembly Input 0 00 01 Tray 1 Tray 1 HDP825 ONLY Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 487 RESTRICTED USE ONLY HDP8xx Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 Fargo Electronics Inc Category Part Part Description Alternate Part MSRP List Number
150. d Type by clicking on the Default button If using cards that differ from the Card Type Glossy PVC or Matte PVC options select one of the Card Type Custom options 2 Adjust the Dwell Time and temperature settings manually to ensure proper image transfer Determine the appropriate settings for the card stock by setting the Transfer Dwell Time and Transfer Temperature to the default settings Print a card e ifthe HDP Film is not transferring properly adjust these settings accordingly OR e If the Film is transferring properly perform a final durability test called the Tape Test For instructions on how to do a tape test see Conducting the Tape adhesion Test procedure in Section 3 page 181 Transfer Dwell Time 2 0 seconds inch Transter Temperature 176 0 Centigrade J HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 207 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Flattener Temperature Step Procedure 1 Use the Flattener Temperature control to set the temperature of the Printer s built in Card Flattener This setting may vary depending on the card type e When using the standard UltraCard Glossy or HDP Card Matte PVC Card Type option the Printer Driver automatically optimizes this setting according to whether printing single or dual sided cards In general single sided prints require a hotter Flattener temperature OR e When using another type of card stock
151. d externally to a PC These often share the same data cable or port as a Printer and may be the source of communication problems Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 514 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Overlaminate Term Definition Pinch roller A free spinning non driven roller that presses the card against the drive roller on the opposite side to ensure an adequate normal force for proper traction Pixel Short for picture element The smallest element of a graphic Platen The hard rubber roller that drives the media through the Printer providing support to the backside of the media during printing or laminating PET Abbreviation for polyester terephthalate often called polyester Sheets of PET are laminated with sheets of PVC to produce thermal acceptance composite cards Port A communication interface serial or parallel used for the transference of data PolyGuard A 1 mil or 6 mil thick polyester material that enhances card security and durability applied over the printed surface with a hot roller Available as clear or with embedded holographic type security images Portrait A document layout that is viewed with the document s long axis in a vertical orientation Potentiometer An electronic resistor with a variable resistance value that can be mechanically set P
152. de D840865 342 Replacing the Pinch Roller Spring Plate Back Input Side D840865 343 Replacing the Pinch Roller Spring Plate Back Output Side D840865 344 Replacing the Drive Pulley Back 2 D850190 345 Replacing the Gear Card Transport 2 760330 346 Replacing the Compound Gear D841032 347 Replacing the Base Module D841082 348 Card Input Hopper Components Replacements 350 Replacing the Input Hopper D841087 350 Replacing the Separator Adjustment Assembly D840995 351 Replacing the Flipper Table Sensor Board Assembly 140407 352 Replacing the Card Low Sensor Board Assembly 140407 353 Replacing the Cleaning Roller Drive Idler Gear 2 760401 354 Replacing the Card Feed Gear 3 810271 on the Flipper Table Encoder Feed Motor E000062 355 Replacing the Card Feed Shaft Gear on the Cleaning Roller Assembly 810271 _ 356 Replacing the Feed Encoding Motor Assembly E000062 357 Replacing the Cleaning Roller Assembly 840102 358 Replacing the Flipper Table Position Motor 840124 359 Replacing the Card Feed Motor Assembly D841105 360 Replacing the Flipper Table Card Sensor Assembly D840625 361 Replacing the Card Feed Sensor D840624 362 Replacing the Magnetic Encoder Head 840104 363 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 6 RESTRICTED USE ONLY Fargo Electronics Inc Replacing the Encoder Card Sensor
153. der uses an HID ProxPoint Plus reader mounted on the e card docking station inside the Printer Encoder The ProxPoint is a read only device producing a Wiegand signal that is converted to RS 232 using a Cypress Computer Systems CVT 2232 Application programs can read information from HID prox cards via a RS 232 signal through a dedicated DB 9 port on the outside of the Printer labeled Prox RAM Random Access Memory A storage device for digital information to be held temporarily to facilitate processing Rasterize The process of converting the elements of a graphic into a bitmap to be printed Reboot Cycling the power to the Printer so that it resets and reinitializes Registration The quality of the alignment of the separate primary color images YMCK Resident Font A set of characters loaded into the Printer memory that can be programmed to print those characters on the card without rasterizing the image Resin A semi solid material Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 516 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Merchandise Authorization Term Definition Resolution The number of individual Pixels in a graphic taken over a given length used to indicate the sharpness of the picture and the level of detail The number of elements in the printhead determines Far
154. ding Lamination E Panel Rezin Card Device Options Image Color Image Transter Ribbon Type YMER Full Color Fesin Black x Film Type ler o Color Matching Algebraic Fesin Dither Optimized tor Graphics W Print Both Sides Print in Single Card Mode Split 1 Set of Ribbon Panels Print Back Side First Tl Disable Printing T Print Back Side Only Rotate Front 180 Degrees Iv Rotate Back 180 Degrees HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 198 RESTRICTED USE ONLY Fargo Electronics Inc Using the Disable Printing option Use this option to disable the printing capabilities of the Printer yet still allows the Printer to encode cards Note This option is useful to encode or re encode preprinted cards without wasting additional time or printing supplies Step Procedure 1 Select this option to ensure no print data will be sent to the Printer while all encoding instructions will be sent according to how they are configured within the software HDPS25 LC Card Printer Printing Preferences ix Magnetic Encoding Lamination K Panel Resin Card Device Options Image Color Image Transfer fick Full Color Resin Black Ribbon Type Sac Color Matching algebraic st s Resin Dither Optimized for Graphics Print Both Sides Print in Single Card Mode E piti Set of Ribbon Panels Link Card to Print Job Print Back Side First Print Ba
155. ding Mode Verification Auto Eject 1st Error Manual Eject Each Error Coercivity ae High Co C LowCo Se gE Magnetic Track Selection Track1 Track2 Track3 Enable MLE Support Magnetic Track Options Bit Density Character Size ASCII Offset C 75 BPI C SBits NULL C 128 BPI 7 Bits SPACE 210 BPI C Bits C ZERO Shift Data Left C NoLRC Even Party C Odd Parity C No Parity C Even Party Odd Parity Cancel Apply Help HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 220 RESTRICTED USE ONLY Fargo Electronics Inc Encoding the Mode Coercivity Magnetic Track Selection Use the ISO option for encoding capability for either high or low coercivity cards on tracks 1 2 and 3 and is the industry s standard mode of magnetic encoding Step Procedure 1 Select the Coercivity option to select the Magnetic Stripe type that matches the card type e High Coercivity 2750 4000 Oersted Fargo s High Coercivity UltraCards are 27500e e Low Coercivity 300 Oersted 2 Select the Magnetic Track Selection option to specify which track is to be configured through the Magnetic Track Options if the application being used requires customization of the standard ISO encoding process 3 Customize these options if the application requires it even though the default ISO Magnetic Track Options should be correct for most app
156. dows 2000 Windows XP Step Procedure 1 Click the Start button point to Settings and select Printers 2 Click on the HDP800 Series LC Card Printer icon with the right mouse button and select Document Defaults if using Window NT or Printing Preferences if using Windows 2000 XP Note If you would like to permanently save the Printer Driver settings so you will not need to change them again do so through the main Printer Driver setup window described above Although most applications do allow you to change these same Printer Driver options from their own Print screens the settings may not be permanently saved 3 To change or verify the appropriate Printer Driver options for the print job please refer to the topics describing each of the Printer Driver s tabs HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 186 RESTRICTED USE ONLY Fargo Electronics Inc Using the Device Options tab The HDP825 LC Card Printer Printing Preferences window is used throughout this section for consistency within this document for the entire HDP 800 Series See the HDP820 HDP820 LC and HDP825 Card Printer Printing Preferences windows as needed for your specific printer 6 HDP825 LC Card Printer Printing Preferences Magnetic Encoding Lamination K Panel Resin Card Device Options Image Color Image Transfer Ribbon Type YMER Full Color Resin Black gt o C Color Matching fAlebsic o itsti s sS YS
157. dvances forward one panel from supply advances until the Print Film Sensor senses 1 mark on the Film 9 The Transfer Ribbon advances forward one panel onto take up advances until the transfer Film Sensor senses 1 mark on the Film 10 The Transfer Ribbon reverses for one panel from take up reverses until transfer the Film Sensor senses 1 mark on the Film 11 The Transfer Ribbon reverses for one panel onto supply reverses until the Print Film Sensor senses 1 mark on the Film 12 The Transfer Ribbon reverses for one panel from take up reverses until the Transfer Film Sensor senses 1 mark up on the Film 13 The Transfer Ribbon reverses for one panel onto supply reverses until the Print Film Sensor senses 1 mark on the Film HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 xi RESTRICTED USE ONLY FARGO Electronic Inc Reviewing the Lamination Module Sequence of Operations The LAM sequence of operations begins after printing has occurred with the Card Printer Step Process 1 The card is fed onto the Lamination Module Flipper Table 2 The card is fed to the Card Position Sensor 3 The Lamination Ribbon Motor begins cycling until the Upper Lamination Sensor detects the mark 4 The Card Feed Motor activates to center the card on the Platen Roller 5 The Lamination Roller Lift Motor cycles until the Lamination Roller Lift Sensor detects state change Continu
158. e Printer e Clear OR e Holographic g HDP820 LC Card Printer Printing Preferences 4 Tx Magnetic Encoding Lamination K Panel Resin Card Device Options Image Color Image Transter Ribbon Type TEER Full Color Resin Black z Clear Holographic Resin Dither Optimized for Graphics HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 189 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting for the color matching Allows selection of the color matching option that best fits the requirements of the print job Step Procedure 1 Select None a if interested in print speed rather than print color b if color correcting the image for printing has already been done or c if using third party color matching software OR Select Algebraic to allow the Printer Driver to make very simple fast color balance adjustments Note This option gives a natural looking image without slowing down the processing speed of the Printer Driver It also allows further customization of the printed color of the cards through the Image color tab OR Select Monitor to allow the Printer Driver to make color corrections similar to the Algebraic option but through a more complex color matching algorithm Note This option shifts colors more radically so the colors in the image will more closely match how they appear on screen S HDP820 LC Card Printer Printing Preferences _
159. e 183 507 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 524 RESTRICTED USE ONLY Dye Migration 507 Dye Sub Intensity slide 201 dye sub printed image 201 Dye Sublimation 16 507 Dye Sublimation Cyan Panel 32 Dye Sublimation Magenta Panel 32 dye sublimation ribbon Panels 201 Dye Sublimation Yellow Panel 32 E E card 507 E card Docking Station 507 ECP Mode Enhanced Capabilities Port Mode 507 edge of card 462 Edge to Edge 507 Edge to Edge printing 235 EE Checksum Error 51 438 EE Error 52 EE Memory 507 EE Memory Error 51 438 EEPROM Electrically Erasable Programmable Read Only Memory 507 Ejecting Used Card 52 embedded contaminants 106 Emissions Standards 11 Enable MLE Support checkbox 223 Encode Station 27 Encoder smart card 507 Encoder Card Sensor 364 Encoder Settings 83 461 Encoder Wheel 286 288 324 334 508 encoding data 83 Encoding data sent in error 76 Encoding Errors 76 Encoding Feed Motor Assembly 357 encoding instructions 199 Encoding Mode 221 Encoding Module 78 82 Encoding Options 13 End Sentinel ES 227 Engine 508 Enhanced Communication Port ECP mode 61 EOF End Of Form 508 Fargo Electronics Inc EPP Enhanced Parallel Port 508 EPROM Electronically Programmable Read Only Memory 508 Error displayed on startup 90 Error Attention Screens 29 Escape sequence 508 ESD 164 245 259 ESD
160. e A high capacity storage device in a PC consisting of non removable magnetically encodable platters Hardware Physical components of a system such as the Printer the PC the power supply HDP High Definition The High Definition Printing process prints full color images onto Printing clear HDP transfer film InTM The HDP film is then fused to the card through heat and pressure via a heated roller The printhead is capable of 256 shades with a sharper print and better color match Head Abbreviation for printhead Heat sink A device used to dissipate heat into the ambient Heat Seal A resinous film transferred by the printhead onto the back of an HDP intermediate transfer film to facilitate adhesion HiCo High The coercivity value of magnetic media between 2500 4000 Oe Coercivity ISO 7811 6 Fargo s High Coercivity encodes at 2750 Oe HTML HyperText Markup Language A standard protocol used to format text files for use in a browser or on the Internet HTTP HyperText Transfer Protocol A standard protocol by which computers can transfer data compatible through multiple platforms IC Integrated Circuit An electronic device that contains many individual circuits interconnected and placed within a discrete package ID Identification An abbreviation for identification HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 Continued on the next page
161. e Manual Rev 5 0 27 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components LCD and Softkey Control Pad continued Component Description The Cancel button Use this button to cancel print jobs and reset the Printer for the next print job e This Cancel function will cancel all print jobs in the Printer and will completely reset the Printer In this case be sure to cancel the print jobs from the PC before pressing YES e Canceling all print jobs in the middle of a batch print will force the Printer to waste or delete any images that may already have printed on the HDP film Lr Caution To avoid this select the Print in Single Card Mode option from the Printer Driver before sending the next print job If a card is left within the Printer after a print job is canceled it will automatically be ejected The Pause button Use this button to pause the Printer at any time during operation Note the Printer will always finish its current task before pausing When the Printer is paused the LED Light will flash and the Pause softkey button will change to Resume Press Resume to continue Printer operation The LED Light This light works in conjunction with the Printer s LCD Display to help communicate the Printer s current status It is especially effective when you are too far away from the Printer to read the LCD Display The following explains how to interpret both LED Lights on the exterior
162. e Printer packaging when transporting the unit HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 163 RESTRICTED USE ONLY Fargo Electronics Inc Section 4 Printer Adjustments The purpose of this section is to provide the User with specific information on Printer adjustment procedures Safety Messages review carefully Symbol Critical Instructions for Safety purposes A Danger Failure to follow these installation guidelines can result in death or serious injury Information that raises potential safety issues is indicated by a warning symbol as shown to the below To prevent personal injury refer to the following safety messages before performing an operation preceded by this symbol To prevent personal injury always remove the power cord prior to performing repair procedures unless otherwise specified To prevent personal injury make sure only qualified personnel perform these procedures A Caution This device is electrostatically sensitive It may be damaged if exposed to static electricity discharges Information that raises potential electrostatic safety issues is indicated by a warning symbol as shown to the below To prevent equipment or media damage refer to the following safety messages before performing an operation preceded by this symbol To prevent equipment or media damage observe all established Electrostatic Discharge ESD procedures while
163. e and Gray Align YMC to print a test card 2 Examine the test card 3 Select MENU Setup Printer and Transfer Temperature 4 Record the Transfer Temperature value on the test card last printed 5 Adjust the Transfer Temperature value e Decrease the Transfer Temperature setting if the HDP Film appears to be creasing or wrinkling on the printed card OR e Increase the Transfer Temperature setting if the printed image has ragged edges where the HDP Film seems to have peeled off To ensure adequate transfer see Selecting the Appropriate HDP Printer Driver Settings procedure for the Tape adhesion Test in Section 3 page 179 and Conducting the Tape adhesion Test procedure in Section 3 page 181 6 Press SELECT to save the value 7 Print a test card as described in Step 1 8 Repeat Steps 1 to 7 until the Film transfers correctly to the card HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 458 RESTRICTED USE ONLY Fargo Electronics Inc Setting the Flattener Temperature The Flattener Temperature controls the heat of the Flattener Note The Flattener will straighten a card after the image has been transferred to it This may be adjusted from the LCD Menu or from the Image Transfer tab of the Driver Setting the Printhead Resistance Step Procedure 1 Locate the Printhead Setting Number on the bottom of the Printhead The number reads R XXXX 2 Sele
164. e built with fonts saved in the Printer memory so users of AS400 can write escape codes and print from the Printer ASCII American Standard Code for A standard for processing information in computer processors An 8 bit character set of 255 decimal numbers each assigned to Information numbers letters punctuation and special characters Interchange AT Refers to an IBM standard in early computing with regard to the chipset and function of the parallel port set up in the BIOS B Black Black Dye Sublimation Panels are distinguished from the black Panel using resin by the use of B for dye sublimation black K denotes resin black Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 502 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Term Definition Barcodes A Series of alternating black and white stripes of varying widths each character denoted by a set number and width of black stripes that allows characters to be optically read by a computer Batch print A file sent down from the computer that contains commands to print a number of cards sequentially Battery Back up A power supply that can keep AC electronic equipment running for a short time when power is interrupted allowing enough time for the user to save data and close the machine properly Bi directional A communication sta
165. e sure the Printer Driver is installed correctly Note Especially if an obsolete Driver was recently removed d Be sure the correct setup options within the Printer Driver are selected e Confirm that the Driver is current by checking at www fargo com 3 Verify the use of an inadequate data cable a Use a double shielded parallel cable no longer than six feet in length Note Data transmission failure can be attributed to a long or faulty parallel cable b Use a double shielded I EEE 1284 compliant cable to reduce the effect of radio emissions from computers monitors and other equipment that may broadcast Radio frequency interference RFI Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 60 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Communication Errors continued Step Procedure 4 Determine if there is interference from an external device a Do not use an A B switch box dongle key or other peripheral in line with the parallel cable If using a switch box dongle key or other peripheral remove it while testing communication between the computer and the Printer If needed replace the switch box dongle key or other peripheral once it is determined that the cause of the interference is not the switch box or peripheral Alternative Add a second parallel port into the computer if a second Printer is required Determine the proble
166. eception the operator is required to take whatever steps are necessary to correct the interference ITS EMC The Card Printer has been tested and complies with EN55022 Class B 1995 and EN82082 1 1997 standards for EMI emissions Note Based on the above testing the Printer manufacturer certifies that the Card Printer complies with all current EMC directives of the European Community and has placed the CE mark on the Card Printer License Number J99032510 TUV GS The Card Printer has been tested and complies with IEC950 and bears the TUV GS mark License Number S9971826 UL The Card Printer is listed under UL 1950 INFORMATION TECHNOLOGY EQUIPMENT File Number E145118 Volume 1 Section 15 Agency Listings Term Description Emissions CE FCC CRC c1374 BSMI ITS EN 55022 Class B 1995 FCC Class Standards B EN 82082 1 1997 Safety UL 1950 CSA C2 2 No 950 95 and TUV GS EN 60950 A1 A4 A11 Standards HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 11 RESTRICTED USE ONLY Fargo Electronics Inc Technical Specifications Term Description Accepted Standard Card Sizes HDP820 820 LC e CR 80 3 375 in x 2 125 in 85 6mm x 54mm corresponds to ID1 e CR 90 3 63 in x 2 37 in 92mm x 60mm e CR 100 3 88 in x 2 63 in 98 5mm x 67mm laminate with CR 90 or CR 100 size PolyGuard only if laminating with HDP800 Series LC
167. ect a preset test image Note These images help to determine if the Printer is functioning properly 2 Scroll to the desired test image from the Select Test Image options and press the Select button Reviewing the Gray Align YMC K Self Test Step Procedure 1 Use this card to determine Image Placement and confirm that the Printer is working properly See Printer Setup in Section 8 page 447 Note The image consists of sixteen 16 gray scale boxes and alignment arrows The gray boxes are composed from a composite of YMC color panels HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 132 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Color Resin YMCK Self Test Step Procedure 1 Use this card to determine Image Placement and confirm that a the image colors are properly reproduced and b the Resin Panel is printing properly Note The Image consists of twelve spot colors YMC and RGB as well as gray density bars and thin resin lines HI Reviewing the Color Bars YMC Self Test Step Procedure 1 Use this card to confirm that image colors are properly reproduced Image consists of sixteen graduated steps of RGB and YMCK Note This print will provide maximum image size giving complete card coverage on a CR 80 sized card HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 133 RESTRICTED USE ONL
168. ectronics Inc Section 5 Cleaning This Section deals with the Printer s internal and external maintenance in regards to the unit s cleaning and general upkeep Note The Printer should be cleaned on a regular basis to insure that the Printer consistently produces high quality output A Danger Be sure to disconnect the Printer s power cord whenever performing any type of maintenance procedure unless otherwise directed IMPORTANT Fargo Card Printers require highly specialized Print Ribbons to function properly To maximize Printer life reliability printed card quality and durability you must use only Fargo Certified Supplies For this reason your Fargo warranty is void where not prohibited by law if you use non Fargo Certified Supplies To order additional materials please contact your authorized reseller Using the Required Supplies For the maintenance procedures outlined for the Printer you will need a Printer Cleaning Kit available from the reseller This optional kit includes the following e Printhead Cleaning Pens pre moistened with 99 99 isopropyl alcohol for cleaning the Printer s Printhead e Cleaning Cardss with an adhesive backing for cleaning the Printer s Cleaning Rollers e Cleaning Pads pre moistened with 99 99 isopropyl alcohol for cleaning the Printer s Platen Rollers Card Feed Rollers and general inside and outside area A Danger As with any electronic device internal components of the Printer such
169. ectronics Inc Using the Encoding Mode option Use the Encoding Mode option to specify which magnetic encoding standard to use e The HDP Card Printer can be installed with one of two types of factory installed Magnetic Stripe Encoding Modules e Change the encoding mode and coercivity setting or modify the ISO standards for tracks 1 2 and 3 by correctly modifying these Magnetic Encoding options Step Procedure 1 Select the ISO Standard Encoding Module with a dual coercivity high or low encoding head Note By default the Printer Driver is set to encode according to ISO standards onto high coercivity Magnetic Stripes OR Select the JIS Il Standard Encoding Module commonly used in Japan Select the JIS Il mode to encode only Track 2 Note 1 The JIS Il option provides encoding compatibility with the JIS C 6220 Type Il cards commonly used in Japan No encoding customization options are available with the JIS II mode Note 2 A JIS Il Magnetic Head must be installed in the Printer to use any of the JIS II options in the Driver Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 219 RESTRICTED USE ONLY Fargo Electronics Inc Using the Encoding Mode option continued 2 HDP825 LC Card Printer Printing Preferences me 2 x Card Device Options Image Color Image Transfer Magnetic Encoding Lamination K Panel Resin Enco
