Colour ID Card Printer MAGICARD Enduro Maintenance Manual Magicard Enduro single sided colour ID Card Printer Magicard Enduro Duo double sided colour ID Card Printer - 3633-9001 3633-9021 Magicard Enduro Mag single sided colour ID Card Printer Magicard Enduro Duo Mag double sided colour ID Card Printer - 3633-9002 3633-9022 Magicard Enduro single sided colour ID Card Printer with Smart Encoder Magicard Enduro Duo double sided colour ID Card Printer with Smart Encoder - 3633-9005 3633-9025 Magicard Enduro Mag single sided colour ID Card Printer with Smart Encoder Magicard Enduro Duo Mag double sided colour ID Card Printer with Smart Encoder - 3633-9006 3633-9026 Duplex Upgrade Kit Ethernet Upgrade Kit - 3633-0052 3633-0096 Standard Standard Standard Standard Ultra Electronics Card Systems www.magicard.com Standard Standard Option Option Option Option
Ultra Electronics Card Systems CONTENTS Contents. - 2 Conventions. - 4 Warnings, Cautions and Notes. - 4 Safety Instructions . - 4 - Section 1 Introduction to the Printing Process. . - 6 - Section 1.1 Section 1.2 Card Design Limitations . - 8 Badge Design . - 8 - Section 2 Key features of the Magicard Enduro . - 9 - Section 2.1 Specification of the Magicard Enduro . - 10 - Section 3 Component Layout. - 11 - Section 4 Dye Film Options. - 14 - Section 4.1 Section 4.2 Loading the Dye Film. - 15 Cards . - 16 - Section 5 Single / Double-sided Upgrade. . - 18 - Section 6 Ethernet Upgrade. - 19 - Section 7 Philosophy. - 20 - Section 7.1 Section 7.2 Section 7.3 Section 7.4 Repair and Maintenance . - 20 The Warranty . - 21 Internet Support . - 22 Recommended Tools . - 22 - Section 8 Cleaning the Printer. . - 23 - Section 8.1 Section 8.2 Section 8.3 Section 8.4 Section 8.5 Cleaning is Important. - 23 Cleaning Supplies. - 23 Cleaning the Printer Rollers. - 24 Replacing the Cleaning Roller . - 25 Cleaning the Print Head. . - 26 - Section 9 Magicard Enduro Driver. . - 27 - Section 9.1 Section 9.4 Section 9.5 Section 9.6 Installation of Ultra Driver . - 27 Un-install Continued . - 31 Un-installing the Driver for Windows Vista & 7. . - 32 Driver Description . - 33 - Section 10 Printer Display . - 34 - Section 10.1 Section 10.1.1 Section 10.1.2 Section 10.1.3 Section 10.1.4 Section 10.1.5 Section 10.1.6 Section 10.2 Section 10.2.1 Section 10.2.2 Section 10.2.3 Operational Mode . - 34 Test Card Mode. - 35 Printer Cleaning Mode. - 35 Printer Info Mode . - 36 Hand Feed Mode. - 37 Advanced Menu Mode. - 37 Exit Menu. - 37 Maintenance Mode . - 38 Soak Test Mode . - 38 Sensor Test Mode . - 39 Previous Menu. - 40 - Section 11 Print Head Replacement . - 41 - Section 11.1 Section 11.2 Section 11.3 Section 11.3 Section 11.4 Section 11.5 Print Head Damage. . - 41 Print Head Electronic Failure. - 42 Replacing the Print Head. - 42 Replacing the Print Head Cont. . - 43 Setting the Print Head Density calibration. . - 44 Print Head Setup and Adjustment . - 45 - Enduro Maintenance Manual -2-
Ultra Electronics Card Systems Section 12 Dismantling and Assembling the Printer . - 46 - Section 12.1 Section 12.2 Section 12.3 Section 12.4 Section 12.5 Section 12.6 Section 12.7 Section 12.8 Section 12.9 Section 12.10 Section 12.11 Section 12.12 Section 12.13 Section 12.14 Section 12.15 Section 12.16 Section 12.17 Section 12.18 Removing & Refitting the Printer Casing. . - 46 Removing & Refitting the Front Fascia Cover . - 46 Removal & Refitting of the Top Dye Film Sensor . - 47 Removing & Refitting of the Lower Dye Film Sensor. . - 47 Removal and Refitting of the Card Thickness Adjuster . - 48 Removing & Refitting the Controller PCB. - 48 Removing & Refitting of the Front & Rear Card Sensor . - 49 Removing & Refitting the LCD Display. - 49 Removal & Refitting of Left Side Components . - 50 Removal and Refitting of Right Side Components . - 51 Removal & Refitting of the Drive Motors & Front Card Sensor. . - 52 Removal of the Chassis Cover. - 53 Removal of the Rotation Unit. - 54 Removal of the Idle Rollers . - 54 Removal and Refitting of the Large Bearing Plate . - 55 Removal and Refitting of the Small Bearing Plate. - 55 Removal and Refitting of Rollers . - 56 Removal & Refitting of the Card Guide & Middle Card Sensor . - 56 - Section 13 Troubleshooting. - 57 - Section 13.1 Section 13.2 Section 13.3 Section 13.3 Section 13.4 Section 13.5 Initialisation Sequence. - 57 Hardware Problems . - 58 Image Problems . - 59 Image Problems Cont. - 60 Printer Driver Problems . - 61 Magnetic Encoding Problems. - 62 - Section 14 Error Code List . - 63 - Section 14 Section 14 Section 14 Error Code List Cont. . - 64 Error Code List Cont. . - 65 Error Code List Cont. . - 66 - Section 15 Magicard ID Printer Support Utility. - 79 - section 16 Magnetic Encoding. - 89 - Section 16.1 Section 16.2 Section 16.3 Section 16.4 Section 16.5 Section 16.6 Section 16.7 Magnetic Encoding Standards. - 89 Basic Magnetic Encoding. . - 91 Encoding using Badge Printing Software. . - 92 ASCII Character Set Supported by the Enduro . - 93 ISO Standards . - 93 Error Checking. - 94 Fitments to the Printer. . - 95 - Section 17 Parts and Part Numbers. - 96 - Section 17.1 Section 17.2 Section 17.3 Section 17.4 Section 17.5 Section 17.6 Section 17.7 Section 17.8 Section 17.9 Section 17.10 External Components . - 96 Top Cover Assembly (3633-0150). - 96 Print Head assembly (FG/3633-0160). - 97 Rotation Unit Assembly (3633-0140). - 97 Roller Layout. . - 98 Drive Mechanism Right Hand Side. - 99 Drive Mechanism Left Hand Side. . - 100 Motor Layout and Part Numbers. . - 101 Internal Wiring & Sensor Part Numbers . - 102 Magnetic Encoding Option . - 103 - Section 18 Driver Release History Detail . - 104 - Section 19 Firmware Release History Detail. - 105 - Enduro Maintenance Manual -3-
