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Colour ID Card Printer MAGICARD® Pronto Maintenance Manual

Magicard Pronto single sided colour ID Card Printer - 3649 - 0001 Magicard Pronto Mag single sided colour ID Card Printer - 3649 - 0002

Issue 1 22/01/09

Option Standard Standard Standard

Ultra Electronics Ltd

Pronto Maintenance Manual - 2 -

CONTENTS Contents............................................................................................................................................................................. - 2 -

CONVENTIONS ..................................................................................................................................................................................................... - 4 - Warnings, Cautions and Notes. .................................................................................................................................................................................... - 4 -

SAFETY INSTRUCTIONS................................................................................................................................................. - 5 -

SECTION 1 INTRODUCTION TO THE PRINTING PROCESS................................................................................... - 6 - section 1.1 card design limitations ....................................................................................................................................................................... - 8 - section 1.2 badge design ..................................................................................................................................................................................... - 8 -

SECTION 2 KEY FEATURES OF THE MAGICARD PRONTO....................................................................................... - 9 - section 2.1 specification of the magicard PRONTO........................................................................................................................................... - 10 -

SECTION 3 COMPONENT LAYOUT ............................................................................................................................ - 11 -

SECTION 4 DYE FILM OPTIONS ................................................................................................................................. - 14 - Section 4.1 loading the dye film.......................................................................................................................................................................... - 15 - Section 4.2 cards ................................................................................................................................................................................................ - 16 -

SECTION 5 PHILOSOPHY............................................................................................................................................ - 18 - section 5.1 repair and maintenance................................................................................................................................................................... - 18 -

SECTION 6 WARRANTY INFORMATION .................................................................................................................... - 19 - section 6.1 The warranty.................................................................................................................................................................................... - 19 - Section 6.2 Internet support............................................................................................................................................................................... - 20 - section 6.3 recommended tools ........................................................................................................................................................................ - 20 -

SECTION 7 CLEANING THE PRINTER........................................................................................................................ - 21 - section 7.1 cleaning is important........................................................................................................................................................................ - 21 - section 7.2 cleaning supplies ............................................................................................................................................................................. - 21 - section 7.3 cleaning the printer Rollers .............................................................................................................................................................. - 22 - section 7.4 replacing the cleaning roller............................................................................................................................................................. - 23 - section 7.5 cleaning the Print Head. .................................................................................................................................................................. - 24 -

SECTION 8 MAGICARD PRONTO DRIVER................................................................................................................. - 25 - section 8.1 installation instructions for Windows 2000/xp/2003 server & VISTA. .............................................................................................. - 25 - section 8.1 installation instructions for Windows 2000/xp/2003 server & VISTA (continued…) ..................................................................... - 26 - section 8.2 un-installing the driver for windows 2000 / xp / 2003 server............................................................................................................ - 27 - section 8.3 un-installing the driver for windows vista. ........................................................................................................................................ - 28 - section 8.4 driver description ............................................................................................................................................................................. - 29 -

SECTION 9 PRINTER FUNCTIONS ............................................................................................................................. - 30 - section 9.1.1 printing a Test Card ......................................................................................................................................................................... - 30 - section 9.1.2 Printer cleaning mode...................................................................................................................................................................... - 30 - section 9.2.1 soak test mode ................................................................................................................................................................................ - 31 -

SECTION 10 PRINT HEAD REPLACEMENT ................................................................................................................. - 32 - section 10.1 Print Head damage......................................................................................................................................................................... - 32 - section 10.2 Print Head Electronic failure. ........................................................................................................................................................... - 33 - section 10.3 replacing the Print Head. ................................................................................................................................................................. - 33 - section 10.3 replacing the Print Head (cont). ....................................................................................................................................................... - 34 - section 10.4 Setting the Print Head density calibration........................................................................................................................................ - 35 - Section 10.5 Print Head setup and adjustment .................................................................................................................................................... - 36 -

SECTION 11 DISMANTLING AND ASSEMBLING THE PRINTER ................................................................................ - 37 - section 11.1 removing & refitting the printer casing. ............................................................................................................................................ - 37 - Section 11.2 Removing & Refitting the front fascia cover .................................................................................................................................... - 37 - section 11.3 removal & refitting of the top dye-film sensor .................................................................................................................................. - 38 - section 11.3 removing & Refitting of the lower dye-film sensor. .......................................................................................................................... - 38 - section 11.5 removing & Refitting the controller pcb............................................................................................................................................ - 39 - section 11.6 removing & refitting of the front & rear card sensor......................................................................................................................... - 40 - section 11.8 removal & refitting of left side components...................................................................................................................................... - 41 - section 11.9 removal and refitting of right side components................................................................................................................................ - 42 - section 11.10 removal & refitting of the Drive motors & front card sensor. ............................................................................................................ - 43 - Section 11.11 removal of the chassis cover ........................................................................................................................................................... - 44 - section 11.13 removal of the idle rollers................................................................................................................................................................. - 45 - section 11.16 Removal and refitting of rollers ........................................................................................................................................................ - 46 - section 11.17 removal & refitting of the card guide & middle card sensor ............................................................................................................. - 46 -