170. ed 10 92 150285 Motor Card Motor only Fed D850425 Assembly Stepper Motor Stepper with 91 65 Motor pulley Printheads 81570 Kit Printhead Kit Printhead HDP 699 00 Replacement HDP D840854 Assembly Assembly 0 00 Printhead Printhead Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 489 RESTRICTED USE ONLY HDP8xx Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 Fargo Electronics Inc Category Part Part Description Alternate Part MSRP List Number Description Price Rollers 840102 Assembly Cleaning Roller Cleaning 194 42 Roller Assembly 840220 Roller Card Inverter Roller Flip Table 49 21 Roller 84031411 Roller Card Full Roller Full Card 48 69 Width 840320 Roller Platen LAM Roller Platen 45 63 D840811 Roller Platen Print Roller Platen 82 94 Transfer orange D840926 Roller Card Support Roller Card 112 06 Support D840993 Roller Input Feed Roller Card Feed 51 94 High COF D850308 Roller Cleaning Roller Cleaning 38 16 Driven Driven D850415 Roller Card Feed Roller Card Feed 35 30 HDP 825 ONLY D850466 Roller Card Feed Roller Card 29 32 Black Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 490 RESTRICTED USE ONLY HDP8xx Series ID Card Printer Recommended Spare Parts List Effective Date
171. ed on the next page Lamination Station Securing 4 E Latches Lamination Top Cover o Lamination Em LED Light Button Resume pause Button Card Output P Hopper Rejection Card Hopper HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 xii RESTRICTED USE ONLY FARGO Electronic Inc Reviewing the Lamination Module Sequence of Operations continued Step Process 6 The Card Feed Motor and the Lamination Ribbon Motor activate for the length of the card 7 The Lamination Roller Lift Motor cycles until the Lamination Roller Lift Sensor detects state change 8 The card is fed back to the Flipper Table 9 The Flipper Table Clutch engages 10 The Flipper Table Motor activates until the Card is inverted based on the Flipper offset setting 11 The Flipper Table Clutch disengages 12 The card is fed off the Flipper Table 13 The Flipper Table Clutch engages 14 The Flipper Table Motor activates until the Flipper Table is homed 15 The Flipper Table Clutch disengages 16 Repeat Steps 2 through 7 17 The card is fed out of the Printer HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 xiii RESTRICTED USE ONLY FARGO Electronic Inc Reviewing Lamination Module Boot up Sequence Step Process 1 The Lamination Headlift turns until the head up position is returned fr
172. elect button Note This should cause the Flipper Table to attempt to home itself If this is not the case continue to Step 3 below Test the Flipper Home Sensor 140407 a Remove the screws from the rear cover b Tilt the back cover outwards from the Printer c Using a Digital Voltmeter connect the negative lead to its ground d Connect the positive lead to Pin 4 of J58 on the Lamination Board e f covered the voltage should read approximately 9 VDC e f uncovered the Sensor should read 3 0 to 3 3 VDC e If the voltages from the Flipper Home Sensor do not match replace the Sensor HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 72 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Cards being fed improperly off the Flipper Table Symptom Cards feed off the Flipper Table over the card feed path or under the card feed path Step Procedure 1 Adjust the Flipper Offset a Select Menu on the LCD Display b Select Setup Printer and Flipper Offset c Change the setting in small increments Note A positive adjustment will lower the side of the Flipper Table closest to the Exit Hopper d Press Select to save the new value 2 Ensure the roller tension Spring is tensioned properly a Manually insert a card under the Flipper Table Roller b There should be sufficient resistance from the tensioning Spring to hold the card in place when rotating the Flipper Table
173. en the Printer asks if you would like to continue press YES a Wait while the Printer restarts into the System Upgrade mode b Verify that the interface cable is securely connected to both the Printer and the computer and press the START button e The Printer will wait up to 60 seconds to receive the Firmware update before timing out e The clock will be indicated on the LCD Display From the Firmware Updater software click the Send Update button to bring up the Firmware Updater dialog box as shown on the next page Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 471 RESTRICTED USE ONLY Fargo Electronics Inc Updating the Main Firmware continued Firmware Updater ersion 3 0 6 Download Update File Select Update File Send Update File Firmware Updater xj i The print spocler ts sending Firmware Update data to your printer Please refer to the LOD display on your printer For update completion ratification Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 472 RESTRICTED USE ONLY Fargo Electronics Inc Updating the Main Firmware continued Step Procedure 8 Wait The Firmware update will now take a few minutes Check the Printer s LCD for the status Note When the update is complete the LCD will indicate if the update was successful 9 If the Upgrade Successful i
174. ening the Card Lamination Module continued Step Procedure 3 To close the Lamination Station push the Lamination Station down until its blue Securing Latches close securely Note The Lamination Station must be closed securely in order for your Printer to operate It is also recommended that the Top Cover be closed whenever laminating for reliability and safety reasons HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 139 RESTRICTED USE ONLY Fargo Electronics Inc Loading the Overlaminate The loading process for both the Thermal Transfer Film and the PolyGuard Overlaminate material is the same Refer to the following steps to load either type of overlaminate into the Printer A Danger Do not touch the metal Lamination shield or the Lamination Roller when loading overlaminate You will burn yourself Step Procedure 1 Open the Lamination Module s Top Cover and Lamination Station 2 Remove the overlaminate from its packaging 3 The supply end of the overlaminate roll is the side containing the fresh unused portion of the overlaminate The take up end is the other side Take Up Roll Supply Roll HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 140 RESTRICTED USE ONLY Fargo Electronics Inc Loading the Overlaminate continued Step Procedure 4 a Place the supply end of the overlaminate roll in between the two black
175. ensity slide by clicking and dragging the slide s box e Move the slide to the left to cause less heat to be used in the printing process thus generating a lighter print OR e Move the slide to the right to cause more heat to be used thus generating a darker print Note This slide only affects those images printed with dye sublimation ribbon Panels YMC Magnelio Enoeding Lemmaton K Pana Reon Cad Devico Options Image Color Image Trarsfei Ribbon Type vac Full Color 2 Resin Black Fim Type Clear bA Color Matching algebraic z None Resin Dikha PExEL Magenta Balance j 22 Cyan Balance 34 Dye Sub Intensity YMC Resin Heat K ee 0 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 201 RESTRICTED USE ONLY Fargo Electronics Inc Using the Image color tab continued Step Procedure 4 Control the amount of heat the Printer uses when printing with the resin black Panel by adjusting the Resin Heat slide e Move the slide to the left to cause less heat to be used in the printing process causing resin images to be lighter or less saturated OR e Move the slide to the right to cause more heat to be used causing resin images to be darker or more saturated Note This control can be helpful for fine tuning the sharpness of resin text and bar codes Continued on the next page Magnetic Encoding Lamination K Panel Resin Cad Devi
176. er table Spring 0 92 A80Dx 1 0L x 036 150074 Spring COMP Hub Spring 0 92 A80Dx 1 0L x 036 150093 Spring EXT 25 x Dancer Springs 1 72 018 x 1 5 150240 Power Supply Power Supply 308 75 Switching 150W Switching 150W 150240 Power Supply Board Power 308 75 Switching 150W Supply 510885 Software INSTL CD Software 0 00 Professional 2 installation CD 510890 E Card Software CD E card Developers 0 00 CD Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 484 RESTRICTED USE ONLY HDP8xx Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 Fargo Electronics Inc Category Part Part Description Alternate Part MSRP List Number Description Price Misc 810455 Spring Spring 2 22 Hardware Thermocouple Thermocouple 810480 Spring Card Idler U Shaped Springs 1 54 810492 Encoder Wheel Encoder Wheel 12 81 Ribbon Drive 810492 Encoder Wheel Encoder Wheel 12 81 Film Drive 840104 Assembly Magnetic Head 222 37 Magnetic Head 3 Channel HI CO 840255 Link LAM Cover Link Lam Cover 8 13 840272 Spring Head Printhead Spring 15 80 FORCE 840274 Mount Printhead Printhead Bracket 6 44 Lower 840366 Gas Spring Gas Spring 68 90 D840507 Assembly Assembly 299 00 Magnetic Head JIS2 Magnetic Head JIS2 D840638 Deflector Ribbon Ribbon Deflector 0 00 PRN D840698 Deflector Ribbon Transfer Peal
177. er will display READY to indicate that the Printer is ready for operation Note The Printer will stay in this mode until it receives a print job or it is turned OFF If the Release Lever is unlocked the Release Lever Unlocked screen will appear to remind you this item is open If the Print and Transfer Stations are opened the Printer Open screen will appear Press either the Forward or Back buttons to move the Printer s card path rollers in the indicated direction Use the scroll buttons to select between moving the Print Side Card Rollers or the Input Side Card Rollers This is helpful when cleaning the Printer or if clearing jammed media In any of these screens the Printer will always display the Menu option above the center softkey button Press this button to access the Printer s menu options Note The Menu option is available only in the Ready Printer Open screens If the Printer is equipped with the Card Lamination Module and the Lamination Station is opened no LCD message will appear Instead the Lamination Module s LED will flash Note To move the Lamination Module s rollers push the Module s Cancel or Resume buttons If both the Print Station and Lamination Station are open the LCD s FORWARD and BACK softkey buttons will move ALL rollers In any of these screens the Printer will always display the MENU option above the center softkey button Press this button to access the Printer s menu options Note The MENU option
178. eriod of time the transfer temperature setting in the LCD is set too high 2 Adjust the Transfer Temperature setting a Press Menu on the LCD b Select Setup Printer scroll down and then select Transfer Temp from the menu c Reduce the current value by 5 d Press OK and exit out of the menu e Run a self test f Ifthe Transfer Cooling message still appears repeat steps a through e g If the Transfer Cooling message is not displayed continue printing 3 Verify if the Thermocouple has failed a Check the Thermocouple by using a Multimeter to check the leads across the Thermocouple Control C111 on the Lamination Board Note The voltage should be equal to the desired temperature degrees C divided by 100 with an accuracy of 10 degrees C e g 150 degrees equals 1 5VDC b If the correct value is not retuned the Thermocouple may need to be replaced 4 Verify if the Lamination Board is functioning properly Replace the Lamination Board as needed See the Replacing the Lamination Board 140402 procedure in Section 5 page 368 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 97 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Card Jam Error Message Symptom Card may be blocked or restricted in the Transfer Station Step Procedure 1 Continue printing with the same card by leaving the power ON and opening the Print Station and Transfer Station a Press the
179. erlaminate from the supply roll onto the take up roll Note Ensure the overlaminate is passing beneath both the supply and take up rolls Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 101 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Overlaminate Jam continued Step Procedure 4 a Once the jam is cleared replace the media and close the Lamination Module b Press the Lamination Module s Resume button to retry Lamination depending on the error and how far you moved the card or overlaminate this may not be possible c Press the Lamination Module s Cancel button to reset the Lamination Module for the next card Note The Lamination Module buttons only affect the card in the Lamination section The Printer s LCD softkey buttons affect any card in either the Print Station or the Lamination Station e g the Lamination Module s Cancel button cancels only the Lamination job the Printer s CANCEL softkey button cancels both the print and Lamination jobs e f both the Print Station and Lamination Station are open the LCD s FORWARD and BACK softkey buttons will move all rollers e f only the Lamination Module is opened only the Lamination Module buttons will move the Lamination rollers HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 102 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Card Lamination Pla
180. erosol can delivered by through nozzle at a high speed Used in the Printer to blow out debris Contrast The degree of difference in luminance of two areas Control Panel The Panel on the Printer from which the user can control Printer functions The Printer is usually composed of the control buttons and an LED or LCD Display HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 Continued on the next page 504 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Term Definition CR79 A card dimension standard of 2 0625 L X 3 3125 W 0 002 W 0 005 L or 52 400 X 84 150 mm CR 80 A card dimension standard of 2 125 X 3 370 0 002 W 0 005 L or 53 975 X 85 598 mm CR 90 A card dimension standard of 2 375 X 3 625 0 002 W 0 005 L or 60 325 X 92 075 mm CR 100 A card dimension standard of 2 625 X 3 875 0 002 W 0 005 L or 66 675 X 98 425 mm Cursor The marker in the LCD Display Window that indicates the active selection Darkness A reference to color saturation DB 9 A 9 pin D shaped connector typically used in serial port interfaces DC Motor A Motor that works on DC with continuous motion DC Direct Current Electronic flow that is unidirectional flowing from the positive to negative of a power source Default A setting or parameter that comes preset from the factory i
181. ers Service Manual Rev 5 0 Continued on the next page 517 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Term Definition Self test A pre determined print file used to confirm Printer operation typically sent from the Driver or stored in the Printer s memory Sensor An electro mechanical electro optical device used to indicate a change in state in the Printer such as when a card reaches a certain location Serial The transfer of data one bit at a time and in sequential order communications using a single wire Serial interface A sub D 9 pin input output port on the Printer used for serial communication with the PC for AS400 operating systems or for e card encoding SIMM Single In Line An array of memory chips attached to a printed circuit Board that Memory Module installs in a slot on the main Board Simplex Single sided printing SmartGuard An application from Fargo Electronics that allows users to prevent access to the Printer through the use of a personally encoded smart card SmartGuard SmartGuard is a Printer security option that uses a custom access card and a built in reader to restrict Printer access Only a valid access card can enable the Printer to print cards SmartShield This option allows the Printer to print custom security images on the card that reflect under a black or UV light source Smart Card Smart cards have a
182. ervice Manual Rev 5 0 449 RESTRICTED USE ONLY Fargo Electronics Inc Aligning the Print Offset This procedure positions the image correctly on the HDP Film Refer to the Preparing to adjust the Print Offset Transfer TOF and Transfer EOF procedure in Section 8 page 449 for proper sequence Step Procedure 1 Choose MENU Print Test Image and Gray Align YMC to print a test card 2 a Examine the test card The open end of the Outer Alignment Arrows should appear at the edge of the Film shown below as a dotted line b Go to step 5 on the next page to adjust the Print Offset if the test card does look like the display shown below 3 Select MENU Setup Printer and Print Offset 4 Record the Print Offset value on the test card last printed Outer Alignment Arrows Edge of Transfer Film TOF EOF Leading Edge Trailing Edge of Card of Card Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 450 RESTRICTED USE ONLY Fargo Electronics Inc Aligning the Print Offset continued Step Procedure 5 Measure the distance from the top edge of the transferred area to the top edge of the inward pointing arrows 6 Calculate the Print Offset value e Inches 32 Distance x 300 e Millimeters 32 Distance x 11 8 Example Inches 32 020 x 300 34 Note The result of this equation
183. ese settings unless directed to do so by Fargo Technical Support or instructions in this Service Manual Changing these settings may negatively affect Printer output Note Located on the back of the Printer is a label that states the factory defaults for all settings along with the Printer serial number a b Use these values to reset the Printer for Printer problems To adjust Print Offset Transfer Temperature Flattener Temperature or Image Darkness attempt to make these changes through the Printer Driver Image Transfer and Image color controls prior to changing the internal Printer settings Perform these four 4 procedures as a single alignment process Transfer Tension Print Offset Transfer TOF and Transfer EOF The goal of these procedures is to align the printed image and the HDP Film precisely with the edges of the card Note When aligned properly the edge of the card will fall directly between all of the Outer and Inner Alignment Arrows The numbers being entered for the settings are measured in Pixels The number of Pixels is equal to the measurement in inches multiplied by 300 Note For example 0 100 in multiplied by 300 equals 30 Pixels 0 1 x 300 30 The alignment test image is designed for setting these parameters Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 447 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Printer Set
184. etup Printer Scroll down to Encoder Settings c Change the Prox Setting from None to Installed 2 Check the appropriate software user s manual for specific encoding instructions if the encoding data was sent in error Resolving the No Smart Encoder Error Message Symptom The Printer is receiving encoding data but the Printer is not configured with this Encoder type Step Procedure 1 Verify that the LCD Setting are correct a Press Select on the LCD b Select Setup Printer Scroll down to Encoder Settings c Change the Smart Setting from None to Installed 2 Check the software user s manual for encoding instructions if the encoding data was sent in error HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 83 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Failed Smart Encode Error Message Symptom The card s smart chip was not encoded properly Step Procedure 1 Check to ensure that the cards are loaded with the smart chip facing up and are being fed into the Printer first 2 Verify that the card is entering the E card Docking station properly a b c d Open the front access door Send an encoding print job from the computer Watch the card feed into the Printer and enter the E card Docking Station If the card is not feeding into the E card Docking Station properly the Flipper Offset may need to be adjusted See Resolving the Card
185. f Card gt TE o Si Leading Edge gt lt gt K HDP Transfer Film Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 452 RESTRICTED USE ONLY Fargo Electronics Inc Setting the Transfer TOF continued Step Procedure 3 Record the Transfer TOF value on the test card last printed 4 Select MENU Setup Printer and Transfer TOF 5 Measure the distance from the leading edge of the card to the leading edge of the transferred image 6 Calculate the Transfer TOF value for inches or mm e Inches 40 Measurement x 300 e Millimeters 40 Measurement x 11 8 Example Inches 40 050 x 300 45 7 Adjust the Transfer TOF value 8 Press SELECT to save the value 9 Print a test card as described in step 1 10 Repeat Steps 1 to 9 until the test image is correctly positioned HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 453 RESTRICTED USE ONLY Fargo Electronics Inc Setting the Transfer EOF This procedure controls the point on the card at which the Transfer Roller lifts and ceases transfer Refer to the Preparing to adjust the Print Offset Transfer TOF and Transfer EOF procedure in Section 8 page 449 for proper sequence Step Procedure 1 Choose MENU Print Test Image and Gray Align YMC to print a test card 2 a Examine the test card Note
186. fourth digits in the serial number indicate the week the printer was built e g the digits 45 indicate week 45 of that year 80453289 The last four digits indicate the sequence number for the numeric order in which the printers were built Reviewing Example No 2 Serial Number A1280224 1 A1280224 The first two digits in the serial number indicate the year the printer was built e g the letter and digit A1 indicate the year 2001 A1280224 The third and fourth digits in the serial number indicate the week the printer was built e g the digits 28 indicate week 28 of that year A1280224 The last four digits indicate the sequence number for the numeric order in which the printers were built HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 479 RESTRICTED USE ONLY Fargo Electronics Inc Section 12 Reviewing Spare Parts Lists Reviewing Spare Parts List for HDP 800 Series Card Printer HDP8xx Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 For current pricing see http www fargopartner com support_services Category Part Part Description Alternate Part MSRP List Number Description Price Belts and 140212 O Ring 1 024 Belt O Ring Film 1 00 Gears Compound 23811 Motors 140212 O Ring 1 024 Belt O Ring 1 00 Compound 23811 Ribbon Motor 140212 O Ring 1 024 Belt Ribbon 1 00 Compound 23811 Lamination Drive O Ring
187. gnation of colored ribbon by the Panels of color in the order in which they are printed Yellow Y Magenta M Cyan C Black K Overlay O YMCKOK The designation of colored ribbon by the Panels of color in the order in which they are printed Yellow Y Magenta M Cyan C Black K Overlay O Black K used for backside black only printing HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 521 RESTRICTED USE ONLY Index A A B switch box 61 63 About button 237 absolute failure 183 AC Alternating Current 502 accelerated wear dye migration 181 Accepted Card Compositions 12 Accepted Card Thickness 12 Accepted Standard Card Size 12 access card 59 Access Card 58 502 Access Card Deleted 58 Access Card Ready 58 Accessories Program Group 61 Add Cards 50 adhesion 183 502 adhesives 178 Adjust Film Tension 120 Adjust Image Darkness 128 Adjust Image Position controls 205 Adjust Image Transfer tab 121 Adjust Printhead Bracket Adjustment Screws 116 128 Adjust the Transfer Tension procedure 122 Adjusting the Flipper Offset 71 73 78 Adjusting the Image Darkness 117 Adjusting the Ribbon Tension 115 Adjusting the Transfer Temperature 97 Adjusting the Transfer Tension 122 Agency Listings 11 Algebraic 190 502 Align ribbon error 85 Aligning Film 50 Aligning Ribbon 50 all Printers share all print jobs 197 ANSI Ameri
188. go Printer resolution RFI Radio Electromagnetic waves radiated by poorly shielded cables or Frequency electronic devices that interferes with the operation or data Interference transfer of another device RGB The three primary colors of the luminance or additive model Red Green Blue Combinations of these three colors can produce practically all the colors of the spectrum that humans can detect Computer monitors operate on an RGB model Ribbon The dye impregnated film that is used for color printing Ribbon cable Parallel wires held flat in a row by plastic insulation RibbonTraq A Fargo Electronics method of placing bar code like marks on the transition area between color Panels These marks are arranged for detection by a reflective Sensor array for the identification of ribbon type and the ribbon position RMA number Return A number acquired from Fargo Support which authorizes the return of merchandise for repair or credit number Roller Elements of the Printer used for the transport of media consisting of a rotating steel shaft for ribbon or a rotating steel shaft with a rubber cylinder installed at the shaft midpoint for moving cards RS 232 An interface standard established in 1969 by the Electronic Industries Association regarding the connecting of computer peripherals Saturation A measure of the degree of color from gray with the same brightness HDP 800 Series Card Printer Encod
189. h quality wrist strap grounded to avoid potential damage To prevent equipment or media damage always remove the Ribbon and Cards from the Printer before making any repairs unless otherwise specified To prevent equipment or media damage take jewelry off of fingers and hands as well as thoroughly clean hands to remove oil and debris before working on the Printer HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 136 RESTRICTED USE ONLY Fargo Electronics Inc Opening the Card Lamination Module Step Procedure 1 Open the Top Cover of the Lamination Module by lifting up on its bottom edge and tilting it back into its fully open position Note The Top Cover is designed to hold its last position to prevent it from falling shut HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 137 RESTRICTED USE ONLY Fargo Electronics Inc Opening the Card Lamination Module continued Step Procedure 2 Open the Lamination Station by lifting up on the blue Securing Latches Pull the Lamination Station up and back into its fully upright position Note the Lamination Station is also designed to hold its last position to prevent it from falling shut HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 RESTRICTED USE ONLY Fargo Electronics Inc Op