Ultra Electronics Card Systems CONVENTIONS WARNINGS, CAUTIONS AND NOTES. Throughout this guide, the following conventions are used to identify important information. WARNING Warning messages indicate where personal injury could result from not following the correct procedures. CAUTION Caution messages indicate where damage to equipment could result from not following the correct procedures. NOTE Notes convey important information that is identified within the text. The information contained in this document is subject to change without notice. Ultra Electronics Limited shall not be liable for errors contained herein or for incidental consequential damages in connection with the furnishing, performance or use of this material. This document contains proprietary information belonging to Ultra Electronics Limited and may not be wholly or partially copied, stored in a data retrieval system, disclosed to third parties or used for any purpose other than that for which it was supplied, without the express written authority of Ultra Electronics Limited. All rights are reserved. MAGICARD , Rio, Tango, UltraCoverplus, Alto, Opera, Prima, Prima 2E, Prima 3, Prima 4 Holokote, Rio 2, Tango 2, Rio 2E, Tango 2E, Enduro, Enduro . Ultra Shield MAGICARD is registered as a Trademark with the United States Patent and Trademark Office, Reg. No. 2,197,276 The Ultra Secure feature of Magicard Printers is protected by US PATENT No: 5,990,918 and by EUROPEAN PATENT SPECIFICATION EP 0 817 726 B1. Microsoft and Windows 2000, XP, Vista, 7, Server 2003 and Server 2008 are trademarks of Microsoft Corporation. Copyright 2004 Ultra Electronics Limited Enduro Maintenance Manual -4-
Ultra Electronics Card Systems SAFETY INSTRUCTIONS Use the Power Source supplied with the printer by Magicard. Do not to spill any liquid on the Printer. Ensure that the power supply cord is not longer than 2 metres in length and includes a properly grounded connection. If using this printer in Germany: To provide adequate short-circuit protection and over-current protection for this printer, the building installation must be protected by a 16 Amp circuit breaker. Bei Anschluß des Druckers an die Stromversorgung muß sichergestellt werden, daß die Gebäudeinstallation mit einem 16 A-Überstromschalter abgesichert ist. When Handling the Printer: Avoid touching the thermal printing edge of the Thermal Print Head. Any grease and contamination will shorten its life. Before transporting the Printer, remove the dye film and card hoppers and pack the printer in its original packaging. Location Requirements for your Printer: A clean, dry level surface. Adequate space for: Cable access at the rear. Allowance for air circulation. An adequately ventilated room. The correct Power Supply provided by Magicard. Ambient temperature 10 to 30 degrees C. Relative Humidity 20/70% RH. Protection from direct sunlight and chemicals. Protection from abrupt temperature changes. Enduro Maintenance Manual -5-
Ultra Electronics Card Systems SECTION 1 INTRODUCTION TO THE PRINTING PROCESS. Sublimation uses heating elements in a rigid ceramic print head to transfer colour into or onto the PVC plastic surface from the Dye Film ribbon. The colours Yellow, Magenta & Cyan are absorbed into the PVC and the Black (K) & Clear Overcoat is heated onto the card surface. Dye Sublimation Dye Sublimation, or Dye-Sub, is known for its high quality photographic output. Dye Sublimation is also known as “Dye Diffusion” or “Thermal Transfer”. Inside the Dye Sublimation printer is a roll of transparent film that resembles sheets of red, blue, yellow, and black coloured cellophane bonded together end to end. On one surface of this film are solid Dyes corresponding to the four basic colours used in printing: cyan, magenta, yellow and black. Between the solid Dye and the film, is a layer of release agent, which controls the amount of dye released at each temperature. The Print Head is heated up as it passes over the film, causing the dye to vaporise and permeate the glossy surface of the PVC card before returning to solid form on cooling. This is sublimation. The Clear Overcoat Layer The Overcoat layer acts as a protective film against wear and fading and can also carry a secure image, which cannot be photocopied – e.g. the Magicard Holokote security watermark. ID Card with Overcoat