SECTION 12 TROUBLESHOOTING ............................................................................................................................... - 47 - Section 12.1 initialisation sequence...................................................................................................................................................................... - 47 - Section 12.2 hardware problems.......................................................................................................................................................................... - 48 - Section 12.3 image problems ............................................................................................................................................................................... - 49 - Section 12.3 image problems COnt...................................................................................................................................................................... - 50 -



Section 12.4 printer driver problems..................................................................................................................................................................... - 51 - Section 12.5 Magnetic encoding problems........................................................................................................................................................... - 52 -

SECTION 13 MAGICARD SUPPORT UTILITY............................................................................................................... - 53 -

SECTION 14 MAGNETIC ENCODING............................................................................................................................ - 58 - section 14.1 magnetic encoding standards.......................................................................................................................................................... - 58 - SECTION 14.2 Basic Magnetic Encoding. ............................................................................................................................................................... - 60 - SECTION 14.3 Encoding using Badge printing Software......................................................................................................................................... - 61 - section 14.4 ASCII Character Set supported by the PRONTO............................................................................................................................ - 62 - section 14.5 ISO standards.................................................................................................................................................................................. - 62 - section 14.6 error checking. ................................................................................................................................................................................. - 63 -

SECTION 15 FITMENTS TO THE PRINTER. ................................................................................................................. - 64 -

SECTION 16 PARTS AND PART NUMBERS................................................................................................................. - 65 - section 16.1 external components ....................................................................................................................................................................... - 65 - section 16.2 Top cover assembly (3633-0150) .................................................................................................................................................... - 65 - section 16.3 Print Head assembly (FG/3649-0160) ............................................................................................................................................. - 66 - section 16.5 Roller Layout.................................................................................................................................................................................... - 67 - section 16.6 Drive mechanism right hand side. ................................................................................................................................................... - 68 - section 16.7 Drive mechanism left hand side....................................................................................................................................................... - 69 - section 16.8 Motor layout and part numbers........................................................................................................................................................ - 70 - section 16.9 Internal wiring & sensor part numbers ............................................................................................................................................. - 71 - section 16.10 Magnetic encoding option................................................................................................................................................................ - 72 -

SECTION 17 PRONTO SPARES LIST............................................................................................................................ - 76 -

SECTION 18 FIRMWARE RELEASE HISTORY............................................................................................................. - 77 -

SECTION 19 PRONTO ERROR CODES........................................................................................................................ - 78 -



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, Holokote, Rio 2, Tango 2, Rio 2E, Tango 2E, 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 and Vista are trademarks of Microsoft Corporation. Copyright © 2004 Ultra Electronics Limited.



SAFETY INSTRUCTIONS Only use the Power Source supplied with the Printer by Magicard. Do not to spill any liquid on the Printer. Ensure that the Power Supply cable 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 Print Head. Any grease and contamination will shorten the operational life. Before transporting the Printer, remove the Dye-Film and Card Hoppers and pack the Printer in it’s 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 Centigrade.

Relative Humidity 20/70% RH.

Protection from direct sunlight and chemicals.

Protection from abrupt temperature changes.



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 are heated onto the Card surface.

Dye Sublimation

Dye Sublimation, or Dye-Sub, is known for it’s 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.

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 Printer 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 Printer 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 it’s surface, dye sublimation prints resist fading and are colourfast.

ID Card with Overcoat Layer used as a Security Watermark



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 “Sticky” Roller 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 can be due to various issues such as in transmitted light from the monitor colours can look different than viewing reflected light from the Card. All monitors will show the same image slightly differently. Different plastic surfaces will give differing results and the Dye-Film could vary slightly from batch to batch. For these reasons, the Printer Driver has been designed to allow the user to adjust various aspects of the colour output.



SECTION 1.1 CARD DESIGN LIMITATIONS It is important to remember that no Printer of this type will give the same quality / quantity of output as can be achieved with a mass production Offset Printer. These Printers use a completely different process, print the same image hundreds of times on large sheets of material, punch the finished Card out of the sheet and cost 10 times as much to purchase. As long as badge designs are created to suit the dye sublimation process and the type of Card being printed, the results will look as good to the naked eye as the far more expensive machines and can be personalised from Card to Card.