190. hanging the Encoder Settings 461 Setting the Magnetic TOF 462 Setting the Magnetic TOF 463 Adjusting the Flipper Offset 464 Adjusting the Lamination Flipper Offset 464 Adjusting the LAM TOF and EOF 465 Adjusting the Lamination Sensor Calibration 466 Adjusting the Lamination Temperature Setting 466 Show the Error Count 466 Using the Show Card Count option 467 System Upgrade Firmware Upgrade 467 Section 10 Firmware Updates 468 Firmware Updater Application Program 468 Downloading Firmware Updates 470 Updating the Printer s Firmware 471 Updating the Main Firmware 471 Updating the LCD Firmware 474 Firmware Upgrades as of 10 07 03 476 Section 11 Fargo Technical Support 478 Contacting Fargo Technical Support 478 Reading the Serial Numbers on a Fargo printer 479 Finding out when a Fargo Card Printer was manufactured 479 Reviewing Example No 1 Serial Number 80453289 479 Reviewing Example No 2 Serial Number A1280224 479 Section 12 Reviewing Spare Parts Lists 480 Reviewing Spare Parts List for HDP 800 Series Card Printer 480 Reviewing Spare Parts List for Card Lamination Module 494 Glossary of Terms 502 Index 522 Appendix A Engineering Drawings 535 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 8 RESTRICTED USE ONLY Fargo Electronics Inc Appendix B Technical Updates 535 Appendix C Miscellaneous 535 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 9 RESTRICTED USE ONLY Section 1 Specificati
191. harges Information that raises potential electrostatic safety issues is indicated by a warning symbol as shown to the below To prevent equipment or media damage refer to the following safety messages before performing an operation preceded by this symbol To prevent equipment or media damage observe all established Electrostatic Discharge ESD procedures while handling cables in or near the Circuit Board and Printhead Assemblies To prevent equipment or media damage always wear an appropriate personal grounding device e g a high quality wrist strap grounded to avoid potential damage To prevent equipment or media damage always remove the Ribbon and Cards from the Printer before making any repairs unless otherwise specified To prevent equipment or media damage take jewelry off of fingers and hands as well as thoroughly clean hands to remove oil and debris before working on the Printer HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 RESTRICTED USE ONLY FARGO Electronic Inc HDP 800 Series Card Printer Encoders Overview Reviewing the HDP 800 Series Block Diagram 30 47 2 j 27 a 28 Motors Sensors 1 Card Input 13 Card Low 32 Card Input Roller 2 Card Feed Stepper 14 Card Detection 33 Cleaning Cartridge 3 Flipper Stepper 15 Flipper Table Card 34 Flipper Tab
192. has occurred in the permanent circuit memory Step Procedure 1 Reboot the Printer 2 If the problem persists the Main Print Board will need to be replaced See Replacing the Main Print Board A000271 procedure in Section 5 page 367 for instructions 3 As an alternative to replacing the Main Print Board the chip U16 080239 may be replaced Note Fargo recommends that only a qualified electronics technician perform this procedure Resolving the EE Checksum Error Symptom An error has occurred in the permanent circuit memory Step Procedure 1 Reboot the Printer 2 If the problem persists the Main Print Board will need to be replaced See Replacing the Main Print Board A000271 procedure in Section 5 page 367 3 As an alternative to replacing the Main Print Board the chip U16 080239 may be replaced Note Fargo recommends that only a qualified electronics technician perform this procedure HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 438 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the DRAM Memory Error Symptom An error has occurred in the removable memory Module SIMM Step Procedure 1 Reboot the Printer 2 If the problem persists remove the rear cover and ensure that the SIMM 080229 is seated properly 3 If the memory Module is not seated properly remove the Board and reinstall 4 If the installat
193. hat has alternating patch configurations on the same roll e g full patch on the front of the card and half patch on the back Continued on the next page Lamination Type Lamination Side Film Lamination Film Lamination No Lamination 0 6 PolyGuard Lamination Transfer Dwell Time 22 apc 1 0 PolyGuard Lamination PoljGuard Alternating Patch Sensors Transfer Temperature 125 5 Centigrade Default HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 241 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Transfer Dwell Time and Transfer Temperature Step Procedure 1 Adjust the Transfer Dwell Time and the Transfer Temperature to control the Lamination Dwell Time or through put speed of a card in seconds inch and the Lamination Temperature Selecting the Sensors button and Defaults button Step Procedure 1 Select the Sensors button to bring up a separate dialog box to calibrate the Lamination Sensor See the next page 2 Click on the Default button to return the Transfer Dwell Time and Transfer Temperature to the Default settings for the Lamination Type being used Lamination Side Lamination Type No Lamination Transfer Dwell Time 2 2 seconds inch z Sensors Tranter Temperature 125 5 Centigrade Default Cancel Apply Help HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 242 R
194. he Print and Transfer Station b Use the arrows on the LCD panel to move the card forward or backward to free the card 2 Inspect the Card Feed Roller Motors for proper operation a Leave the power ON and open the Print and Transfer Stations b Press the FORWARD button to advance the card or the BACK button to reverse the card Use these buttons to move the card through the Encoder 3 Ensure that the cards are feeding into the Encoding Module properly a Reset power on the Printer to clear any error messages b Open the Front Access Door c Select the Menu from the LCD d Select the Print Test Image from the menu e Select the Magnetic Test from the menu f Acard is then fed from the input hopper onto the Flipper Table and rotated into the Encoding Module If the card appears to jam against the components of the encoding assembly the Flipper Offset may need to be adjusted 4 Adjust the Flipper Offset a Select the Menu on the LCD Display b Select the Setup Printer Scroll down to the Flipper Offset c Change the setting on small increments Note A positive adjustment will lower the side of the Flipper Table closest to the Exit Hopper d Press Select to save the new value HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 78 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Printer being unable to read Encoded Magnetic track Data problem Step Procedure 1 Verify that the
195. he five 5 Ribbon Sensors 140404 and 140407 at their connection to the main Board c Use a Multimeter to ground the negative lead to the chassis and put the positive lead on pins 3 5 7 9 and 11 of J65 on the main Board d Place a RibbonTraq mark over the Ribbon Sensor Note The voltage should be less than 1 VDC e Remove the RibbonTraq mark from the Ribbon Sensor Note The voltage should be greater than 3 5 VDC f Replace the Sensor if the voltages are incorrect Resolving the Headlift Error Message Symptom The Printer was unable to raise or lower the printhead Step Procedure 1 Press the Resume button to retry 2 If the Headlift does not rotate check the Headlift Motor to ensure that it is running 3 If the Headlift Motor is not running replace the Headlift Motor as described in the Replacing the Headlift Motor Assembly D840980 procedure in Section 5 page 292 4 If the head cycles but does not stop at the position every time check the Headlift Sensor as described in Sensor Testing in Section 7 page 440 5 If the Headlift Sensor is failing replace it See the Replacing the Headilift Sensor Assembly procedure D804983 in Section 5 page 294 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 88 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Printer pausing between Panels problem Symptom The Printhead Fan is not operating properly
196. his window to the directory of where the latest HDP Firmware is located on the PC This Firmware file will always have a s19 extension Once the Firmware file is selected the HDP needs to be restarted into SYSTEM UPGRADE mode e Atthe PRINTER READY screen select the menu option e Then press the DOWN arrow until the brackets are around the System Upgrade e Then press the Select option e When the screen Displays Are you sure you want to continue Select YES e When the Printer reboots it will be in System Upgrade mode and will begin to count down from 60 seconds to 0 sec e As the HDP LCD display begins its countdown click the Print button on the 32 bit Print Spooler The HDP Display should then run through its Update process After it has completed reboot the Printer Turn the power off and then back on and then test HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 64 RESTRICTED USE ONLY Card Feeding Errors Resolving the Card Feeding problem HDP820 820 LC Symptom Two or more cards are feeding at the same time or cards are not feeding Fargo Electronics Inc properly Step Procedure 1 Remove the stack of cards Note Ensure that the cards are not sticking together Manually separate them if needed Lr Caution Do not touch the surface of the card because dirt or oil from the hands can damage card quality 2 Slide the left wall of the Input Hopper to the
197. hted with a dotted outline b Delete an area by using the Defined Area arrows to select the area and click on the Delete button Note If all areas are deleted the K Panel Resin options will automatically be deselected 2 Select the Print YMC Under K option to print all black in the designated areas with the Yellow Y Magenta M and Cyan C ribbon Panels directly beneath the resin black K Panel Note Select this option if printing resin black text or barcodes onto a colored background to provide a more gradual transition between the two OR Select the Print K Only option to print all black in the designated areas only with the resin black K Panel or to print resin black onto a white background to maximize the sharpness of printed text and barcodes Print All Black With E Fanel T Full Card M Defined Areals T Undefined Area s Print YMC Under K ie Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 216 RESTRICTED USE ONLY Fargo Electronics Inc Selecting the Print YMC under the K and Print K Only options continued S HDP820 LC Card Printer Printing Preferences l 2 x Card Device Options Image Color Image Transfer Magnetic Encoding Lamination K Panel Resin CR 80 Card Size f Front C Back i inches i mm Defined Area Da dh Direction Card Travels Through Printer Delete Print All Black with K Fanel T Full Card I
198. ibed in the remainder of this section 010 7 25mm space Internal Card Guide HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 148 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Internal Card Guide The Internal Card Guide is what holds the card in position as it feeds through the Card Lamination Module This guide is factory set to handle standard CR 80 sized cards To adjust this guide please refer to the following steps Note If adjusting for an oversized card you must also adjust the Printer s Internal Card Guide Step Procedure 1 Slightly loosen the two 2 screws which fasten the Internal Card Guide to the Printer s main chassis Continued on the next page Ssa u EN Internal Card Guid Blank Card Screws HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 149 RESTRICTED USE ONLY Fargo Elec
199. ication program that supports a multiple page document duplex printing Note The program must be able to send down two or more separate pages to be printed within the same document Print a full color ID format on the front of the card and Monochrome text or bar codes on the back by creating e the frontside of the card on page 1 of the document e the backside on page 2 Note The Printer Driver will always place all odd numbered pages on the front side of the card and all even numbered pages on the back side with this option selected Ribbon Type YMA Full Color Resin Black Fimtye cer i Color Matching Algebraic 0 SM Resin Dither Optimized for Graphics Print in Single Card Mode Split 1 Set of Ribbon Panels Tl Link Card to Print Job Print Back Side First I Disable Printing J Print Back Side Only Rotate Front 180 Degrees Rotate Back 180 Degrees HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 192 RESTRICTED USE ONLY Fargo Electronics Inc Using the Split 1 Set of Ribbon Panels option Use this option to provide the most economical means of printing a dual sided card since a single set of ribbon Panels is essentially split to print both the front and backsides of a card Step Procedure 1 Select this option to automatically print full color on the front of a card and resin black on the back of a card using either of the Full color YMCK or YMCKK Pri
200. ies Card Printer Encoders Service Manual Rev 5 0 470 RESTRICTED USE ONLY Fargo Electronics Inc Updating the Printer s Firmware Now that you have installed and opened the Firmware Updater program and downloaded the firmware update file you can begin updating your printer s firmware It is important to note that there are two types of Firmware for certain Fargo Printer models the Main Firmware and the LCD Firmware each of which has a slightly different update process Updating the Main Firmware Step Procedure 1 If you haven t already done so select Start gt Programs gt Fargo and open the Firmware Updater program From the Firmware Updater program click the Select Update File button as shown on the next page in the Firmware Updater Version 3 0 6 window Go to the folder in which you saved the update file select it and click Open Note The file name location and version will appear in the Firmware Updater window as shown on the next page Click the Select Printer button and select the specific Fargo Printer model click OK Once your printer model has been selected the Send Update button will become active At this time the Printer must be prepared to receive the Firmware update file To do this make sure the Printer is powered ON and in its READY mode Then press the Printer s MENU button Use the scroll buttons to scroll down to the System Upgrade option and press SELECT Wh
201. ific Printer model as shown here Step Procedure 1 Once the existing Printer Driver is deleted the updated version can be installed The best way to get Printer Driver updates is to download them from the Fargo website 2 a To download the latest Printer Driver version click on the Printer Driver s highlighted exe file name on the web site You will then be prompted to Save this program to disk Fargo s downloadable Printer Driver files have names ending in exe and are self extracting Zip archives Note A Zip archive is a package containing one or more files that has been zipped to make it smaller and provide easy downloading of numerous files simultaneously An archive that is self extracting is capable of unzipping itself b Click OK then choose the folder in which you would like to save the Printer Driver file Note You may want to save it in an empty folder to prevent mingling its files with others already on the computer c Once the file has completely downloaded to the computer unzip the contents of the file by simply double clicking on it Note The archive will unzip itself revealing its contents as a new list of files within the folder 3 To install click the Start button point to Settings and select Printers 4 Double click on the Add Printer icon 5 Follow the on screen instructions to begin installation Note When prompted click on the Have Disk button the Install From Disk windo
202. ime unlimited pass Weight HDP820 825 70 Ibs 31 8kg HDP820 LC 825 LC 87 lbs 39 5kg LC Module 21 lbs 9 5 kg HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 15 RESTRICTED USE ONLY Fargo Electronics Inc Functional Specifications The Card Printer utilizes two different yet closely related printing technologies to achieve its remarkable direct to card print quality for dye sublimation and resin thermal transfer The Card Printer will print from any IBM PC or compatible running Windows 98Se Me Windows NT 4 0 Windows 2000 or Windows XP Pro The following describes how each of these technologies works Function Description Dye Dye Sublimation is the print method the Card Printer uses to produce Sublimation smooth continuous tone images that look photographic Note This process uses a dye based ribbon roll that is partitioned by a number of consecutive color Panels Process colors The Panels are grouped in a repeating Series of three process colors yellow magenta and cyan YMC along the entire length of the Print Ribbon Panels The Printer always prints the yellow Panel first followed by the magenta Panel and the cyan Panel Printhead As the Print Ribbon passes beneath the Printhead hundreds of thermal elements within the Printhead heat the dyes on the ribbon Note When these dyes are heated they vaporize and diffuse into the surface of the card A separate pass is
203. in the input hopper Ensure that the cards are loaded properly in the Input Hopper a Load the cards into the Printer by inserting them straight into the hopper and setting them on the feed Roller Verify that the Hopper Lift A000124 is operational a b Reset Power to the Printer Open the Card Hopper Door and watch to verify that the Hopper Cycles on startup If the Hopper does not cycle on startup remove the top cover and verify that the Hopper Lift Motor is plugged in properly If the Hopper Lift Motor is plugged in disconnect it and attach a 9 volt battery to the leads If the Motor turns replace the Main Board as needed Insert cards neatly stacked Card Hopper side view Cards ra 72 Card Feed Roller HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 70 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the stalled Cards on or at the Feed Rollers Step Procedure 1 Clear the stalled card a Open the Print and Transfer Station b Use the arrows on the LCD panel to move the card forward or backward to free the card Inspect the Card Feed Roller Motors for proper operation a Leave the power ON and open the Print and Transfer Stations b Press the FORWARD button to advance the card or the BACK button to reverse the card Note Use these buttons to move the card through the Printer c Verify that there is nothi
204. ing Rollers Note Alternatively placing the assembly under lukewarm water may clean the Cleaning Roller Once cleaned replace the Cleaning Roller Assembly and close the Front Access Door Caution Ensure that the Cleaning Roller Assembly is completely dry before reinstalling into the Printer Inspect the Card Feed Motors for proper operation a b Leave the power ON and open the Print and Transfer Stations Press the FORWARD button to advance the card or the BACK button to reverse the card Use these buttons to move the card through the Printer HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 67 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Card Feeding Errors HDP825 825 LC Symptom Two or more cards feed at the same time or the cards will not feed at all Step Procedure 1 Clean the Input Roller a Open the Printer s top covers and remove all cards and print Ribbons from the Printer Leave the Printer power ON and the top covers open throughout this procedure Note The card cleaning cartridge can also remain within the Printer during this cleaning process Use a cleaning card from the Printer Cleaning Kit and remove its adhesive backing paper Insert the cleaning card into the Exception Card Slot until the card stops e Verify that the longest non adhesive end of the cleaning card enters the Printer first and that the sticky side is faci
205. inter Scroll down to Encoder Settings c Change the Mag Setting from None to Installed 2 If the encoding data was sent in error check the in house software user s manual for encoding instructions HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 76 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Failed Magnetic Encode Error Message Symptom The magnetic stripe was not encoded properly Step Procedure 1 Check to ensure that the cards are loaded with the magnetic stripe facing down and towards the back of the Printer Check the Magnetic Offset Setting a Press Menu on the LCD b Select Setup Printer Scroll down to Encoder Settings c Select Magnetic TOF d Verify that the current value matches the default value listed on the back of the Printer Verify the Driver Settings a Ensure that the coercivity setting in the Driver corresponds to the type of cards that are being used e High Coercivity 2750 Oersted e Low Coercivity 300 Oersted Note See the Using the Magnetic Encoding tab procedure in Section 3 page 218 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 77 RESTRICTED USE ONLY Fargo Electronics Inc Removing the Card jam in the Printer s Magnetic Encoding Area Symptom A card is jammed in the magnetic encoding area of the Printer Step Procedure 1 Clear the jammed card a Open t
206. ion Allows you to manually tighten the HDP film after loading or whenever Knobs the Transfer Station is opened as shown below Continued on the next page Tighten Film Tension Knobs as indicated whenever Transfer Station is opened Film Tension Knobs Transfer Station HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 19 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components Access Card Slot to Parallel Interface Port continued Component Description Front Access Opens to allow access to the inside of the Printer Door LCD Display Displays the current status of the Printer LED Light Indicates the Printer ON OFF pause and error conditions Print Station Prints images onto the HDP film Printhead The component of the Print Station that actually does the printing This component is fragile and must not be bumped or touched with anything other than a cleaning pen Softkey Buttons Current function is displayed above the button and will change depending upon the Printer s mode of operation Continued on the next page softkey Buttons scroll Buttons VA HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 20 RESTRICTED USE ONLY Printer Components Access Card Slot to Parallel Interface Port continued Fargo Electronics Inc Component Description Scroll Buttons Used to scroll through menus and sub menus
207. ion appears correct and the error persists the SIMM 080229 on the Main Print Board will need to be replaced Resolving the RAM Memory Error Symptom An error has occurred in the permanent circuit memory Step Procedure 1 Reboot the Printer 2 If the problem persists replace the Main Print Board See Replacing the Main Print Board A000271 procedure in Section 5 page 367 3 As an alternative to replacing the Main Print Board the chip U17 080229 may be replaced Note Fargo recommends that only a qualified electronics technician perform this procedure Resolving the FPGA Error Symptom An unexpected hardware error has occurred Step Procedure 1 Reboot the Printer 2 If the problem persists the Main Print Board will need to be replaced See Replacing the Main Print Board A000271 procedure in Section 5 page 367 3 As an alternative to replacing the Main Print Board the chip U2 080066 may be replaced Note Fargo recommends that only a qualified electronics technician perform this procedure HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 439 RESTRICTED USE ONLY Fargo Electronics Inc Sensor Testing Step Procedure 1 Check the voltage to determine if a Sensor is working 2 a Test the voltage of each Sensor using ground GRD Chassis to the correct pin on each connector See Sensor Location and Voltages tab
208. is appears as an error see the Install new film and press Resume to the Resolving the Film Sensor continue errors procedure in Section 2 page 93 Flattener The card flattener was unable to See Resolving the Temperature Time out reach optimum temperature Timeout Error Message procedure in Section 2 page 99 FPGA An unexpected hardware error has See the Resolving the FPGA Error Timeout occurred procedure in Section 8 page 439 Head Lift The Printer was unable to raise or See the Resolving the Headlift lower the Printhead Error Message in Section 2 page 88 Head Please enter a value for head See the Setting the Printhead Resistance resistance in the LCD Printer Setup Resistance procedure in Section Error menu 9 page 459 Head A hardware fault has prevented See the Resolving the Printhead Voltage Error setting the correct Printhead voltage Temp Error Message procedure in Section 2 page 90 Heat Source Off The Transfer Roller and Flattener were turned off to save energy while idle Press OK to turn the Heat source back on Initializing Indicates the Printer is beginning its See Printer Components LCD startup system check and Softkey Control Pad in Section 1 page 25 Job The Feed Module is out of sequence See Resolving a Job Mismatch Mismatch with the Transfer section error in Section 2 page 81 Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0
209. it may be necessary to adjust this setting to optimize the flatness of the cards Any changes made to the Flattener temperature will be saved upon exiting the Printer Driver setup Note If the Printer is equipped with a Lamination Module and Lamination is being used the Flattener will be disabled 2 Click on the Default button to return to the factory default setting Image Position Vertical J Fa o Horizontal fo A gt l Direction Card Travels Through Printer Transfer Dwell Time 2 0 seconds inch Transfer Temperature 175 0 Centigrade Flattener Temperature 75 0 Centigrade Default HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 208 RESTRICTED USE ONLY Fargo Electronics Inc Using the K Panel Resin tab Use this tab to adjust the CR 80 Card Size the Direction the Card Travels through the Printer the Print All Black With K Panel options and the Defined Areas Use this tab to control where the resin black K Panel of a full color ribbon is printed e f printing with a ribbon type that does not have a K Panel such as the YMC ribbon type all K Panel Resin options will be grayed out Resin black text is desirable due to its sharp saturated color and resin black barcodes are required to ensure readability when scanned by an infrared barcode reader Note The Printer Driver will automatically print all TrueType black text and TrueT
210. just the Card Flattener Step Procedure 1 Open the Card Lamination Module 2 Remove the overlaminate material if installed Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 143 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Card Flattener continued Step Procedure 3 If laminated cards are bowing upward turn the Card Flattener Adjustment Knob clockwise Note This pushes the flattener roller down to increase the reverse bending pressure For best results turn the knob one full rotation then print and laminate a test card Repeat this process as necessary 4 If the card is bowing downward the reverse bending pressure may be too great In this case rotate the adjustment knob counter clockwise Note Some card types have very low heat resistance and may not be acceptable for laminating Adjustment Knob HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 144 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Card Guide Rail If applying PolyGuard Overlaminate you may find that the individual patch from the overlaminate roll may be off center when applied to a card Note Although the patch placement will vary slightly from card to card they should never hang over the edge of the card e To center the vertical placement of these patches across the card width a me