Layer used as a Security Watermark Dye Sublimation / Inkjet Printing. There are two factors that contribute to the quality of Dye Sublimation printers. The first is continuous tone, and the other is un-dithered colour. In Dye Sublimation printing, colours are not laid down as individual dots, as is done in inkjet printers. The colour produced by a dye-sub is the result of the mixing of pigments to get the actual colour. This is in contrast to most other printing methods which use a tight group of coloured dots which, when seen by the human eye from a distance, appear to be a colour (a process known as “dithering”). Under magnification, the dots are clearly different colours, and when seen close up with the naked eye the picture appears grainy. Because only one colour needs to be printed (instead of up to four), a Dye Sub can place more dots on a card. It can take a 1200 dpi printer to get the same resolution a 300 dpi dye-sub printer is capable of. Another difference that helps is that because the colour sublimates on the card instead of being laid down as little dots, the edges of each pixel are blurred. This gives the impression of blending for a more natural appearance. Dots from an inkjet leave large white gaps in between pixels, giving the impression of a grain. Since longevity is something we all want from our prints, it’s also reassuring to know that because dyes sublimate instead of just being painted onto its surface, dye sublimation prints resist fading and are colourfast. Enduro Maintenance Manual -6-
Ultra Electronics Card Systems Subtractive Colour. This section contains some background material on the colour process used in printing. The colours (Yellow, Magenta, and Cyan) used in dye sublimation use a subtractive colour process. Subtractive colour starts with an object (often a substrate such as paper or plastic) that reflects light and uses colourants (such as pigments or dyes) to subtract portions of the white light illuminating an object to produce other colours. If an object reflects all the white light back to the viewer, it appears white. If an object absorbs (subtracts) all the light illuminating it, no light is reflected back to the viewer, it appears black. It is the subtractive process that allows everyday objects around us to show colour. Colour paintings, colour photography and all colour printing processes use the subtractive process to reproduce colour. In these cases, the reflective substrate is canvas (paintings) or paper/plastic (photographs, prints), which is usually white. Colour monitors, TV’s, projectors etc. use the additive process. Subtractive colour process (YMC) Additive colour process (RGB) In theory, overprinting all three colours produces black. In reality, a dark grey is produced, so black is used as a fourth printing ink, hence the ‘K’ (for monochrome) in YMCK. The K Resin layer allows very sharp defined black text, barcodes etc. to be added. Printing. Due to the ceramic print head being rigid the quality of the card surface is extremely important if high quality images are to be produced. Cards should be selected which are cut cleanly at the edges and have perfectly flat surfaces. There are various card manufacturers and several different types of PVC card. Each of these will accept colour in differing amounts using the same print head temperature. This is due to the PVC being used and the manufacturing process. When printing a full colour card, the print head will get progressively hotter as it works. This is compensated for in the printer firmware but it may affect how evenly some card designs print. Dust and debris on the card surface will cause small white blemishes to appear in the image so keeping the cards and tacky rollers clean is imperative. The printer creates the card by placing layers of dye onto the card in the following sequence: Yellow: (Y) Magenta: (M) Cyan: (C) Black: (K) or Resin black Clear: (O) or Overcoat. The Overcoat layer acts as a protective film against wear and fading and can also carry a secure image, which cannot be photocopied. (Ultra Secure). Colours appearing on the monitor will not always be exactly the same as those printed by a printer; this ca
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ReTransfer ID Card Printer - User Manual . 4 . GENERAL INFORMATION . This document contains proprietary information belonging to Magicard Ltd. and may not be wholly or partially copied, stored in a data retrieval system, or used for any purpose other than that for which it was supplied, without the express written authority of Magicard Ltd.
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ID Card Printer - User Manual - 6 - Open printer, then: A. Pull out the unused cleaning roller. B. Peel off white protective layer carefully to reveal tacky surface. C. Place cleaning roller back into printer. Hopper & Stacker Prepare the cleaning roller HOPPER: Insert the hopper into the aperture at the back of the printer and click
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