211. k cards Since the dye sublimation and the resin thermal transfer print methods each provide their own unique benefits Print Ribbons are available in dye sublimation only and combination dye sublimation resin versions To make it easier to remember which Print Ribbons are which a letter code has been developed to indicate the type of ribbon Panels found on each ribbon This letter code is as follows Es Dye Sublimation Yellow Panel m Dye Sublimation Magenta Panel fe Dye Sublimation Cyan Panel Resi Resin Black Panel E Heat Seal Panel HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 32 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components Blank Cards A Caution Never run cards with a contaminated dull or uneven surface through the Printer Printing onto such cards will ultimately lead to poor print quality Always store the card stock in its original packaging or in a clean dust free container Do not print onto cards that have been dropped or soiled Type Description Card Size The HDP825 and HDP825 LC Card Printers accept only standard CR 80 sized cards 3 375 L x 2 125 W 85 6mm L x 54mm W with a thickness of 30 mil 030 762mm to 70 mil The HDP820 Card Printers accept CR 80 to CR 100 sized cards Card The Printer will print onto any card with a clean level and polished PVC Design surface Card Suitable cards must have a polished PVC surface free of fingerprin
212. k3 Enable MLE Support HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 224 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Shift Data Left Use the Shift Data Left option which applies to all tracks when selected Step Procedure 1 Select this option to shift the recorded magnetic data to the left hand side of the card s Magnetic Stripe Note This is useful in situations that require cards to be readable with insert type readers HDP825 LC Card Printer Printing Preferences 2 x Card Device Options Image Color Image Transfer Magnetic Encoding Lamination K Panel Resin r Encoding Mode Verification i50 JISII Auto Eject 1st Error L Manual Eject Each Error Retries 2 H M Coercivity HighCo C Low Co m Magnetic Track Selection LRC Generation C NoLRC Even Parity C Odd Parity Tacki Track2 Track 2 Enable MLE Support ee m Magnetic Track Options Bit Density Character Size ASCII Offset C 75 BPI 5Bits NULL C 128 BPI 7 Bits SPACE 210 BPI C Bits C ZERO Character Parity No Parity Even Parity Odd Parity Shift Data Left Default Cancel Apply Help HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 225 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the ISO Track Locations The magnetic Encoding Module encodes o
213. key buttons that appear below the LCD Buttons Display Their current function is indicated by the words appearing above them This function will change according to the Printer s current mode of operation e Press the corresponding softkey button under the choice you want to select If no word appears above a particular button this indicates it has no function in that particular mode of operation The Printer also has another type of button on its control pad called scroll buttons These buttons are located just to the right of the LCD Display e Use these buttons to scroll through help text to navigate through the Printer s menus and to adjust certain Printer settings LCD Display The Printer s LCD Display will change according to the Printer s current mode of operation System Check When the Printer is first powered ON the Printer s system check screens Screens will briefly appear to display and test the amount of installed Printer memory align the Print Ribbon and HDP film and lastly to display the READY screen and current Firmware version Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 25 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components LCD and Softkey Control Pad continued Component Description Ready Printer Open Screens Once the Printer has finished its system check and with the Print and Transfer Stations closed the Print
214. lay will prompt you to either press the RESUME button or the CANCEL button e Press the RESUME button to retry printing depending on the error and how far the card or ribbon have been moved this may not be possible e Press the CANCEL to reboot the Printer and cancel all jobs within the Printer s memory In this case cancel and resend the print job from the computer For best results cancel the job from the computer first then press the Printer s CANCEL button Resolving the Print Ribbon Error Message Symptom The Print Ribbon is not installed properly or has run out jammed broken or been damaged Step Procedure 1 See the Resolving the Ribbon Alignment Error Message procedure in Section 2 page 10 for details HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 86 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Print Ribbon Out Error Message Symptom The Print Ribbon has run out Step Procedure 1 Install a new ribbon and press Resume to continue Resolving the Wrong Print Ribbon Error Message Symptom The Print Ribbon installed in the Printer does not match the ribbon type selected in the Printer Driver Step Procedure 1 Verify that the ribbon is installed properly a Ensure that the ribbon is loaded with the supply side closest to the Card Output Hopper and rolling from the top of the spool to the top of the take up s
215. le cleaning If using a Printer with a Card Lamination Module attached wipe the Lamination Platen Roller clean as well 7 Replace the printing supplies and close the Print and Transfer Stations after the rollers are clean and completely dry Transfer Platen Roller HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 257 RESTRICTED USE ONLY Fargo Electronics Inc Section 7 Packing the HDP800 Series Card Printer The purpose of this section to provide the User with a specific packing procedure for the HDP 800 Series Card Printer Follow this instruction to pack the Card Printer for transport Step Procedure 1 Clean the inside of the Printer with deionized air Wipe it down with a lint free cloth 2 Clean the Printhead with a Printhead pen 3 Insert the cardBoard dancer stiffener into the base Module 4 Lock the Release Lever to secure the latch mechanism 5 Pack the Printer in the original carton and packing materials 6 Be sure to enclose any necessary paperwork test cards etc HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 437 RESTRICTED USE ONLY Fargo Electronics Inc Section 8 Board Level Diagnostics The purpose of this section to provide the User with specific Board Level Diagnostic procedures for Board Errors and Sensor Testing for the HDP 820 Card Printer Board Errors Resolving the EE Memory Error Symptom An error
216. le Roller 4 Lamination Stepper 16 Encoding TOF 35 Flipper Table 5 Print Stepper 17 Flipper Home 36 Encoding Module 6 Lamination Headlift 18 Card TOF 3 7 Encoding Feed Roller 7 Film Supply 19 Lower Film 38 Card Feed Roller 8 Film Take Up 20 Film Take Up Encoder 39 Card Feed Roller 9 Ribbon Supply 21 Thermocouple 40 Platen Roller 10 Ribbon Take Up 22 Film Supply Encoder 41 Flattener Roller 11 Print Headilift 23 Upper Film 42 Card Feed Roller 12 Stacker Lift 24 Ribbon Sensor Array 43 Flattener Cooling Fan 25 Ribbon Encoder 44 Lamination Roller 26 Print Headlift 45 Transfer Platen Roller 27 Thermistor 46 Printhead 28 Stacker Lift 47 Printhead Cooling Fan 29 Stacker Full 48 Film Cooling Fan 30 Cover Interlock 49 Card Input Hopper 31 Release Lever 50 Card Output Stacker HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 vi RESTRICTED USE ONLY FARGO Electronic Inc Reviewing HDP 800 Series Card Printer Sequence of Operations The following sequence describes a dual sided full color print job with magnetic encoding This Printer also has an optional Card Stacker installed Note The HDP825 825 LC Printers have two 2 Card Input Hoppers that load 100 cards in each Hopper Step Process 1 The File information is received from the PC 2 The Heater warms up and or maintains the heat on the hot Roller u
217. le on the next page b Block a slot Sensor with a card c Cover a reflective Sensor with a card 3 a Troubleshoot the Ribbon Sensor by using the RibbonTraq markss on the ribbon and Film to cover the ribbon and Film Sensors Note The numbers indicate the location on J65 as shown in the Sensor Location and Voltages table on the next page Open the upper Module to find the Ribbon Sensor orientation Note The numbers indicate the location on J65 as shown in the Sensor Location and Voltages table on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 440 RESTRICTED USE ONLY Reviewing the Sensor Location and Voltages Fargo Electronics Inc Sensor Location Pin Board Low Range VDC High Range VDC Upper Film J66 8 Print Blocked 0 Unblocked 5 Sensor Upper Film J66 4 Print Unblocked 17 Blocked 3 0 3 3 Encoder Lower Film J65 8 Lam Covered 9 Uncovered 3 5 5 0 Sensor Lower Film J65 4 Lam Unblocked 17 Blocked 3 0 3 3 Encoder Card Position J62 4 Lam Unblocked 17 Blocked 3 0 3 3 Sensor Ribbon J64 4 Print Unblocked 17 Blocked 3 0 3 3 Encoder Flipper Table J58 4 Lam Unblocked 17 Blocked 3 0 3 3 Card Sensor Flipper Table J64 8 Lam Covered 9 Uncovered 3 0 3 3 Sensor Card Hopper J64 12 Lam Covered 9 Uncovered 3 0 3 3 Sensor Card Input J64 4 Lam Unblocked 9 Blocked 3 0 3 3 Sensor Printhead lift J64 8 Print Unblocked 9 Blocke
218. lications Note All options must be changed separately for each of the three individual tracks a Set these options back to the ISO standard settings once they have been changed by selecting the Default button for each of the separate tracks Magnslio Enooding EEA UK Panel Resh Encoding Mode Verficaben Suto Eject 1s Error C Manual Eject Each Errol ti Cowrevity a D HighCo Lowlo ASEE a Magnelic Track Selection Tracki C Track2 Tack3 I Enable MLE Support Magnetic Task Options Bit Denaky Charasler Sizs ASO Ollos 75 BPI C5 Bis NULL 123 BPI 2 Bes SPACE f S10 BPI C 8 Bhe r ZERO LAC Generation Charasiet Parity f NoLAC 7 No Parity T Shift Data Left Ever Parky C Even Parky C Odd Panty Ode Party HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 221 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Magnetic Track Options Use these options to customize the ISO encoded data format for each of the Magnetic Stripe s three tracks Step Procedure 1 Specify which of the three 3 tracks to customize by selecting one of the three track options e After making the required selection the Magnetic Track Options box displays the current set of customization options for the selected track e Remember that each track must be customized independently of the other two Card Device Options Image
219. llowing steps using Step 1A or Step 1B as appropriate Step Procedure 1A Option A Insert the Software Installation CD into your computer s CD drive The CD browser is set to automatically open after a few seconds however you will not need the browser portion of the CD for this process a Once the CD browser has opened close it by clicking on the exit icon shown below b Use My Computer or Windows Explorer to view the contents of the CD Windows Explorer can be opened by selecting it from the Start Programs menu c Open the Utilities folder then open the Firmware Updater folder a J 1B Option B Go to the Fargo Electronics Technical Support Web site http www fargo com tech_support Click on the Firmware Updater Program link HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 468 RESTRICTED USE ONLY Fargo Electronics Inc Firmware Updater Application Program continued Step Procedure 2 Click on OK when prompted to Save this Program to Disk and then select a folder in which to save the Updater file 3 a Once the file has been downloaded navigate to the location where the file was saved The Firmware Updater program has been compressed for ease of downloading b Decompress the file by double clicking on the UPDATER EXE icon 4 Double click on the SETUP EXE file to launch the Firmware Updater Setup Program 5 Follow the on screen instructions t
220. m with printing from the application a Print a self test from the Printer as described in the Printing a Test Image procedure in Section 8 page 132 to verify that the Printer itself is functioning properly Print the Windows test page that is located in the General tab of the Driver Use WordPad a Windows 95 98 ME NT 2000 XP word processing program in the Accessories Program Group e Open the program and type This is a Test e Select File gt Page Setup and click on the Printer button e Ensure that the HDP800 Series Card Printer is selected and click OK e Change all the margin settings to zero 0 and click OK e Select File gt Print on the Menu Bar Determine if the parallel port mode is set correctly or incorrectly a Verify that the parallel port is set to Enhanced Communication Port ECP mode Note Determine the port mode by checking the Device Manager tab in the system control panel Change the port mode to ECP in the computers BIOS if the port mode is not set correctly Note Refer to the computer manual for instructions on how to change Parallel Port mode Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 61 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Communication Errors continued Step Procedure 7 Determine whether there is adequate or inadequate hard drive space A Caution A large volume of tempor
221. made for each of the three color Panels on the ribbon color Shades By combining the colors of each Panel and by varying the heat used to transfer these colors it is possible to print up to 16 7 million different shades of color Note This blends one color smoothly into the next producing photo quality images with absolutely no dot pattern Dye Diffusion Thermal Transfer It is the process of heating a dye suspended in a cellulous substrate until the dye can flow diffusing into the dye receptive surface of the card or InTM This produces the image in the surface of the card Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 16 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components Access Card Slot to Parallel Interface Port Component Description Resin Thermal Transfer Resin Thermal Transfer is the print method the Printer uses to print sharp black text and crisp bar codes that can be read by both infrared and visible light bar code scanners Like dye sublimation this process uses the same thermal Printhead to transfer color to a card from a resin only Print Ribbon or the resin black K Panel of a full color Print Ribbon The difference however is that solid dots of resin based ink are transferred and fused to the surface of the card Note This produces very durable saturated printing Access Card Slot If using the Printer s optional Smart
222. mp through the LCD Setup Menu and print a card 3 Ensure that the Modules are seated properly a Open the front access door b Ensure that the release lever is completely in the upright and locked position c Verify that the latches are completely locked down HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 121 RESTRICTED USE ONLY Fargo Electronics Inc Resolving an incomplete transfer on the leading edge problem Symptom If incomplete transfer is limited to the leading edge the Transfer Tension is set too high Step Procedure 1 Decrease the Transfer Tension through the LCD a Select the Menu from the LCD b Select the Setup Printer and then select Transfer Tension c In increments of one decrease the Transfer Tension through the LCD Setup Menu and print a card Resolving an incomplete transfer on the trailing edge problem Symptom If incomplete transfer is limited to the trailing edge the Transfer Tension is set too low Step Procedure 1 Increase the Transfer Tension through the LCD a Select Menu from the LCD b Select Setup Printer and then select Transfer Tension c In increments of one increase the Transfer Tension through the LCD Setup Menu and print a card Mike Berman Student 3957105 Library Code 2439 554 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 122 RESTRICTED USE ONLY Fargo Electronics I
223. n Using the Print on Back Side Only option Using the Rotate Front 180 Degrees or Rotate Back 180 Degrees options U U U Jsing the Print in Single Card Mode option Jsing the Link Card to Print Job option Jsing the Disable Printing option Using the Image color tab Using the Image Transfer tab Adjusting the Image Position controls Adjusting the Transfer Dwell Time and Temperature Adjusting the Flattener Temperature Using the K Panel Resin tab Selecting the Full Card with the K Panel Resin tab Selecting the Defined Area s with the K Panel Resin tab Selecting the Undefined Area s with the K Panel Resin tab Defining the Area to activate the Card Grid Measuring the Total Card area Measuring the Area to be positioned on the Card Selecting the Print YMC under the K and Print K Only options Using the Magnetic Encoding tab Using the Encoding Mode option Encoding the Mode Coercivity Magnetic Track Selection Reviewing the Magnetic Track Options Reviewing the Enable MLE Support checkbox Reviewing the Verification options Reviewing the Shift Data Left Reviewing the ISO Track Locations Sending the Track Information Reviewing the Sample String Reviewing the ASCII Code and Character Table Using the Card tab Selecting the Card Size from CR 80 CR 90 or CR 100 Selecting the Custom Card Size Selecting the Card Type Reviewing the Orientation Specifying the Copies Clicking on the About button Using the Lamination tab only with Card Lamin
224. n required for all e card options or 3rd party smart card encoding e Contact Smart Card Encoder ISO 7816 Parts 1 4 T 0 amp T 1 e Contactless Smart Card Encoder MIFARE e Prox Card Encoder HID read only Note Corporate Express 1000 Cards can be used with special order Weigand ASCIll Converter Fargo Certified Supplies Fargo Card Printer Encoders require highly specialized media to function properly To maximize printed card quality and durability printhead life and printer encoder reliability use only Fargo Certified Supplies Fargo warranties are void where not prohibited by law when non Fargo Certified Supplies are used HDP Film Options e Clear 1 250 prints e Standard Holographic e Custom Holographic special order HDP Film Storage Temperature 77 F 25 C or lower for no longer than 1 5 years Humidity 20 to 80 Non Condensing Input Hopper Card Capacity HDP820 HDP820 LC 250 cards 030 762mm HDP825 HDP825 LC 200 cards 030 762mm Interface e Centronics parallel IEEE 1284 Compliant e Optional USB to Parallel Adaptor e Interfacing information for E card Options Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 13 RESTRICTED USE ONLY Fargo Electronics Inc Technical Specifications continued Term Description Maximum Accepted Card Width Range HDP825 825 LC only 2 125 in to 2 6
225. n Driver or Firmware Performance parameters may be customized in the Driver but can be reset to the factory values usually through the push of the default button The default values for the Firmware are usually denoted on a label attached to the Printer Defrag Abbreviation for defragmenting The process of reformatting data on a hard drive so that it uses space more efficiently DIP switches Dual In line Package Switches A small array of mechanical switches installed on the Board that can be configured to change Printer operations including providing a variety of self tests Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 505 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Term Definition Direct to Card DTC Printing The Direct to Card printing process prints digital images directly onto any plastic card with a smooth clean glossy PVC surface Dither A system of distributing dots to control the hue brightness and or saturation In Monochrome printing this controls the brightness In color printing dithering can supply a larger color gamut than non dithering In the Driver dither modes can be selected to provide better image quality depending on the type of image to be printed Dongle A peripheral that attaches to a port to act as a key for an installed application The PC is able to run that appli
226. n embedded computer circuit that contains either a memory chip or a microprocessor chip There are several types of smart cards Memory Contact Contactless Hybrid Twin Combi Dual Interface Proximity and Vicinity Software Instructions saved in computer memory that directs the computer to perform certain tasks and functions Spooler A computer application that allows the spooling of print jobs HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 Continued on the next page 518 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Term Definition Spooling Rather than moving a print job directly to the Printer the job is written to the disk so that the user can access the application faster while Windows takes care of printing in the background SS Start Sentinel The character denoting the end of a magnetic data string Stacker The device that moves the finished cards onto the output column ordering them First In First Out Stepper Motor A Motor whose shaft turns in discrete steps rather than continuously String A sequence of characters that form a line of data Surface mount A method of mounting circuit elements onto the surface of a circuit Board attached at solder pads rather than through holes in the Board Surge Protector An electronic device placed in serial to the Printer s power supply that prevents damage to the Pri
227. n the card b If the Lamination is hanging off the leading or trailing edge of the card see the Resolving the Card Lamination Placement errors procedure in Section 3 page 103 3 Test the Card Detection Sensor D840624 a Remove the rear cover b Using a Digital voltmeter connect the negative lead to ground c Connect the positive lead to Pin 1 of J6 e f blocked the voltage should read 4 9 to 5 5 VDC e f unblocked the Sensor should read 0 15 to 0 18 VDC d If the voltages do not read correctly replace the Sensor HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 75 RESTRICTED USE ONLY Fargo Electronics Inc Magnetic Encoding Errors Symptom Either a no output is encoded b it is unable to read encoded data on card or c an LCD error occurs Resolving the No ENC Response Error Message Step Procedure 1 Verify connections a Ensure that the two wires to J62 on Lamination Board are properly seated 2 Verify if the Lamination Board is bad a Replace the Lamination Board See the Replacing the Lamination Board 140402 procedure in Section 5 page 368 b See if the error repeats itself Resolving the No Magnetic Encoder Error Message Symptom The Printer is receiving encoding data but the Printer is not configured with this Encoder type Step Procedure 1 Verify if the LCD Setting is incorrect a Press Select on the LCD b Select Setup Pr
228. nc Resolving the Image Placement problems Symptom Printing is cut off or is not centered on the card or a white border appears Step Procedure 1 Verify that the HDP Film spools are wound evenly a Ifthe spools are wound unevenly replace the roll of HDP Film b Ensure that the film is not telescoping on the roll If it is cut the Film off of the take up spool and reattach it 2 a Ensure that the HDP film is aligned with the red alignment arrows on the Transfer station b If itis not aligned properly it may be necessary to replace the roll of Film or cut and reattach the film to the Take up Spool 3 Verify that the Ribbon and Film are properly seated on both sides Note The Hubs axels should rotate as you rotate the spool a Replace the Hubs if it is not properly seated on both sides See the Replacing the HDP 800 Series Ribbon Hub procedure in Section 6 page 294 4 Verify that the Dancer Rollers spin freely by opening the top and middle Modules and manually spinning the Dancer Rollers 5 Confirm that the correct Card Size option is selected in the Printer Driver setup a Open the Printer control panel from the computer e If using Windows 98Se ME right click on the HDP800 Series Card Printer Icon and select Properties e If using Windows NT 4 0 right click on the HDP800 Series Card Printer and select Document Defaults e If using Windows 2000 XP right click on the HDP800 Series Card Printer
229. ndard that allows two way data transfer between PC and Printer BIOS Basic The part of the operating system in a computer that handles Input Output System communication between the PC main Board and its peripherals Typically residing in chip based non volatile memory Bit An abbreviation for binary digital Each bit is an element of information that can have two states off and on Bit map A graphic produced by an array of Pixel elements with the color hue brightness and saturation information stored in bits The more bits the more values and thus the greater variety 1 bit color is black and white 8 bit color produces 256 shades of gray and 24 bit color can produce 16 7 million colors Board A term used for the circuit Board a hard Mylar plate made of many layers which hold the electronic circuit elements and wire traces Boot up A Series of operations that the Printer runs through when power is first applied including a Series of initializing status testing and a diagnostics program to ensure a ready state Buffer A block of memory in the Printer or PC that holds print files until the processor is ready to print them Cable A set of conductors wrapped together and often concealed within insulation used for signal transfer from one device to another with connectors on either end that allows the cable to be removed HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 Continued on the next page 503 R
230. nded Spare Parts List Fargo Electronics Inc Effective Date January 2004 Category Part Part Description Alternate Part MSRP List Number Description Price Belts and F000109 Belt 180 GRV 080P Belt Flipper Drive 12 68 Gears 1 8W F000158 O Ring 103 X 1 063 Belt O Ring 103 X 1 17 SH A 80 1 063 Boards 820593 Assembly Board Sensor Assembly 45 22 Ribbon ID Sensor Board A000242 Assembly PCB LED Sensor Assembly 115 00 and Switch SELM PCB LED and Switch SELM A000250 Assembly PCB Main Board Main 900 00 SE Laminator Cables D870169 Cable LAM Control Cable LAM Control 0 00 Board Board D870170 Cable LAM Print Cable LAM Print 30 16 Board Board D870177 Assembly Power Cable Assembly 0 00 Cable S3 LC IN Power Cable S3 LC IN D870182 Assembly Cable LC Cable LC Steppers 0 00 Steppers D870192 Assembly Cable LC Cable LC Clutch 0 00 Clutch Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 495 RESTRICTED USE ONLY HDP8xx LAM Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 Fargo Electronics Inc Category Part Part Description Alternate Part MSRP List Number Description Price Covers D870088 Base Plate Base Plate 0 00 D870124 Cover LAM Output Cover LAM Output 45 50 D870143 Cover LAM Main Cover HDP 8XX 390 00 Cover LAM Main D87
231. ng Cancel reboots the Printer Encoder HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 476 RESTRICTED USE ONLY Fargo Electronics Inc Firmware Upgrades as of 10 07 03 continued Here are tips for optimized operation You should allow your Printer Encoder to warm up for a period of 15 minutes before operation Always make sure that you have the latest Driver and Firmware Remember the recommended relative humidity range for HDP Printer Encoders is 20 to 80 If you operate outside this range you may experience some flashing smudging or chipping Follow the procedures provided below as needed e For flashing follow this procedure Note Flashing is characterized by visible flaking of the Transfer Film overhanging the card edges Flashing is typically caused by high Transfer Temperature or high Transfer Tension a Verify that the Flash Fans D840769 are functioning and are spinning in the correct orientation b Verify that the Flattener Guides are parallel with the Center Plate and adjust the Figure TL 1547 Lower the Transfer Tension according to the acceptable variation d Adjust the Driver settings to decrease the Transfer Dwell Time e Check for poor alignment of the Peel off Bars the Reference Blocks and the Lamination Module e For smudging follow this procedure Note Smudging is characterized by a wavy clouding or fading of the card image This normally appears at one end of the c
232. ng DOWNWARD Press the FORWARD button several times to feed the Cleaning Card all the way through the Printer Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 68 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Card Feeding Errors HDP825 825 LC continued Step Procedure 2 Ensure the Card Thickness Lever is set correctly as shown below a Press the Card Thickness Lever Lock and then push the Card Thickness Lever up or down to the appropriate setting b with any of the Card Thickness settings move the slide slightly toward a higher setting until the cards begin feeding if the Printer seems unable to feed cards at the selected setting c Move the slide slightly toward a lower setting if the Printer seems to double feed cards Note The card thickness slide is adjustable to accommodate card thickness variations that often occur even within standard card sizes HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 69 RESTRICTED USE ONLY Resolving the Card Feeding Errors HDP825 825 LC continued Fargo Electronics Inc Step Procedure 3 a Check for static build up between cards Note Occasionally a static charge will build up between the surfaces of two or more cards causing them to stick together Reduce or eliminate this static charge by separating the cards manually before placing them
233. ng a card format always set the card size or page size within the card design program to the exact Print Length and Width dimensions listed in the Printer Driver Continued on the next page gt HDP820 LC Card Printer Printing Preferences x Magnetic Encoding Lamination k Panel Resin Card Device Options Image Color Image Transter Card Size CR 50 f inches f mm ER 80 IERI ntLenath 3452 Custom Catto UltraCards Glossy PWC HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 231 RESTRICTED USE ONLY Fargo Electronics Inc Selecting the Card Size from CR 80 CR 90 or CR 100 continued See three previous procedure EN fs i her Hogi biron s m Dika Gere Hoge Grein ah i Daja spe HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 RESTRICTED USE ONLY Fargo Electronics Inc Selecting the Custom Card Size Select the appropriate custom card size according to the dimensions of the card stock Step Procedure 1 a Select the Custom option and enter the dimensions of the card into the Print Width and Print Length boxes if using a card size that varies from the CR 80 CR 90 or CR 100 b Add 04 1mm to each dimension to ensure Edge to Edge printing f HDP820 LC Card Printer Printing Preferences Magnetic Encoding Lamination k Panel Resin Card Device Options Image Color Image Transfer CR a f
234. ng obstructing the card as it travels through the Printer Resolving the jammed Cards on the Flipper Table Step Procedure 1 Clear the jammed card a Open the Print and Transfer Station b Use the arrows on the LCD panel to move the card forward or backward to free the card 2 Inspect the Card Feed Roller Motors for proper operation a Leave the power ON and open the Print and Transfer Stations b Press the FORWARD button to advance the card or the BACK button to reverse the card Note Use these buttons to move the card through the Printer 3 Adjust the Flipper Offset a Select the Menu on the LCD Display b Select the Setup Printer Scroll down to the Flipper Offset c Change the setting on small increments Note A positive adjustment will lower the side of the Flipper Table closest to the Exit Hopper d Press Select to save the new value HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 71 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Flipper Alignment Error Message Symptom A Flipper Alignment error was displayed on the LCD Step Procedure 1 Check for any obstruction a Open the Front Access Door b Ensure that there are no obstructions Verify Motor Operation a Test the Flipper Table Home Sensor 140407 by entering the FLIPPER OFFSET in the PRINTER SETUP menu on the LCD display b Without making any adjustment press the S
235. nics Inc Selecting the Lamination Side Step Procedure 1 a Select the No Lamination option if you do not want to use the Printer s built in laminator b Select Laminate Front Side Laminate Back Side or Laminate Both Sides to specify the side s of the card to laminate Continued on the next page Lamination Side Lamination Type Fim Lamination Laminate Front Side Laminate Back Side E Laminate Both Sides secondsyinch Sensors Default Transfer Temperature 125 5 Centigrade HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 240 RESTRICTED USE ONLY Fargo Electronics Inc Selecting the Lamination Type Step Procedure 1 Select one of the Lamination Type options according to which type of Lamination media is currently installed Two types of overlaminates are supported by the Driver Film Lamination and PolyGuard Lamination Custom versions of each type are also available e Select the Film Lamination option if the Thermal Transfer Film Overlaminate type is installed in the Lamination Module e Select the 0 6 PolyGuard Lamination option or 1 0 PolyGuard Lamination option for either patch thickness Note These require different heat settings and Lamination speeds Select the appropriate option according to the thickness of the PolyGuard material you are using e Select the PolyGuard Alternating Patch option only if using PolyGuard material t
236. nificant transfer to the tape and is an absolute failure Result 2 Sample 2 shows that very slight transfer to the tape can be acceptable without sacrificing overall image durability on matte finish cards Result 3 Sample 3 shows no transfer to the Tape and is an Absolute Pass If the tape test indicates inadequate adhesion increase the heat setting by 5 degrees print another card and try the tape test again Once the temperature has been increased 4 times 20 degrees reset temperature to default and increase the Dwell Time by 5 second Repeat this process until adequate adhesion is achieved Use the YMCKH ribbon if printing to a matte surfaced card Note This ribbon provides a Heat Seal Panel that allows for improved adhesion to non glossy PVC surfaces Ensure that the cards in use have a surface roughness Ra of 60 micro inches or less This information should be available from the card manufacturer HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 183 RESTRICTED USE ONLY Fargo Electronics Inc Printer Driver Options Installing Printer Driver Updates Occasionally new Printer Driver versions are released which have new or updated features Before installing an updated Printer Driver version always delete the existing Printer Driver version from the system To do this select Start Programs and point to the Fargo folder Then select the Uninstall Printer Driver icon for the spec
237. ns the number of verification retries may be specified A range of 1 5 retries is available Step Procedure 1 Select the Auto Eject 1st Error option which instructs the Printer to automatically eject a card containing magnetic data that cannot be verified e Only the first mistakenly verified card will be automatically ejected If a second consecutive card cannot be verified the Printer will signal an error and go into manual eject mode e The auto eject option is the most direct means of dealing with mistakenly verified cards but may be undesirable if batch printing since mistakenly verified blank cards are ejected into the same stack as verified printed cards OR Select the Manual Eject Each Error option so the Printer will signal an error on its LCD Display stating that the magnetic data could not be verified Note When this occurs press the Cancel soft key to manually eject the mistakenly verified card This option is helpful since Magnetic Stripe verification can sometimes require more than a single pass HDP825 LC Card Printer Printing Preferences 2 x Card Device Options Image Color Image Transfer Magnetic Encoding Lamination KPanelResn M Encoding Mode Verification So C JIS II Auto Eject 1st Error Resvsesen Manual Eject Each Error r Coereivity HighCo Low Co Retries 2 4 m Magnetic Track Selection Tracki Track2 Trac
238. nsfer Stations HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 110 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Card surface debris problems continued Step Procedure 3 Clean the Cleaning Rollers a b c d g Open the Front Access Door of the Printer Depress the Cleaning Roller Lock Pull the Cleaning Roller Assembly out of the Printer Clean the rollers with one of the adhesive backed Cleaning Cards from the Printer Cleaning Kit Remove the card s adhesive backing paper and slide the card between the rollers until all dust particles are removed Flip over the Cleaning Card to clean both the top and bottom Cleaning Rollers Note Alternatively placing the assembly under lukewarm water may clean the Cleaning Roller Once cleaned replace the Cleaning Roller Assembly and close the Front Access Door A Caution Ensure that the Cleaning Roller Assembly is completely dry before reinstalling into the Printer Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 111 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Card surface debris problems continued Step Procedure 4 Clean the Platen Roller Leave the Printer power ON and open the Print and Transfer Stations Remove the print ribbon and HDP Film Locate the Print Platen Roller as shown below Use a Cleaning Pad from the Printer
239. nt Ribbons e f using a YMCK ribbon type the front of the card is printed with the ribbon s YMC Panels and the back is printed with the K Panel e f using a YMCKK ribbon type the front of the card is printed with the YMCK Panels and the back is printed with the second K Panel Note 1 This option is automatically enabled when the YMCKK ribbon type is selected Note 2 The Print Both Sides option is automatically enabled when this option is selected Note 3 This option is not available if using a YMCKH or YMC Print Ribbon Ribbon Type YAR Full Color Resin Black Eilm Type ler o Color Matching Algebras i stst lt lt s s sS YS Resin Dither Optimized for Graphics V Print Both Sides Print in Single Card Mode I Link Card to Print Job Print Back Side First I Disable Printing Print Back Side Only Rotate Front 180 Degrees Rotate Back 180 Degrees HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 193 RESTRICTED USE ONLY Fargo Electronics Inc Using the Print Back Side First option Step Procedure 1 Select this option if you need to print the first page of a two page document on the backside of the card The second page of the document will be printed on the front side of the card HDP825 LC Card Printer Printing Preferences 2 x Magnetic Encoding Lamination K Panel Resin Card Device Options Image Color Image Tr
240. ntain a log of up to 255 errors c track how many times specific errors occur and d determine if certain errors are occurring more than others in order to pinpoint an area in the Printer requiring attention Step Procedure 1 Use the scroll buttons to move through the Exception Log Press the Reset button to clear the existing error log and start a new log Note The error log will stop logging errors once it has reached its error occurrence limit of 255 c See LCD SmartGuard Messages in Section 2 page 50 for information about these messages e ERROR LOG e START Type of Error Occurrences X Number of times e ERROR LOG END HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 466 RESTRICTED USE ONLY Fargo Electronics Inc Using the Show Card Count option Step Procedure 1 Use this option to view the total Card Count CC Pass Count PC Transfer Count TC and Lamination Count LC e The Card Count is the total number of cards the Printer has produced e The Pass Count is the total number of print passes made by the Printhead Note A pass is measured each time a single ribbon Panel is printed or passes beneath the Printhead e The Transfer Count is the total number of times the Printer transfers an image to a card In most cases this information is only necessary for certain warranty requirements however it can also be a helpful way to measure a Printer s overall
241. ntains black resin for transfer to the card surface Also used in reference to the application of preference to items printed on the card those using the black Panel in lieu of a process YMC black Lamination The application of a film or resinous substance fused by heat and pressure to the surface of a card LAN Local Area Network An array of several computers connected through a Series of data transfer cables for the sharing of data and peripherals HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 Continued on the next page 511 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Term Definition Landscape A document layout that is viewed with the document s long axis in a horizontal orientation LCD Liquid Crystal Display A device that contains a liquid crystal between two pieces of polarized film through which reflected or ambient light can pass When a current is applied the liquid s polarity changes and blocks the passage of the light resulting in an opaque area of the display The areas are arrayed to form characters LED Light Emitting Diode A semiconductor that emits light when a current is applied Media A generic reference to anything onto which the Printer can transfer an image including cards ribbon and film LoCo Low The coercivity value of magnetic media between 250 600 Oe Coercivity ISO 7811 2 Fargo s
242. nter from electronic surges and electrical current that is outside of the normal parameters Switch Box An electromechanical device to which a user may connect several peripheral devices to the parallel port simultaneously yet using the selector switch to designate the active port TAC Thermal Acceptance Composite cards Card stock produced by laminating sheets of PVC with sheets of PET for better thermal distortion resistance Ultra III cards Temp file A temporary file generated automatically by Windows to store the information for an active document Windows should delete these files when the application is closed Test print A file stored in or generated through windows that is sent to the Printer to test basic functionality Thermistor An electronic resistor on the printhead with a resistance value that varies in proportion to the heat to which it is exposed Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 519 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Term Definition Thermocouple A device for measuring temperature using a junction of two wires of dissimilar metals that produce a voltage when heated that varies proportionally with the temperature Thin Film Overlaminate A 0 25 mil thick resin material that enhances card security and durability applied over the printed surface with a h
243. nthead D840854 procedure in Section 5 page 281 3 Confirm that the cooling fan above the Printhead is operating properly Note Upon power up the fan should run momentarily and shut off 4 Replace the Main Print Board if problem still remains See Replacing the Main Print Board A000271 procedure in Section 5 page 367 for instructions Resolving the Printer Open Error Message Symptom The Printer is operating with the Print and or Transfer Station open Step Procedure 1 Ensure that both the Print and Transfer Stations are completely closed and that the release lever is secured 2 If the Print and Transfer Stations are completely closed check the Sensor 140107 as described in Sensor Testing in Section 7 page 440 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 90 RESTRICTED USE ONLY Fargo Electronics Inc Transfer Process Errors Resolving the Upper and Lower Film errors Symptom Lower or Upper Film Sensor may have failed Step Procedure 1 Verify if the Lower Film Sensor 840199 has failed a Check the voltage for the Film Sensor where it connects to the Lamination Board b Place a Film mark over the Film Sensor Note The voltage should be less than 1 VDC c Remove the Film mark from the Film Sensor Note The voltage should be greater than 3 4 VDC d Replace the Sensor if the voltages are incorrect 2 Verify if the Upper Film Sensor D8
244. nto tracks in accordance with an ISO 7811 2 Magnetic Stripe For track locations review the display below 0 223 0 353 0 493 maca fox ay TRACK2 0 110 Ss TRACK3 0 110 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 226 RESTRICTED USE ONLY Fargo Electronics Inc Sending the Track Information Magnetic track data is sent in the form of text strings from the application software to the Printer Driver In order for the Printer Driver to differentiate between Magnetic Track data and the rest of the printable objects specific characters must be added to the magnetic data to be encoded These specify the data that is to be encoded the tracks to encode and mark the start and stop of the data string In some cases these specific characters are automatically added to the string of track data by ID software applications In most cases the user must manually add these characters to the string of Magnetic Track data If these characters are not added to the track data the text intended for the Magnetic Track will appear as printed text on the card To avoid this track information must be entered as described below Step Procedure 1 When entering track data the tilde character is entered first followed by the track number 1 2 or 3 on which the data should encode This is followed by the data to be encoded e The first character of this data string must be the
245. o back to the original Film Tension value Lower the Film Drive by one 1 increment and repeat Steps a to c above until the film wrinkle is alleviated Mike Berman Student 3957105 library Code 2439 554 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 120 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the incomplete Transfer problems Symptom Printed image has ragged edges HDP Film seems to have peeled off Step Procedure 1 Ensure that the Lamination Roller makes uniform contact with the card a Confirm that 1 the Lamination Roller moves up and down freely and 2 the Thermocouple wire does not restrict movement 2 Increase the Transfer Temperature setting within the Image Transfer tab of the Printer Driver a Open the Printer control panel from the computer e If using Windows 98Se ME right click on the HDP800 Series Card Printer Icon and select Properties e If using Windows NT 4 0 right click on the HDP800 Series Card Printer and select Document Defaults e If using Windows 2000 XP right click on the HDP800 Series Card Printer and select Printing Preferences b Click on the Image Transfer tab c Adjust the Transfer Temperature to a more positive value OR Increase the Transfer Temperature through the LCD a Select Menu from the LCD b Select Setup Printer and then select Transfer Temp c In increments of three increase the Transfer Te
246. o complete installation Once installed the Firmware Updater icon will appear in the Start Programs Fargo folder 6 Select the Firmware Updater icon displayed below to open the Firmware Updater application program pj Firmware Updater HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 469 RESTRICTED USE ONLY Fargo Electronics Inc Downloading Firmware Updates Step Procedure 1 Refer to the following steps to download Firmware updates 2 Select the Download Firmware button If you have Internet access this will automatically take you to the Firmware Updates section of the Fargo website If it does not manually open your browser and go to the Firmware Updates section in the Fargo Electronics Technical Support Web site http www fargo com tech_support 3 Select your specific printer model and click on the Submit button Click on the Firmware file link labeled for the specific Printer model 4 Click on OK when prompted to Save this Program to Disk and then select a folder in which to save the Update file 5 a Once the file has been downloaded navigate to the location where the file was saved Note The Firmware Update file has been compressed for ease of downloading b Decompress the file by double clicking on the designated icon Firmware Updater ersion 3 0 6 L i FARGO Download Update File Select Update File Send Update File HDP 800 Ser
247. o the default flat position The Flat Sensor and counted steps are used to determine the angular position All stop 24 Steppers engage to move the card OFF the Flipper and to a position near the hot Roller using Card Feed Sensors and a step count All stop 25 Stepper engages to move the card to a position directly under the hot Roller The Top of Form Sensor determines card edge and number of steps to position card All stop Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 RESTRICTED USE ONLY FARGO Electronic Inc Reviewing HDP 800 Series Card Printer Sequence of Operations continued Step Process 26 If the heater is not at the required temperature yet the job will pause 27 The Headlift Motor turns ON to lower the hot Roller and will stop when the Headilift Sensor is activated All off 28 The Stepper and Ribbon Drive engage to laminate the printed Film onto the card They will turn off after a given number of steps based on the position given by the card Sensor All stop Note The Ribbon Encoder is active during this step 29 The Headlift Motor turns on to raise the hot Roller stopping when the Headilift Sensor is activated 30 The Ribbon Drive and Stepper turn ON for a given number of clicks based on ribbon encoder until the ribbon is released 31 The Stepper turns ON to move the card through the flattening
248. of the Printer e Off Indicates the Printer power is OFF e Solid GREEN Indicates the Printer is powered ON and ready for operation e Flashing GREEN Indicates a Printer ERROR or ATTENTION condition Refer to the Printer s LCD Display for information Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 28 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components LCD and Softkey Control Pad continued Component Description Error Attention Screens The Printer is capable of communicating two similar yet different types of message or prompt screens The first is called an ERROR screen Note This screen appears if an error occurs and will completely stop Printer operation In this case the LCD will display ERROR on the first line and a brief description of the error on the second line If multiple errors occur at the same time the first line will display ERROR 1 of 2 or whatever the total number of errors may be To see the other error s use the scroll keys e Press the Help button if you would like a more detailed explanation of the error message This will bring up the help screen explaining the nature of the error and how to correct it If necessary use the scroll buttons to scroll down the paragraph of help text e Press Quit when you are done reading Once the error is corrected resume operation or reset the Printer according to how you were in
249. om 1 and Custom 2 options to save custom Dwell Time dwell temperature and Flattener temperature controls on the Image Transfer tab a Click on the Custom 1 or Custom 2 options and enter a name for the card stock b Click on the Image Transfer tab to adjust the Dwell Time and temperature sliders to the appropriate settings Note These settings will be saved for the custom card type when the Printer Driver setup window is closed Magnetic Encoding Lamination K Panel Resin Card Device Options Image Color Image Transfer m Card Size CR 80 inches mm Print width 2 204 Print Length 3 452 4 m Card Type UltraCards Glossy P C UltraCards Glossy PYC HDF Cards Matte P C Custom 1 Custom 2 Transfer Dwell Time 2 0 secondsinch Transfer Temperature 175 0 Centigrade s HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 235 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Orientation Select either the Portrait or Landscape radio buttons for Orientation Step Procedure 1 Select Portrait to cause the card to print in a vertical orientation OR Select Landscape to cause the card to print in a horizontal orientation as shown on the next page Specifying the Copies Specifies the number of copies to be printed Onentation Portrait Landscape Copies fr El Test Frint About HDP 80
250. om Headlift Sensor 2 The Lamination Ribbon Motor activates to determine the presence of a roll of lamination 3 The Lamination Flipper table homes itself 4 The Card Sensor checks for the presence of a card and ejects it if found HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 xiv RESTRICTED USE ONLY Fargo Electronics Inc Table of Contents Section 1 Specifications Reviewing the HDP800 Series Printers Overview table Regulatory Compliances Agency Listings Technical Specifications Functional Specifications Printer Components Access Card Slot to Parallel Interface Port Printer Components LCD and Softkey Control Pad Printer Components Centronics Type Parallel Interface Printer Components Print Ribbons Printer Components Blank Cards Printer Components Card Input Hopper HDP820 820 LC Printer Components Card Input Hopper HDP825 825 LC Printer Components Card Output Hopper Printer Components Lamination Roller Reviewing the Card Lamination Module Reviewing the Lamination Top Cover and Station Reviewing the Securing Latches and Lamination LED Light Reviewing the Cancel button Reviewing the Resume pause button Reviewing the Rejection Card Hopper and Card Output Hopper Reviewing the Module and Printer interaction Reviewing the Module and LCD Display interaction Reviewing the Module s Programmed
251. ommunication Cable to the Printer s Communication Port Note Both are labeled with a green COM label Push firmly to ensure both are securely connected Note The port and cable are keyed for one way installation 12 Leaving the Print Station and Transfer Station in the fully open position move the Release Lever to the Locked position to close the Printer s Securing Latches Note This will hold them out of the way for the next steps 13 Set the Card Lamination Module onto the Printer by lifting it up about 4 inch 10cm off the table top and sliding it down onto the Printer s Baseplate Note Be sure no cables are pinched or damaged during this step HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 Continued on the next page 159 RESTRICTED USE ONLY Fargo Electronics Inc Attaching the Card Lamination Module continued Step Procedure 14 Insert three 3 screws into the top of the Card Lamination Module shown below Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 160 RESTRICTED USE ONLY Fargo Electronics Inc Attaching the Card Lamination Module continued Step Procedure 15 Insert one 1 black screw into the bottom front of the Card Lamination Module as shown below Continued on the next page
252. on the SmartGuard Access Card was successfully deleted Press the OK button to continue Access Card Ready The SmartGuard data has successfully been encoded onto the SmartGuard Access Card Press the OK button to continue Delete Card Data To delete the SmartGuard Access Card data press the Yes button To cancel the deletion process press the NO button Insert Access Card You are trying to print without the SmartGuard Access Card inserted Insert a valid SmartGuard Access Card Insert New Card To duplicate the SmartGuard Access Card remove the valid access card and insert a blank access card Press the Copy button to complete duplication or press Cancel to cancel duplication Invalid Access Card The SmartGuard Access Card is invalid or is inserted backwards or up side down Insert a valid SmartGuard card or reinsert the card properly with the chip end down and facing you Invalid You have entered an invalid Re enter the correct password Password SmartGuard password using any of the standard keyBoard characters Reading Indicates the Printer is reading the data Press the OK button to continue Access Card from the SmartGuard Access Card Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 58 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing SmartGuard Error and Status Messages Cause and Solu
253. onics Inc Adjusting the Film Drive The Film Drive sets the baseline for the Film Tension and should not be adjusted by the reseller or the end user Adjusting the Ribbon Tension This procedure controls the tension of the color ribbon during printing in order to adjust the image placement Adjust the ribbon tension if the ribbon wrinkle is appearing on the card Step Procedure 1 Be sure the Transfer Tension Print Offset Transfer TOF and Transfer EOF are set properly before adjusting the Ribbon Tension 2 Choose MENU Print Test Image and Gray Align YMC to print a test card Examine the test card 3 a Select MENU Setup Printer and Ribbon Tension b Record the Ribbon Tension value on the test card 4 Adjust the Ribbon Tension value if needed 5 Press SELECT to save the value 6 Print a test card as described in step 1 7 a Repeat Steps 1 to 6 above until the test image is correctly positioned or ribbon wrinkle is alleviated b Refer to the HDP Transfer Film display See Setting the Transfer TOF procedure in Section 8 page 452 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 457 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Ribbon Drive The Ribbon Drive sets the baseline for the Ribbon Tension and should not be adjusted by the reseller or end user Adjusting the Transfer Temperature Step Procedure 1 Choose MENU Print Test Imag
254. ons Fargo Electronics Inc The purpose of this section is to provide the User with specific information on the Regulatory Compliances Agency Listings Technical Specifications and Functional Specifications for the HDP 800 Series Card Printer Encoders Reviewing the HDP800 Series Printers Overview table HDP800 Series Input Card Accepted Encoding Lamination Hoppers Capacity Card Size Modules Module HDP820 Dual Sided 1 250 CR 80 Optional Optional Card Printer Encoders CR 90 amp CR 100 HDP820 LC Dual 1 250 CR 80 Optional Included Sided Card CR 90 amp Printer Encoders CR 100 HDP825 Dual Sided 2 200 CR 80 Optional Optional Card Printer Encoders HDP825 LC Dual 2 200 CR 80 Optional Included Sided Card Printer Encoders HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 10 RESTRICTED USE ONLY Fargo Electronics Inc Regulatory Compliances Term Description CSA The Printer manufacturer has been authorized by UL to represent the Card Printer as CSA Certified under CSA Standard 22 2 File Number E145118 FCC The Card Printer complies with the requirements in Part 15 of the FCC rules for a Class B digital device Note These requirements are designed to provide reasonable protection against harmful interference in a residential installation If equipment operation in a residential area causes unacceptable interference to radio and TV r
255. or LC D870228 Assembly Hopper Sensor Assembly 11 70 Sensor Hopper D870241 Assembly Lower Sensor Assembly 0 00 LAM Sensor Lower LAM 501 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms Term Definition 24 bit color A color depth for an image that uses 8 bits for each color red blue green combining the possible 256 shades to provide a color depth of 16 7 million colors AC Alternating Current An electrical current that reverses its direction at regular intervals typically 50 60 times a second Access Card The card for the SmartGuard security system A cared with embedded electronics that can be removed from the Printer locking the Printer and preventing unauthorized use adhesion The firm attachment of a material to the card surface confirmed by using the Tape Test pulling an applied piece of adhesive tape Scotch 600 or equivelent off the card at 1 sec in to see if any material is pulled off by the tape Algebraic A type of color matching that takes the colors value of Pixels and applies them to an algebraic equation to adjust the levels of hue saturation and brightness ANSI American National Standards Institute The United States Representative to ISO providing standardization for U S Manufactures prior or in addition to acceptance by ISO AS400 An IBM operating system running on a main frame DTC500 Fargo Printers ar
256. ot roller Available as clear or with embedded holographic type security images Through hole A method of mounting circuit elements with the leads passing through holes in the circuit Board and soldered on the opposite side Timeout An interruption of a print job that occurs when a function is not completed in the time allotted by the operating system TOF Top of Form The leading edge of the card as it travels through the Printer Track The area on a mag stripe designated to contain the magnetic data string Troubleshooting The process of investigating and determining the cause of a problem TrueType TT A font format that produces each character using a mathematical equation rather than a graphical representation resulting in a much sharper cleaner image UltraCard The Fargo brand of card stock recommended for use in Fargo Printers with the necessary glossy surface and composed of PVC UltraCard IlI The Fargo brand of card stock recommended for use in Fargo Printers that laminate with the necessary glossy surface and composed of PVC and PET to prevent heat distortion Update The process of installing a new revision of software or Firmware to implement new changes to the Printer s command codes and procedures Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 520 RESTRICTED USE ONLY Fargo Electronics Inc
257. perature Note Only matte finished cards with a surface roughness Ra of 60 micro inches or less are recommended HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 180 RESTRICTED USE ONLY Fargo Electronics Inc Conducting the Tape Adhesion Test It is important to conduct Tape adhesion tests because Fargo cannot be certain which transfer temperature and Dwell Time will work best when printing cards other than UltraCard or HDP PVC Note The optimal transfer settings may vary from card type to card type A Caution Inadequate time and temperature could produce cards that are more vulnerable to accelerated wear and dye migration Use sufficient time and temperature to transfer HDP Film to the card to ensure a long lasting durable card Step Procedure 1 Test the adhesion quality of the HDP Film to the card by printing sample cards and completing an adhesive tape test Note The Institute for Interconnecting and Packaging Electronic Circuits IPC outlines a pressure sensitive tape test that evaluates adhesion quality Refer to their IPC TM 650 3 7 1D test manual Section 3 7 Number 1 Select the UltraCards Glossy PVC if the card is glossy and print a test card OR Select the HDP Cards Matte PVC if the card has a buff matte finish and print a test card a Apply a strip of 2 12mm wide Scotch type clear adhesive tape such as 3M brand 600 at least 2 50mm long firmly a
258. pool Verify if the Driver has been set correctly a Open the Printer control panel from the computer e If using Windows 98Se ME right click on the HDP800 Series Card Printer Icon and select Properties e If using Windows NT 4 0 right click on the HDP800 Series Card Printer and select Document Defaults e If using Windows 2000 XP right click on the HDP800 Series Card Printer and select Printing Preferences b Click on the Device Option tab c Verify that the Ribbon Type setting that is listed matches the ribbon that is installed in the Printer Note It may be possible to have Driver settings that are different from those found in the Printer control panel through the software d Check any page setup functions in the software to verify that the Ribbon type matches HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 87 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Unknown Ribbon Type Error Message Symptom The Printer is unable to determine the type of ribbon installed Step Procedure 1 Verify the ribbon type a Ensure that the print ribbon installed in the Printer is an HDP ribbon Note Although similar in appearance a DTC ribbon installed in an HDP Printer will produce an Unknown Ribbon Type error message 2 Test the Ribbon Sensor a Remove the back cover and locate the connector labeled J65 on the main Board b Check the voltage for each of t
259. pper and middle Modules are seated properly and are completely locked down 9 Select the Image Position option within the Image Transfer tab of the Printer Driver a Open the Printer control panel from the computer e If using Windows 98Se ME right click on the HDP800 Series Card Printer Icon and select Properties e If using Windows NT 4 0 right click on the HDP800 Series Card Printer and select Document Defaults e If using Windows 2000 XP right click on the HDP800 Series Card Printer and select Printing Preferences b Click on the Image Transfer tab c Use the horizontal and vertical adjustment settings to center the image on the card 10 Clean the Platen Roller Apap ot p Leave the Printer power ON and open the Print and Transfer Stations Remove the print ribbon and HDP Film Locate the Print Platen Roller as shown below Use a Cleaning Pad from the Printer Cleaning Kit to wipe the roller clean Locate the Transfer Platen Roller as shown below Use a Cleaning Pad from the Printer Cleaning Kit to wipe the roller clean Press the FORWARD and BACK buttons to move the roller back and forth while cleaning Replace the printing supplies and close the Print and Transfer Stations after the rollers are clean and completely dry Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 125 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Image Placement problems continued
260. printing b If the problem persists see the Resolving the Transfer Cooling error procedure in Section 2 page 97 to test the Thermocouple Resolving the Transfer Lift Error Message Symptom The Printer cannot determine the placement of the Lamination Roller Step Procedure 1 Check to ensure that the Transfer Lift Motor 840130 is running a Disconnect the motor from the Lamination Board b Connect a 9 VDC battery to the motor s leads c Replace the Transfer Lift Sensor if the motor does turn See the Replacing the Transfer Lift Sensor procedure in Section 5 page 336 d Replace the Transfer Lift Motor if the motor does not turn See the Replacing the Transfer Lift Motor procedure in Section 5 page 337 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 99 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Output Stacker errors Symptom The Cards feed into the Output Stacker but they are not lifted up into place Step Procedure 1 Check operation with these steps a Reset the power on the Printer b Visually confirm that the stacker cycles on power up 2 Verify that the wires 840121 and 840115 from the Output Stacker are connected properly and are well seated in the wire harness 3 Ensure that the Output Stacker is set to the correct card size a Slide the wall of the Output Stacker to the correct card size 4 Test the operation of the Stacker
261. propriate Defined Area see below to activate the card grid in the upper half of the window e It is through this card grid that up to five areas can be defined as shown below e When the card grid is first activated then a small black square will appear at its default size of 2 x 2 5mm x 5mm and at its default location in the lower left hand corner 0 0 Note This square represents the first defined area d HDP820 LC Card Printer Printing Preferences ajx Card Device Options Image Color Image Transfer Magnetic Encoding Lamination K Panel Resin CA 80 Card Size Front C Back FETT TTT tt ee a 0 200 H m TT 0 200 MEME mon tT X HH ooo ly HH SEHPESE inches tt tt Yt fram EEE oo CTT Detined Area aN cx Direction Card Travels Through Printer Delete HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 213 RESTRICTED USE ONLY Fargo Electronics Inc Measuring the Total Card area Step Procedure 1 Determine the area of the card to define Note This area is indicated by the dashed outline as shown below The easiest way to determine the size of this area is to actually print a card and look at it in the same orientation as when it exits the Printer 2 Measure the total area and enter those dimensions into the dimension boxes Note The minimum size an area can be is 2 x 2 5mm x 5mm identification Card
262. r the Printer s Magnetic Encoding Area in Section 2 page 82 Card Jam A card is jammed in the Transfer See the Resolving the Card Jam Transfer Station of the Printer Error Message procedure in Section 2 page 74 Cards Low _ Indicates there is not an adequate Add cards to the input hopper and supply of cards in the Card Input press Resume to continue Hopper printing Data Input The print data sent to the Printer is See Communication Errors in corrupt or has been interrupted Section 2 page 60 Data The print data sent to the Printer is See Communication Errors in Timeout corrupt or has been interrupted Section 2 page 60 Door Lever You are trying to print with the Front See the Resolving the Printer Unlocked Access Door open or the Release Open Error Message procedure in Lever in the unlocked position Section 2 page 90 DRAM The Printer s memory Module is bad See the Resolving the DRAM Memory or not installed properly Memory Error procedure in Error Section 8 page 439 EE Permanent circuit Board memory is See Resolving the EE Memory Checksum bad Error procedure in Section 8 page Error 438 Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 51 RESTRICTED USE ONLY Reviewing LCD Messages continued Fargo Electronics Inc Message Cause Solution EE Memory Permanent circuit Board memory is See the Resolving the EE Error ba
263. r s LCD Display to Messages in Section 2 page help communicate the Printer s current 50 status The following explains how to interpret the LED Light e Off Indicates the Printer and Lamination Module power is OFF e Solid Green light Indicates the Card Lamination Module is ready for operation e Slow Flashing Green light Indicates the Lamination Module s pause button was pushed and that the Lamination Module is paused This also occurs when the Lamination Station is open e Fast Flashing Green light Indicates the Lamination Module is in need of attention due to an error or an error condition Refer to the Printer s LCD Display for information HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 40 RESTRICTED USE ONLY Reviewing the Cancel button Fargo Electronics Inc Component Description Reference Cancel The Cancel button serves to cancel the See the Using the Button current Lamination job and reset the Card Lamination tab only with Lamination Module for the next Lamination job e If acard is left within the Lamination Module after a print job is canceled it will automatically be ejected into the Rejection Card Hopper Note With the Lamination Module s Transfer Station open this button can also be used to manually rotate the feed rollers forward This is helpful when cleaning the rollers or if clearing jammed media e If you are printing and laminating
264. rd Feeding Errors 68 69 70 card feeds improperly off Flipper table 73 Card flipping area 71 card grid 213 Card Illustration 205 Card Input Guide adjustment 143 144 145 146 147 148 177 184 185 186 Card Input Hopper 17 34 35 276 Card Input Hopper cover 277 332 352 354 Card is encoded 79 Card Jam Flipper 50 Lam 75 Mag 51 Transfer 51 Card Jam 50 Card jam in Printer s smart card encoding area 82 Card Lamination Module 39 Card Low Sensor 353 Card Low Sensor Board Assembly 353 card misfed into Transfer Station 131 Card Output Hopper 17 Card Output Hopper cover 277 332 349 Card Output Hopper Door 276 Card Pusher 131 Card Sensor Assembly Flipper Table 361 Card Separator Adjustment Assembly 177 Card Size 33 231 233 Card Size Knob 124 card size selection 123 card stalls at feed rollers 71 card stock selection 178 Fargo Electronics Inc Card Surface 33 card surface debris problems 110 111 112 Card tab 123 Card Thickness Adjustment Knob 22 177 card thickness settings 69 Card Thickness Slide 69 Card Type 234 235 Card Type 12 Card Type Custom options 207 Card Type option 179 207 Card Type Selection 179 card warping 234 cards look pixilated or grainy 127 Cards Low 51 card s Magnetic Stripe smart chip 196 Card s smart chip encoded improperly 84 CD Compact Disc 504 Centronics 504 Centronics Type Parallel Interface 31 Changing the Encoder
265. rd Plate Guard 21 78 Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 497 RESTRICTED USE ONLY HDP8xx LAM Series ID Card Printer Recommended Spare Parts List Effective Date January 2004 Fargo Electronics Inc Category Part Part Description Alternate Part MSRP List Number Description Price Misc D870135 Guard Heat Roller Guard Heat Roller 12 94 Hardware D870136 Spring LAM PSR Spring LAM PSR 0 00 D870137 Shaft Spring Mount Shaft Spring Mount 0 00 D870150 Hopper LAM Reject Hopper LAM Reject 0 00 D870153 Assembly LAM Arm Assembly LAM Arm 1 109 55 D870168 RTD_Kapton Thermal coupler 116 20 D870194 Assembly LC Heater Assembly LC 0 00 Heater D870210 Assembly LC Film Assembly LC Film 36 15 Take up Take up D870215 Hinge Zero Torque Hinge Zero 0 00 Torque D870224 Bracket Hinge Mount Bracket Hinge 0 00 DTC Mount D870245 Bracket Hinge Mount HDP Upper Lid 50 96 Bracket D880153 Roller DELRIN AF Lamination Pinch 4 22 Card Idler Roller Brown Roller E000267 Clutch Electric Electric Clutch use 53 10 EC20CW1 4 24 with spacer D000186 F000067 Hinge Constant Hinge Constant 13 84 Torque 2 5KG Torque 2 5KG Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 498 RESTRICTED USE ONLY HDP8xx LAM Series
266. rint Driver A software utility that serves as an interface between the Printer and the Windows GDI Graphical Device Interface making the Printer s functions available through the software application It also provides the format information for the rasterizing of the print file including any necessary escape or function commands Print Job A file of one or more cards for the Printer to print including image data and Printer functions transmitted through the parallel interface and at times stored temporarily in the print buffer and spooler Print Server A device used to connect and control a Printer on a network HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 Continued on the next page 515 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Term Definition Printhead The device on a Printer that produces the image on the media PVC Abbreviation for polyvinyl chloride often called vinyl PVC is the component of the 0 002 thick clear dye receptive film on the surface of the identification card and is the primary component of the identification card cores Queue A sequence of files or sets of data awaiting transmission or processing Proximity Prox Card Proximity cards allow access and tracking utilizing contactless technology usually by communicating through a built in antenna Prox Card Encoder The Fargo prox card Enco
267. rint Offset setting by two or three Pixels Note The entire inner alignment arrow will not show up on the card More important is that the card shows equal amounts of the arrows HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 455 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Transfer Tension This procedure positions the image correctly on the card Refer to the Preparing to adjust the Print Offset Transfer TOF and Transfer EOF procedure in Section 8 page 449 for proper sequence Step Procedure 1 Choose Menu Print Test Image and Gray Align YMC to print a test card 2 Record the Transfer Tension value on the test card last printed 3 Examine the test card 4 a Select MENU Setup Printer and Transfer Tension A Caution Reducing the Transfer Tension too much may cause slack in the Film take up which is evidenced by a wrinkling noise and extra Film take up during the release phase b Increase the Transfer Tension if this occurs Note There may be a snapping or clunking sound during Film take up if it is too tight Errors may occur in either case 5 Press the Select button to save the value 6 Print a test card as described in Step 1 7 Repeat Steps 1 to 6 until the Film is applied smoothly to the card without wrinkles or creases HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 456 RESTRICTED USE ONLY Fargo Electr
268. rinter As needed contact the Fargo Technical Support Group by phone at 952 941 0050 or by fax at 952 941 1852 for additional technical assistance OR Contact Fargo Technical Support via the Web http www fargo com tech_support contact_tech support asp Position a phone near the Printer and Computer so Fargo technicians can help to help troubleshoot the Printer s Please have a self test and a sample card ready when calling Fargo Technical Support HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 478 RESTRICTED USE ONLY Fargo Electronics Inc Reading the Serial Numbers on a Fargo printer The purpose of this section is to provide updated instructions for reading serial numbers on a Fargo printer Finding out when a Fargo Card Printer was manufactured You can determine when your card printer was manufactured by reading directly from the serial number affixed to your card printer 1 Year Built The first two digits in the serial number indicate the year that the printer was manufactured 2 Week Built The second two digits indicate the week Numeric Order The last four digits indicate the sequence number for the numeric order in which the printers were built Reviewing Example No 1 Serial Number 80453289 1 80453289 The first two digits in the serial number indicate the year the printer was built e g the digits 80 indicate the year 1998 80453289 The third and
269. rinter Encoders Service Manual Rev 5 0 34 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components Card Input Hopper HDP825 825 LC Type Description Card Input The Card Input Hopper is where cards are initially loaded for printing Hopper Your printer s hopper provides a large door that opens widely to make HDP825 825 card loading simple and closes securely to help protect your card stock LC printers The printer will hold a maximum of 200 cards HDP825 825 LC has two Card Input Hoppers load 100 cards per Hopper based on a standard 30 mil card thickness e Load 100 cards in each of the two 2 Card Input Hoppers in the HDP825 825 LC printers 2 Card Input Hoppers printers have twa HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 35 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components Card Output Hopper Type Description Card Output All standard HDP Card Printers provide a 100 card capacity Card Output Hopper Hopper based on a standard 30 mil card thickness Note This hopper stores the cards after they are printed e Asan option the Printer can also be configured with an automatic Card Output Stacker If the Printer is configured with this option the Card Output Stacker will stack printed cards in a first in first out order Note This option is useful if you need to keep the printed cards in a specific order such as when printing cards
270. rinter from the factory or can be ordered separately as a field upgradeable Module Once attached the Card Lamination Module allows you to apply Fargo certified overlaminates for more secure tamper resistant cards This section explains all aspects of the Card Lamination Module s operation and the overlaminate materials available IMPORTANT Fargo Card Printers require highly specialized Print Ribbons to function properly To maximize Printer life reliability printed card quality and durability you must use only Fargo Certified Supplies For this reason your Fargo warranty is void where not prohibited by law if you use non Fargo Certified Supplies To order additional materials please contact your authorized reseller Adjusting the Card Flattener The Card Lamination Module provides an adjustable Card Flattener that allows you to fine tune the flatness of laminated cards This flattener works by reverse bending cards as they eject from the laminator while they are still warm In most cases card warpage is only a concern when laminating on a single side of card stock which has a PVC based core rather than a polyester based core Cards with a PVC based core are not as heat resistant and are not recommended for use when laminating By default the Card Flattener is configured at the factory to accommodate UltraCard III type card stock Note If you are experiencing an unacceptable amount of card warpage please refer to the following to ad
271. rmly wipe back and forth across the surface of the Printhead d Close the Print Station once the Printhead is completely dry 4 Clean the Cleaning Rollers a Open the Front Access Door of the Printer b Depress the Cleaning Roller Lock c Pull the Cleaning Roller Assembly out of the Printer d Clean the rollers with one of the adhesive backed Cleaning Cards from the Printer Cleaning Kit e Remove the card s adhesive backing paper and slide the card between the rollers until all dust particles are removed f Flip over the Cleaning Card to clean both the top and bottom Cleaning Rollers Note Alternatively placing the assembly under lukewarm water may clean the Cleaning Roller g Once cleaned replace the Cleaning Roller Assembly and close the Front Access Door A Caution Ensure that the Cleaning Roller Assembly is completely dry before reinstalling into the Printer Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 108 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Pixel failure problems continued Step Procedure 5 Clean the Platen Rollers Leave the Printer power ON and open the Print and Transfer Stations Remove the print ribbon and HDP Film Locate the Print Platen Roller as shown below Use a Cleaning Pad from the Printer Cleaning Kit to wipe the roller clean Locate the Transfer Platen Roller as shown below 0929 5
272. rocedures Removing the Print Station cover 840361 Removing the Front Transfer Cover 840362 Removing the Mid Pulley Cover D840166 Removing the Base Module cover 840363 Removing the Card Input Hopper cover 840167 Removing the Card Output Hopper cover 840167 Removing the Back cover Control Panel Assembly Components Replacing the Control Panel Assembly Components Printhead Assembly Components Replacing the Printhead D840854 Replacing the Fan Assembly D840986 Replacing the Head Force Spring 2 840272 Replacing the Ribbon Deflector D840638 Print Station Components replacement Replacing the Headlift Drive O Rings 140212 Replacing the Ribbon Drive O Ring behind the Encoder Wheel 810492 Replacing the Ribbon Sensor Board Assembly 140407 Replacing the Encoder Wheel 810492 Replacing the Ribbon Sensor Array Assembly 840108 Replacing the Ribbon Supply Motor Assembly D840980 Replacing the Ribbon Take Up Motor Assembly D840980 Replacing the Headlift Motor Assembly D840980 Replacing the Ribbon Supply Encoder Sensor Assembly D840982 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 243 244 244 245 246 246 247 248 252 256 258 259 260 260 263 265 266 267 269 270 272 273 273 274 275 276 2AT Bid 278 279 279 281 281 282 283 284 285 285 286 287 288 289 290 291 292 293
273. roken b Press the Resume button to continue or Cancel to reset the Printer Ensure that the ribbon is not stuck to the film a Open the Print and Transfer Stations b Verify that the ribbon is not stuck to the transfer film c If the ribbon is stuck to the transfer film increase the ribbon tension in increments of 5 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 85 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Print Ribbon Jam Symptom Ifthe print ribbon becomes stuck to the HDP film or jammed inside the Printer the LCD Display will indicate that it is jammed Refer to the following steps to clear the jam Step Procedure 1 Leave the power ON and open the Print and or Transfer Stations 2 Remove the Take Up core the side with used ribbon on it from in between the two black Drive Hubs Steadily pull the print ribbon free from where it is jammed e f stuck to the HDP film pull the ribbon off the film Do not jerk the ribbon to free it since this will increase the chance of breaking it e If it does happen to break simply tape the broken end of the Supply Roll directly onto the Take up roll Then wind a few inches worth of ribbon from the supply roll onto the Take up roll Be sure the print ribbon is passing behind both the Supply and Take up rolls Once the jam is cleared replace media and close the Printer At this point the LCD Disp
274. s 46 Initializing 53 inner alignment arrows 455 Input 511 Input hopper 511 Input Hopper 70 Input Hopper Card Capacity 12 13 Input Hopper Door 84 Insert Access Card 58 Insert New Card 58 Interface 13 Fargo Electronics Inc interface cable 471 Intermediate Transfer Media InTM 511 Interpreting LCD Display Messages 466 Invalid Access Card 58 Invalid Password 58 IPC 183 ISO 511 ISO 7811 2 Magnetic Stripe 226 ISO encoded data format 222 ISO option 221 ISO Standard Encoding Module 219 ISO Track Locations 226 J jam cleared 98 jewelry 108 JIS C 6220 Type II cards 219 JIS II Japanese Industrial Standard 511 JIS I option JIS II mode JIS II Magnetic Head 219 JIS II Standard Encoding Module 219 Job Mismatch 53 K K Panel 511 K Panel Resin options 216 K Panel Resin tab 210 211 L Lam Board 100 Lam Error Out Error Message 104 105 Lamination 75 107 511 Lamination 374 375 376 377 379 380 381 382 383 384 386 388 Lamination Assembly 334 335 Lamination Board 72 97 Lamination Board 140402 368 Lamination Boards 91 Lamination Module 40 41 42 43 Lamination Module Board Cover D870151 373 Lamination Module Flipper Electric Clutch E000267 378 Lamination Roller 333 Lamination Sensor 103 104 Lamination Sensor Calibration 103 104 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 527 RESTRICTED USE ONLY
275. s being fed improperly off the Flipper Table in Section 2 page 73 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 84 RESTRICTED USE ONLY Fargo Electronics Inc Printing Process Errors Resolving the Ribbon Alignment Error Message Step Procedure 1 Check that the ribbon is loaded properly and completely seated on the Hubs 2 Check that the marks on the ribbon are complete Check the motor operation to ensure that the ribbon moves in both Forward and Backward directions on Power Up Test the Ribbon Sensor a Remove the back cover and locate the connector labeled J65 on the main Board b Check the voltage for each of the five 5 Ribbon Sensors 140404 and 140407 at their connection to the main Board c Use a Multimeter to ground the negative lead to the chassis and put the positive lead on pins 3 5 7 9 and 11 of J65 on the main Board d Place a RibbonTraq mark over the Ribbon Sensor Note The voltage should be less than 1 VDC e Remove the RibbonTraq mark from the Ribbon Sensor Note The voltage should be greater than 3 5 VDC f Replace the Sensor if the voltages are incorrect Install a new ribbon and press the Resume button to continue if the ribbon is out Clear the jam and reboot the Printer if the ribbon is jammed Repair the ribbon if the ribbon breaks a Repair the ribbon by taping it back on to the take up core if the ribbon is b
276. s displayed click on Exit on the Sending Update to Printer dialog screen 10 Press the Printer s Exit button 11 When prompted turn the Printer power OFF for a few seconds and then back ON to complete the update process Note As the Printer restarts you will see the new Firmware version appear on the LCD 12 a If the upgrade was not successful the LCD will either display Upgrade Failed or Upgrade Firmware Now on boot up b If you receive this message try updating the Firmware again HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 473 RESTRICTED USE ONLY Fargo Electronics Inc Updating the LCD Firmware Step Procedure 1 Make sure the Printer is powered ON connected to the PC and in its READY mode 2 From the Firmware Updater program click on the Select Update File button 3 Go to the folder in which you saved the update file select it and click Open The file name location and version will appear in the Firmware Updater window as shown on the next page 4 Click on the Select Printer button and select the specific Fargo Printer model click OK 5 Click on the Send Update button to bring up the Firmware Updater dialog box as shown on the next page 6 Wait a few minutes while the Firmware updates itself Check the Printer s LCD for the status When the update is complete the LCD will indicate if the update was successful e f Upgrade Successful is displayed
277. s over a network Note In this case this option ensures that all Printers share evenly all print jobs g HDP825 LC Card Printer Printing Preferences Bea Magnetic Encoding Lamination k Panel Resin Card Device Options Image Color Image Transfer Ribbon Type YEO Full Color Resin Black Film Type Cer S SY Color Matching Algebras stsi is sY Fesin Dither Optimized for Graphics W Print Both Sides T Split 1 Set of Ribbon Panels Link Card to Print Job Print Back Side First Disable Printing Print Back Side Only Rotate Front 180 Degrees W Rotate Back 180 Degrees HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 197 RESTRICTED USE ONLY Fargo Electronics Inc Using the Link Card to Print Job option Use this option to link a specific card to a specific print job Generally this option is used mostly when printing and encoding e cards Note In this case it is often critical that an e card with a pre encoded serial number for example coincide with a particular printed image If the two were to get out of sync the card s security could be compromised Step Procedure 1 Select this option to cause the Printer to dispense with the print job if a blank card is removed or ejected Note The next card is then fed into the Printer and the next coinciding print job then printed HDPS25 LC Card Printer Printing Preferences i a x Magnetic Enco
278. s will generally take about 3 to 4 minutes Note The LCD Display will read Laminator Warming or Laminator Cooling whenever the Lamination Roller is heating up or cooling down to the prescribed temperature When the Lamination Module has reached its target temperature Lamination will begin Term Description Reference Programmed Upon initial power up the Lamination See the Using the Lamination Default Module is programmed to heat the tab only with the Card Temperature Lamination roller up to its default Lamination Module in Section 5 page 238 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 46 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Laminator Temperature Adjustment Term Description Reference Laminator To change the temperature of the See the Using the Lamination Temperature Laminator adjust its temperature through tab only with the Card Adjustment the Lamination tab within the Printer Lamination Module in Section Driver setup window New Temperature Settings Once adjusted the new temperature settings will be sent down with the next print job along with the rest of the Printer Driver information Before printing begins the laminator will automatically adjust itself to the new temperature setting Note This new temperature setting will remain programmed within the Printer until it is once again changed within the Printer Driver or until the Prin
279. settings 76 Changing the Encoder Settings 83 chipping of card image 477 Clean inside Printer 246 Clean outside of Printer 246 Clean Platen Roller 125 Cleaning Card 67 68 Cleaning Cards 67 Cleaning Inside Printer 110 Cleaning Kit 108 Cleaning Pen 108 Cleaning Platen Rollers 112 Cleaning Roller 504 Cleaning Roller Assembly 108 251 358 Cleaning Roller Drive Idler Gear 2 354 Cleaning Roller Lock 67 108 111 248 Cleaning Rollers 248 249 250 251 Cleaning the Cleaning Rollers 111 Clear Protective Overlay Panel 32 Clearing card jam 71 Coercivity 504 Coercivity of cards matches Driver setting 80 81 Coercivity option 221 Color Bars YMC 133 color correcting 190 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 523 RESTRICTED USE ONLY color matching 190 504 color matching algorithm 190 color matching software 190 colors 12 Colors misregistered 60 Communication Errors 60 62 Compound Gear 347 Compressed air 504 compressed Firmware Update file 470 Consistent Temperature 47 Contrast 504 Contrast Gamma 201 Control Panel 504 Control Panel Assembly Components 280 Control Panel Bezel 280 Copies 236 copyright version information 237 correct Printer installation 60 Cover Removal 273 CR 100 505 CR 100 patch size 49 CR79 505 CR 80 505 CR 80 CR 90 and CR 100 231 233 CR 90 505 CR 90 or CR 100 49 Cross Member 349 CSA
280. signating a unique Card Type name which then saves custom Image Transfer settings Custom 1 For example Custom 1 could be changed to read as My Cards Custom transfer settings would then be available whenever this Card Type option is selected and would be saved each time the Printer Driver setup window is closed Custom Card stock To determine the proper settings for custom card stock Fargo recommends the Tape Adhesion Test in the next procedure on page 181 Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 179 RESTRICTED USE ONLY Fargo Electronics Inc Selecting the appropriate HDP Printer Driver settings continued Card Ribbon Type Transfer Transfer Time Flattener Temp Temp UltraCards Glossy 175 2 seconds inch Dual Side 75 EVE OR Pang Single Side 90 ribbon HDP Cards Matte 195 2 seconds inch Dual Side 75 PVO non H Panel Single Side 90 ribbon UltraCards Glossy 175 2 seconds inch Dual Side 75 PVC H Panel bold ee ribbon 2 Single Side 90 HDP Cards Matte 175 2 seconds inch Dual Side 75 PVC H Panel ribbon Single Side 90 Based on 30 mil card thickness e For thinner cards reduce the Flattener temperature e For thicker cards increase the Flattener temperature YMCKH Panel ribbon provides a Heat Seal Panel that aids in transferring to matte finished cards and requires a lower transfer tem
281. sing the Thermocouple to help maintain the desired temp The Ribbon Drives turn ON and move until the correct panel is found by the Print Ribbon Sensor array 5 reflective All stop Note The Print Ribbon Encoder is active during this step The Film Ribbon Drive turns ON until the Film is positioned with the Film alignment Sensor All stop Note The Film Ribbon Encoder is active during this step The Headlift Motor engages moving the Printhead down until Headlift Sensor is activated All stop Print Station Card Continued on the next page Printhead LED Light LCD Display Scroll Buttons Card Input Hopper Hopper Output ne F 4 Access Card Slot Front Access Door Card Thickness Adjustment Knob Transfer Station Card Cleaning Assembly Release Lever HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 vii RESTRICTED USE ONLY FARGO Electronic Inc Reviewing HDP 800 Series Card Printer Sequence of Operations cont Step Process 5 The Fan turns ON as required to keep head cool 6 The Ribbon Drives Film Ribbon Drive and Stepper turn ON and the Printhead burns the image data until the image data is depleted All stop Note The Ribbon Encoders are active during this step 7 The Headlift Motor engages moving the
282. ssembly under lukewarm water may clean the Cleaning Roller A Caution Ensure that the Cleaning Roller Assembly is completely dry before reinstalling into the Printer Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 250 RESTRICTED USE ONLY Fargo Electronics Inc Cleaning the Cleaning Rollers continued Step Procedure 5 a Once cleaned replace the Cleaning Roller Assembly and close the Front Access Door b Push the assembly in until you hear the Spring loaded tab click into place Note This assembly must be inserted properly for the Printer to function c Close the Printer s Front Access Door HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 251 RESTRICTED USE ONLY Fargo Electronics Inc Cleaning the Card Feed Rollers Steps Procedure 1 To ensure consistent Printer operation all of the Card Feed Rollers within the Printer should be cleaned approximately every 250 prints or if the rollers are noticeably dirty This helps prevent jams and maintain the best print quality With the Printer power ON use the following steps to clean the rollers Open the Card Input Hopper Door remove the blank cards and locate the two Card Input Feed Rollers A Caution Do not attempt to run a cleaning card through the Printer to clean the Card Feed Rollers Cleaning cards can become jammed in the Card Flattener and damage
283. structed in the help screen The second type of prompt is called an Attention screen Note This screen will not stop Printer operation and serves to communicate helpful reminders such as if you are running low on print supplies and also communicates any other Printer conditions of which you should be aware In this case the LCD will display Attention on the first line and a brief description of the condition on the second line e f multiple messages need to be communicated at the same time the first line will display Attention 1 of 2 or whatever the total number of messages may be e Like error messages help text explaining the particular condition can also be accessed by pressing the Help button Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 29 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components LCD and Softkey Control Pad continued Component Description Access Card Slot This is the slot in which a SmartGuard Access Card is inserted if you are using the Printer s SmartGuard Security Feature Note This unique feature prevents the Printer from operating unless a custom access card is inserted e To use the SmartGuard feature refer to the instructions included with it for information on how to enable and use this security feature e To avoid using the SmartGuard feature do not insert an access card to operate the Printer Access C
284. sulting in Sensor errors HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 94 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Film Sensor errors continued Step Procedure 4 Check for broken Lamination Roller Cover Hinges Note A broken Lamination Roller Cover Hinge 840255 will not allow the Lamination doors to open properly which will result in poorly printed cards and film errors HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 95 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Film Sensor errors continued Step Procedure 5 Check the covered and uncovered voltages of the Lower Film Sensor 840199 This can be measured at J65 Pin 8 on the Lamination circuit Board 140402 e When the Sensor is covered the voltage should be lower than 9 Volts e When the Sensor is uncovered the voltage should be above 3 4 volts Re calibrate the upper film Sensor assembly A000222 Note For proper calibration the clear portion of the film must be installed between the Sensor when making any adjustments e Technician Note 1 The LED light should be OFF when there is no mark present e Technician Note 2 The LED should be ON when a mark is present Check to see if the lower film Sensor assembly 840199 contains spacers e Technician Note 1 These spacers are not needed and should be removed to improve the lo
285. t to move the image toward the rear of the Printer if a positive number is entered and toward the front of the Printer if a negative number is entered OR Use the Horizontal adjustment to move the image toward the card output side of the Printer if a positive number is entered and toward the card input side of the Printer if a negative number is entered Note The maximum value for the Vertical and Horizontal adjustments is 100 Pixels 10 Pixels 0 03 8mm Rear of Printer Card Output f Horizontal Horizontal Card Input Side of Printer Side of Printer am Direction card travels through printer Front of Printer HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 206 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Transfer Dwell Time and Temperature Use the Image Transfer option to control of the Transfer Dwell Time and Transfer Temperature These settings control the speed and temperature at which printed images are transferred from the HDP Film to the card These settings may vary depending on the card type The Printer Driver automatically optimizes these settings according to the selection made in the Card Type option Changes made to the Dwell Time and temperature settings are saved for the selected Card Type option upon exiting the Printer Driver setup in the Printer s Control Panel Step Procedure 1 Return to the factory default settings for the selected Car
286. tall Replace the Printhead if the problem persists HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 128 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Registration problems Symptom Colors are shifted slightly in the image creating colored edges or poor resolution Step Procedure 1 Calibrate the Upper Film Sensor to ensure proper calibration a Position the HDP Film so that a clear portion is between the slotted optical Sensor b Turn the potentiometer on the Sensor Board with a small slotted screwdriver until the LED on the Sensor Board turns ON c Back the potentiometer OFF slowly until the LED just turns OFF Note Ensure that when performing this procedure that there is no direct light shining into the Printer Excessive ambient light in the vicinity of the Printer may also affect the calibration of the Sensor 2 Adjust the Ribbon Tension by 1 and print a sample card e If symptoms appear better continue adjusting until registration problems are gone e f symptoms appear worse adjust the ribbon tension by 1 and print a self test e If symptoms appear better continue adjusting until registration problems are gone 3 Reposition the Film Drive Motor a Loosen the screws that hold the Film Drive Motor located in the middle Module and pull the motor back against the belt b Hold the motor there and tighten the screws that hold the motor in place in
287. tation 90 Operating Temperature 14 O Ring 513 OS Operating System 513 Output 513 output errors 100 Output hopper 513 Output Hopper Card Capacity 14 Output Hopper Full 54 Output Stacker 100 Output Stacker D840590 370 Overlaminate 48 514 Overlaminate Design 49 Overlaminate Jam 101 102 103 Overlaminate Options HDP800 Series LC only 14 Overlay 513 Oversized Cards 514 P Parallel 514 parallel cable 60 Parallel Interface Port 22 Parallel port 514 Fargo Electronics Inc parallel port mode 61 Parts Replacement 258 Pass Count 134 Pause button 28 Pause 55 PC Personal Computer 514 PCB Printed Circuit Board 514 Peel 514 Peel Off 514 Peel Off Bar not straight 131 Peel Off Bar Ribbon Peel Bar 126 131 Peripheral 514 permanent circuit memory 438 PET 515 Photo 191 Pillow Block assembly 353 Pinch roller 515 Pinch Roller Spring Plate Back Input Side 343 Pinch Roller Spring Plate Back Output Side 344 Pinch Roller Spring Plate Front Input Side 341 Pinch Roller Spring Plate Front Output Side 342 Pixel 515 pixel failure problems 108 109 Platen 515 Platen or Flipper Motor D870218 387 389 Platen Roller 112 Platen Rollers 109 256 257 Polyester Patch Overlaminate 48 PolyGuard Overlaminate 48 49 515 poor alignment of Peel off Bars 477 poor image quality problems 127 Port 515 Portrait 515 Portrait Landscape
288. te Jam 101 Resolving the Card Lamination Placement errors 103 Resolving the Lam Error Out Error Message 104 Resolving the Lamination not adhering to the card surface problem 106 Diagnosing the Image Problems 108 Resolving the Pixel failure problems 108 Resolving the Card surface debris problems 110 Resolving the incorrect Image Darkness problems 113 Resolving the Ribbon wrinkle problems 115 Resolving the excessive Resin Printing problems 117 Resolving the incomplete Resin Printing problems 118 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 2 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the HDP Film wrinkle problems 119 Resolving the incomplete Transfer problems 121 Resolving an incomplete transfer on the leading edge problem 122 Resolving an incomplete transfer on the trailing edge problem 122 Resolving the Image Placement problems 123 Resolving the poor Image Quality problems 127 Resolving the Image washout on Film problems 128 Resolving the Registration problems 129 Resolving the Card Skewed Image problems 131 Printing a Test Image 132 Reviewing the Gray Align YMC K Self Test 132 Reviewing the Color Resin YMCK Self Test 133 Reviewing the Color Bars YMC Self Test 133 Reviewing the Card Count Self Test 134 Reviewing the Magnetic Test option 134 Reviewing the Lamination Color Resin YMC
289. ter is turned OFF Automatic Reset Whenever the Printer is turned OFF the laminator will automatically reset itself and return to its default temperature the next time the Printer is turned ON Note Pressing the Lamination Module s or Printer s Cancel button or switching the Printer power OFF and ON both serve to reset the Laminator to its default temperature Consistent Temperature The temperature setting within the Printer Driver stays the same until it is changed 5 page 238 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 47 RESTRICTED USE ONLY Reviewing the Overlaminates Fargo Electronics Inc IMPORTANT Fargo Card Printers require highly specialized overlaminates to function properly To maximize Printer life reliability printed card quality and durability you must use only Fargo Certified Supplies For this reason the Fargo warranty is void where not prohibited by law if you use non Fargo Certified Supplies To order additional materials please contact the authorized reseller Reviewing the Thermal Transfer Film and PolyGuard Overlaminates Transfer Film and PolyGuard Overlaminates either a Thermal Transfer Film overlaminate or a Polyester Patch Overlaminate called PolyGuard Thermal Transfer Film The Thermal Transfer Film overlaminate is a relatively thin material which covers a card Edge to Edge and provides a medium level of card durability and sec
290. termine if the Peel Off Bar is not straight Note The Peel Off Bar should be equidistant from the Lamination Assembly frame at both ends a Verify that the Peel Off Bar and the Ribbon Peel Bar height is correct Note From the front of the HDP Card Printer the Peel Off Bar on the input side the drawing D841085 should be flush with the frame The Ribbon Peel Bar on the output side should have a 3 16 inch 4 5mm gap between the frame and the Ribbon Peel Bar b Remedy the offset printing raising the bar higher off of the card 0 005 inches by loosening the screws for the Peel Off Bar and carefully raising both sides to the same degree Note The Peel Off Bar assembly should be equidistant at both ends from the frame 3 Determine if the card is fed askew into the Transfer Station Interrupt the transfer process to ensure that the card has fed properly into the Transfer Station e If the card has been fed skewed ensure that the card size knob is set to the correct card size e If the card size has been confirmed manually feed a card into the Printer using the Forward and Back soft key buttons on the display e Position the card next to the Spring loaded Card Pusher and ensure that the Card Pusher is applying pressure to the card HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 131 RESTRICTED USE ONLY Fargo Electronics Inc Printing a Test Image Step Procedure 1 Choose Print Test Image to sel
291. that indicates to the processor that what follows is a command and not data ESD ElectroStatic The discharge of static electricity high voltage low current that Discharge can damage electronic devices Ethernet A system of networking a Series of computers for the sharing of data or peripherals Film A thin flexible transparent sheet used to carry dye impregnated material or resin to be transferred to the card Firmware The instruction set stored in chip memory inside the Printer that controls functional and operational data Some models require a chip change for updates some Firmware can be changed by reprogramming from the PC Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 508 RESTRICTED USE ONLY Fargo Electronics Inc Glossary of Terms continued Term Definition Flash Memory A microchip based non volatile memory device that holds its data when power is removed This allows for field reprogramming of the Printer commands such as Printer Firmware upgrades without the necessity of changing chips Font A character set similar in style and form Fonts can be graphical or mathematical constructs represented by a Series of dots or an assembly of curves and lines FPGA Field Programmable Gate Array A microchip with configurable logic circuits installed that is programmed to act as the Printer s central processor
292. the Lamination section The Printer s LCD softkey buttons affect any card in either the Print Station or the Lamination Station e g the Lamination Module s Cancel button cancels only the Lamination job the Printer s CANCEL softkey button cancels both the print and Lamination jobs e f both the Print Station and Lamination Station are open the LCD s FORWARD and BACK softkey buttons will move ALL rollers e f only the Lamination Module is opened only the Lamination Module buttons will move the Lamination rollers HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 74 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Card Jam Lam Error Message Symptom The Card Jam Lam Error is displayed on the LCD Step Procedure 1 Look for a jammed card in the Printer a Open the Printer s top cover b Remove the ribbon from the Printer c Check to see if a card is jammed in the Lam Station of the Printer d Ifa card is jammed in the Printer use the Pause Resume button and the Cancel buttons to move the feed rollers and free the card Note The card can then be fed out of the Printer e If no card was found in the Lam Station continue to Step 2 2 Test the TOF Sensor Note If the Printer has begun laminating the card and then jams it may be possible that the centering of the Lamination of the card has caused the jam a Inspect the card and determine if the Lamination is centered o
293. the new temperature settings will be sent down with the next print job along with the rest of the Printer Driver information New Before printing begins the laminator will automatically adjust itself to the Temperature new temperature setting Note This new temperature setting will Setting remain programmed within the Printer until it is once again changed within the Printer Driver or until the Printer is turned OFF Whenever the Printer is turned OFF the laminator will automatically reset itself and return to its default temperature the next time the Printer is turned ON e Flip the Power Switch to OFF OR e Disconnect the Printer s power cord Technician Note Both the Power Switch and the Printer s power cord serve to reset the laminator to its default temperature The temperature setting within the Printer Driver however will stay the same until it is changed HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 37 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Card Lamination Module A A Danger The Printers Lamination Roller can reach temperatures exceeding 350 F 175 C Use extreme caution when operating the Laminator Never touch the Lamination Roller unless the Printer has been turned off for at least 20 to 30 minutes Select Printer models support the attachment of an optional Card Lamination Module This Module can be ordered pre installed on your Printer from the factor
294. this new position Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 129 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Registration problems continued Symptom Colors are shifted slightly in the image creating colored edges or poor resolution Step Procedure 4 Determine if the Printhead pressure is too high or too low a Remove the Printhead See the Replacing the Printhead D840854 procedure in Section 5 page 281 and bend the two metal Springs slightly toward the back of the upper Module b Reinstall the Printhead and print a test card c If registration does not get better remove the Printhead and bend the two metal Springs away from the upper Module slightly d Reinstall the Printhead and print a self test 5 Verify that the Upper and Middle Modules are seated properly and the Modules are completely locked down HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 130 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Card Skewed Image problems Symptom The self test image appears skewed on the card a Step Procedure 1 Determine if the film is tracking sideways a Open the Lamination station and reload the Transfer Film so that Film moves straight onto spool b Remove as needed the old Film from the take up spool and reattach the Film in the proper location on the spool 2 De
295. tion Table cont Access Card e The SmartGuard Security Feature now protects the Printer e From now on you must insert a valid access card to operate the Printer Message Cause Solution SmartGuard Indicates that the SmartGuard Security Press the OK button to Disabled Feature has successfully been continue disabled Indicates that you no longer need to insert an access card to operate the Printer SmartGuard Indicates that all data has successfully Press the OK button to Enabled been encoded onto the SmartGuard continue Writing Access Card Indicates the SmartGuard Access Card is being encoded Press the OK button to continue HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 59 RESTRICTED USE ONLY Fargo Electronics Inc Communications Errors Resolving the Communication Errors Symptom s Incorrect output communications error on PC or Printer stalling no response from Printer no job printed or paper out error Step Procedure 1 Confirm that the system meets the minimum requirements as shown here e IBM PC or compatible e Windows 98Se ME NT 2000 XP Pentium class 133 MHz computer with 32 MB of RAM or higher e 200 MB free hard disk space or higher e ECP parallel port with DMA access 2 Confirm the correct installation of the Printer Driver a Close the software program and check the Printer Driver b Reboot the computer c Mak
296. tion 2 page 91 Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 56 RESTRICTED USE ONLY Reviewing LCD Messages continued Fargo Electronics Inc Message Cause Solution Transfer The Transfer Roller is warming to the No action required Warming proper temperature Unable To The Printer is unable to feed a card See the Resolving the Card Feed Card from the Card Hopper Feeding problem procedure in Section 2 page 65 Update The system Firmware MUST be See the Updating the Printer s Firmware updated Firmware procedure in Section Now 8 page 471 Unknown The Printer does not recognize the See the Resolving the Unknown Ribbon Type print ribbon that is installed in the Ribbon Type Error Message Printer procedure in Section 2 page 88 Upgrade The Printer was unable to complete a See the Updating the Printer s Failed Firmware upgrade Firmware procedure in Section 10 page 471 Wrong Print The print ribbon installed in the Printer See the Replacing the Wrong Ribbon does not match the ribbon type Print Ribbon Error Message selected in the Printer Driver procedure in Section 2 page 87 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 57 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing SmartGuard Error and Status Messages Message Cause Solution Access Card Deleted The data
297. tion 3 Card Lamination Module The purpose of this section is to provide the User with specific information on Printer adjustment procedures Safety Messages review carefully Symbol Critical Instructions for Safety purposes A Danger Failure to follow these installation guidelines can result in death or serious injury Information that raises potential safety issues is indicated by a warning symbol as shown to the below To prevent personal injury refer to the following safety messages before performing an operation preceded by this symbol To prevent personal injury always remove the power cord prior to performing repair procedures unless otherwise specified To prevent personal injury make sure only qualified personnel perform these procedures A Caution This device is electrostatically sensitive It may be damaged if exposed to static electricity discharges Information that raises potential electrostatic safety issues is indicated by a warning symbol as shown to the below To prevent equipment or media damage refer to the following safety messages before performing an operation preceded by this symbol To prevent equipment or media damage observe all established Electrostatic Discharge ESD procedures while handling cables in or near the Circuit Board and Printhead Assemblies To prevent equipment or media damage always wear an appropriate personal grounding device e g a hig
298. track s specific Start Sentinel SS and the last character must be the specific End Sentinel ES e The characters or data in between the SS and ES can include all of the valid characters specific to each track e The number of these characters however is limited by each track s maximum character capacity e When segmenting track data the appropriate Field Separator FS must be used The table on the next page shows the SS ES FS and the valid characters defined for each track HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 227 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Sample String e Track 1 1 JULIEANDERSON1 234567890 e Track 2 2 1234567890987654321 e Track 3 3 1234567890987654321 Maximum Valid Characters Number of Separator Characters ASCII 32 95 See the table below ASCII 48 63 See the table below ASCII 48 63 See the table below HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 228 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the ASCII Code and Character Table ASCII Code Character ASCII Code Character ASCII Code Character 32 space 56 8 80 P 33 57 9 81 Q 34 58 82 R 35 59 83 S 36 60 lt 84 T 37 61 85 U 38 amp 62 gt 86 V 39 63 87 W 40 64 88 X 41 65 A 89 Y 42 i 66 B 90 Z 43 67 C 91 44 68 D 92 45
299. tronics Inc Adjusting the Internal Card Guide continued Step Procedure 2 Adjust the Internal Card Guide according to the card size on which you intend to print and laminate CR 80 CR 90 or CR 100 Use the card size markings on the Internal Card Guide as a general reference for the proper position As shown here position the card size line at the center of the two adjustment screws Be sure the Internal Card Guide always remains parallel with the Card Guide Rail when adjusting If necessary adjust the Internal Card Guide as described in the remainder of this section Continued on the next page Position line at center of screws HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 150 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Internal Card Guide continued Step Procedure 3 To verify proper adjustment feed a blank card into the Module by inserting it through the output hopper and reverse feeding it by pressing the Lamination Module s Resume button Note Manually position the card so its edge is flush with the Card Guide Rail When adjusted properly there should be a slight space of about 010 25mm between the card edge and the Internal Card Guide as indicated here Note Adjust further to this indicated position if necessary Always make very slight adjustments to the Internal Card Guide and run a test print after each adjustment until
300. ts dust or Surface any other types of embedded contaminants UltraCard Due to the importance of using high quality blank cards a factory approved stock card stock called UltraCard is available and recommended for best results e UltraCard stock has a glossy PVC laminate on top and bottom and is optically inspected to provide the cleanest most scratch and debris reduced cards possible e Two types of these cards are available UltraCard and UltraCard III UltraCard stock has a PVC core and offers medium card durability UltraCard III stock has a 40 polyester core and offers high durability Both types of UltraCards produce printed images with a glossy photo quality finish HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 33 RESTRICTED USE ONLY Fargo Electronics Inc Printer Components Card Input Hopper HDP820 820 LC Type Description Card Input The Card Input Hopper is where cards are initially loaded for printing The Hopper Printer s hopper provides a large door that opens up wide to make card HDP820 820 loading simple and closes securely to help protect the card stock Note LC printer The Printer will hold a maximum of 250 cards HDP820 820 LC in its one 1 Card Input Hopper based on a standard 30 mil card thickness See the Technical Specification e Load 250 cards into the one 1 Card Input Hopper in the HDP820 820 LC printers HDP 800 Series Card P
301. ued on the next page Bottom Edge HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 146 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Card Guide Rail continued Step Procedure 5 If the PolyGuard patch is being placed more toward a card s bottom edge as shown move the Card Guide Rail slightly toward the front of the Printer opposite the direction you would like the patch to move 6 Always make very slight adjustments to the Card Guide Rail and run a test print after each adjustment until the optimum patch position is found Note Be sure the Card Guide Rail always remains parallel to the card path and that the screws loosened in step 1 are retightened after each adjustment Continued on the next page Top Edge Bottom Edge HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 147 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Card Guide Rail continued Step Procedure 7 Once the adjustment is complete be sure that the card is not binding between the Card Guide Rail and the Internal Card Guide Note Depending upon how much you adjusted the Card Guide Rail you may also need to adjust the Internal Card Guide When both are adjusted properly there should be a slight space of about 010 25mm between the card edge and the Internal Card Guide as indicated here If necessary adjust the Internal Card Guide as descr
302. up continued Step Procedure 3 Be sure to run this test after each adjustment Run the Alignment Test Image by selecting the following options MENU PRINT TEST IMAGE and GRAY ALIGN YMC All HDP images must have an extra 0 04 in 1mm over bleed on all sides of the card The Outer Alignment Arrows should fall in this area when the image is properly centered they will be left off of the card when transferred See the Reviewing the Color Bars YMC Self Test in Section 2 page 133 See the display below 4 a Choose MENU Setup Printer and the setting to be changed Change the value and press SELECT to save the value c If the settings are lost due to replacing the Main Print Board set the starting values to the settings listed on the label on the back of the Printer HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 448 RESTRICTED USE ONLY Fargo Electronics Inc Preparing to Adjust the Print Offset Transfer TOF and Transfer EOF Step Procedure 1 Before starting the alignment procedures you must first establish a baseline from which to start the adjustments 2 Select MENU Setup Printer 3 Select the Print Offset button 4 Set to 32 and press the Select button 5 Select Transfer TOF 6 Set to 40 and press the Select button 7 Select the Transfer EOF button 8 Set to 24 and press the Select button HDP 800 Series Card Printer Encoders S
303. up Printer HELP SELECT EXIT HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 Continued on the next page 444 RESTRICTED USE ONLY Fargo Electronics Inc Entering the LCD Menu and Selecting an Option continued Step Procedure 1 Use the scroll buttons to move up or down through the menu options as shown below Note The brackets appear on either side of the active Menu option 2 Press the button below Select to choose an option Choose from these five categories Print Test Image Setup Printer Show Error Count Show Card Count and System Upgrade Softkey Buttons Scroll Buttons VA Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 445 RESTRICTED USE ONLY Fargo Electronics Inc Selecting from the HDP800 Series Menu Option Structure Tree SELECT FUNCTION Prnt Test image Setup Printer menu Show Error Count Show Card Count System Upgrade SELECT TEST IMAGE Gray A yuck ALH tA YMCK Color Bars YMC Nagrrotic Tost Card Count Cotor Revin VMCK L CHANGE PARAMETER Print Offsot Pansier TOF Tanstor BOF Panstor Tension Pim Orive t Ribbon Tension Ribbon Orive f Panster Temperature nr Plattener Temperature Hoad Resistance image Oakes Encoder Settings t Piippor Offset Lamination TOF Lamination EOF Learnt reetion Temp Lam Sensor Calibration
304. urity e PolyGuard Overlaminate PolyGuard is a much thicker material which does not cover Edge to Edge but provides an extremely high level of card durability and security Note PolyGuard is available in either a 1 0 or 6 mil thickness and should always be used for those applications requiring the highest degree of card durability and security Term Description Cross Reference Thermal The Card Lamination Module will accept See the Loading the Overlaminate procedure in Section 3 page 140 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 48 RESTRICTED USE ONLY Reviewing the CR 90 or CR 100 Patch Size Fargo Electronics Inc Term Description Cross Reference CR 90 or PolyGuard Overlaminate is available in a See the Loading the CR 100 standard CR 80 patch size as well as a CR Overlaminate procedure in 90 and CR 100 patch size for laminating oversized CR 90 or CR 100 cards Note Thermal Transfer Film overlaminate will accommodate CR 80 and CR 90 card sizes but is not recommended for CR 100 cards Section 3 page 140 Reviewing the Overlaminate Design Term Description Cross Reference Design Both PolyGuard and the Thermal Transfer See the Loading the Film overlaminates are available in either a clear or generic secure holographic type design Note Custom holographic type overlaminates are also available with specific designs patterns logos and sec
305. urity features Please contact the authorized reseller for more information about custom Overlaminates Overlaminate procedure in Section 3 page 140 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 49 RESTRICTED USE ONLY Fargo Electronics Inc Section 2 General Troubleshooting The purpose of this section is to provide the User with specific procedures relating to the LCD SmartGuard Messages Communication Errors Card Feeding Errors Encoding Errors Printing Process Errors Transfer Process Errors and Diagnosing the Image Problems for the HDP 820 Card Printer IMPORTANT Fargo Card Printers require highly specialized print ribbons to function properly To maximize Printer life reliability printed card quality and durability you must use only Fargo Certified Supplies For this reason your Fargo warranty is void where not prohibited by law if you use non Fargo Certified Supplies To order additional materials please contact your authorized reseller LCD SmartGuard Messages The LCD display shows the current status of the Printer Refer to the cause and solution tables in this section for all possible LCD messages Note These tables display the LCD messages in alphabetical order If the LCD message is communicating an error or requires an action these tables will also offer a solution to what should be done Reviewing LCD Messages Message Cause Solution Add Cards
306. use of the interference is not the switch box or peripheral d Alternative Add a second parallel port into the computer if a second Printer is required 2 Ensure that the proper procedure is being used a Be sure to follow the instructions on the attached HDP Firmware Upgrade Guide to insure that the correct data is being transferred to the Printer b Itis possible that the Firmware Update Program is corrupt In this case the entire program should be uninstalled from the PC and the newest version of the program should be downloaded and installed from Fargo s web site http www fargo com Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 63 RESTRICTED USE ONLY Fargo Electronics Inc Resolving an Upgrade Failed error continued Step Procedure 3 Ensure that the proper procedure is being used a Be sure to follow the instructions on the attached HDP Firmware Upgrade Guide to insure that the correct data is being transferred to the Printer 4 a Itis possible that the Firmware Update Program is corrupt In this case the entire program should be uninstalled from the PC and the newest version of the program should be downloaded and installed from Fargo s web site http www fargo com 5 Update from the 32 bit Print Spooler Install and open the 32 bit Print Spooler program Click on File in the menu and select the Open option Then point t
307. w will appear Continued on the next page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 184 RESTRICTED USE ONLY Fargo Electronics Inc Installing Printer Driver Updates continued Step Procedure 6 Click on Browse navigate to the folder containing the Printer Driver files you just downloaded and unzipped and click on OK Click on OK again to close the Install From Disk window and then click on NEXT 7 Follow the remainder of the on screen instructions to complete installation Note When prompted do not have Windows print a test print since you most likely performed a Printer self test while you were setting up the Printer Once installed the HDP Card Printer icon will appear in the Printers folder HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 185 RESTRICTED USE ONLY Fargo Electronics Inc Setting Up the Printer Driver Once the appropriate Printer Driver for the computer has been installed you will need to set the Driver up with the proper print options To open the Printer Driver setup window please refer to the following steps for the specific operating system Setting up Windows 98SE Windows Millennium Step Procedure 1 Click the Start button point to Settings and select Printers 2 Click on the HDP800 Series LC Card Printer icon with the right mouse button and select Properties Setting up Windows NT Win
308. wer film Sensor signal e Technician Note 2 Units that are between these serials numbers are at risk for having these spacers A1450365 A2150092 Verify the lower Film Sensor bracket 840323 has a flat black finish in the mounting hole for the Reflective Sensor Note If paint does not cover the entire hole the Sensor performance will be negatively affected Replace the lower Film Sensor bracket if it does not See the Replacing the Lower Film Sensor Assembly 840199 procedure in Section 6 on page 328 Verify the Film is located correctly on the roll Note The film placement on the roll should be 10mm 5mm 10 Update to the latest version of Firmware See the Firmware Updater Application Program procedure in Section 10 page 468 HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 96 RESTRICTED USE ONLY Fargo Electronics Inc Resolving the Transfer Cooling error Symptom The LCD indicates a Transfer Cooling error for an extended period of time Driver Settings may be too extreme Step Procedure 1 Verify if the Driver settings are too extreme a Run a self test from the Printer b Select Menu from the LCD c Select Print Test Image from the menu d Select Gray Align Self test from the Menu Note This will cause the Laminator to attempt to operate at the default temperature e If the Transfer Cooling message is not displayed for an extended p
309. xt page HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 168 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Card Input Guide continued Step Procedure 4 Push the Card Input Guide back into position so that it rests flush against the side of the card stack 5 Once the Card Input Guide is adjusted properly retighten the Locking Knob loosened in step 1 1 a 1 F a k St a HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 169 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Card Stacker Output Guide Step Procedure 1 Open the Card Output Hopper Door and locate the Card Stacker Output Guide closest to the front of the Printer e Adjust the stacker s Card Output Guide to the proper card size prior to printing Note This will ensure consistent card ejecting and stacking e Ifthe Card Stacker Output Guide is not set prior to printing it can cause jams Continued on the next page Card Output Guide HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 170 RESTRICTED USE ONLY Fargo Electronics Inc Adjusting the Card Stacker Output Guide continued Step Procedure 2 This guide is adjustable Move the Card Output Guide to the CR 80 CR 90 or CR 100 setting according to the specific size of the cards Continued on the next page HDP 800 Series Card
310. y or can be ordered separately as a field upgradeable Module HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 38 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Lamination Top Cover and Station Component Description Reference Lamination Opens to allow access to the Lamination See the Opening the Card Top Cover Station overlaminate and card path Lamination Module procedure in Section 3 page 137 Lamination Transfers overlaminates onto cards via its See the Loading the Station heated Lamination roller The Lamination Overlaminate procedure in Station must be closed in order for the Section 3 page 140 Printer to begin laminating Lamination Station Securing E Latches Lamination Top Cover Lamination LED Light Cancel Button Resume lt lt Mm pause Button Card Output lt S Hopper W Rejectio n Da E a Card Hopper HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 39 RESTRICTED USE ONLY Fargo Electronics Inc Reviewing the Securing Latches and Lamination LED Light Component Description Reference Securing Locks the Lamination Station securely in See the Using the Latches place when closed Lamination tab only with the Card Lamination Module in Section 5 page 238 Lamination The Lamination LED Light works in See the the Reviewing LCD LED Light conjunction with the Printe
311. ype barcodes only with the resin black K Panel of the Print Ribbon by default e f printing black text or barcodes that are not TrueType fonts or black graphics select one of the three options listed under Print All Black With K Panel see the procedure on the next page The Printer Driver will print areas of the image where it finds black coloring with the Print Ribbon s resin black K Panel as specified by each of the following options f HDP820 LC Card Printer Printing Preferences 2 x Card Device Options Image Color Image Transfer Magnetic Encoding Lamination K Panel Resin CR 80 Card Size Front Back y pw 4X inche si m 0 0 Defined Area x 4 M Direction Card Travels Through Printer Delle Print All Black With K Panel I Full Card I Defined Areals M Undefined Areals Print YME Lndert C Print K Orly Cancel Apply Help HDP 800 Series Card Printer Encoders Service Manual Rev 5 0 209 RESTRICTED USE ONLY Fargo Electronics Inc Selecting the Full Card with the K Panel Resin tab Step Procedure 1 Select the Full Card option to print the resin black K Panel for all black found within all areas of the image as shown below CR 80 Card Size f Front WH 020 x ro Defined Area 0 0 a z Direction Card Travels Through Frinter Print All Black with K Panel Defined Areals Undefined Areals f Print MC Under K

FARGO electronic HDP820 Printer User Manual

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