SECTION 1.2 BADGE DESIGN It is important to realise that it is better to design a badge that will print successfully than attempt to print to the limits of this type of Printer and cause waste and frustration. The main issues to be considered are as follows : The heat in the Print Head accumulates faster if dark colours are printed. The darker the colour the more heat is used to print the layers onto the Card. The Printer will automatically reduce the Print Head temperature to stop the colours getting darker along the length of the Card. This is set up in the mid range of the print density and will be slightly different on dark or light colours. Plain colour areas are the most likely to show any variation so it is better to use textured colours where possible. If a coloured band runs along the Card and into a picture, it will affect the area of the picture where it has increased the Print Head temperature. Pictures will sometimes print better either at the start or the end of the Card, depending on the layout. Always try reversing the whole image to select the best result. When printing on electronic Cards, ensure that the design of the badge allows for any unevenness in the surface due to the embedded chip or antenna, these can cause white or faded patches to appear in the text or image. Ensure that any captured image such as an ID photograph is lit correctly for colour and brightness and is properly focused as the Printer cannot improve poor quality input. If you add a logo or bitmap to the design, ensure that the size of the original does not cause distortion and pixelation if it has to be enlarged or reduced to fit into the design. It is more important to ensure the colour of any picture element is correct when printed (even if the colour looks incorrect on the screen).



SECTION 2 KEY FEATURES OF THE MAGICARD PRONTO

Flexible

Drop in Dye-Film loading with automatic detection and set up for Dye-Film type. Simple no mess cleaning operation. Full Bleed Edge-to-Edge printing as standard option.

Smart

Attractive, compact design. Multicoloured front Panel Button giving a clear indication of status. USB interface. Microsoft Certified “Plug and Play” Driver make the Pronto easy to install and use.

Secure

Magicard Pronto features the patented “Holokote” watermark technology. Holokote watermark is printed on the Card during the normal print cycle at no extra cost. Four Holokote design patterns offered as standard with every Pronto. Holopatch is available using special Card stock to produce a highly visible gold seal. Optional ISO 7811 Magnetic Stripe Encoder.



SECTION 2.1 SPECIFICATION OF THE MAGICARD PRONTO Printing Method : Direct to Card Dye Sublimation. Feed Format : Hand Feed. Resolution : 300 dots per inch (11.8 Dots per mm). Colour Reproduction : 256 graduations for each colour. Internal Memory Size : 8 MBytes. Printing Time : Approximately 35 seconds per side (YMCKO). Approximately 7 seconds for monochrome Printer Interface : USB Rev 1.1 (USB 2.0 compatible). Operating Environment : Temperature 15 – 30 degrees Centigrade Humidity 20% - 70% Storage Environment : Temperature 15 – 55 degrees Centigrade Humidity 20% - 70% Power Source : External Power Supply (auto-selecting). Input Voltage : AC Input 100 – 240 V AC. Input Current Consumption : 1.8 Amps. Frequency : 50 – 60 Hz. Output Voltage : 18 – 24 V DC. Output Current Supply : 3.2 Amps. Output Power Rating : 60 Watts (Max). Weight : 4.4 Kilograms (10 lbs) Dimensions : 270mm (L) x 215mm (W) x 233mm (H) 17.8” (L) x 8.1” (W) x 9.2” (H). Dye-Film loading : Drop in Dye Film design. Dye-Film Set-up : Automatically detects Dye Film. Software : Supplied with Windows 2000, 2003 Server, XP, Vista (32 bit) and

Windows 7 (32 bit) Drivers. Magstripe Encoder : Optional HICO/LOCO Magnetic Stripe Encoder to ISO 7811. Card Size : CR80 - 85.6 x 54.0 mm (3.375” x 2.125”) and

CR79 - 83.9 x 51.0 mm (3.303” x 2.051”) sized Cards. Card Thickness : 0.51 – 1.02mm (0.020” – 0.040”) Card Types : PVC. Holopatch Cards are available. They are used with the Holokote feature to produce a highly visible “gold seal” on the Card. Print Length : Full card 1016 pixels (85.6mm) Print Width : Full card 642 pixels (54.5mm) Safety : CE Certified, UL listing USA EMC : EN 50 081-1 and EN 50 082-1 (Europe) FCC pt 15 curve A (USA) & CSA 08.8 curve A (Canada) Warranty : Two years limited warranty (North America and EU only) Elsewhere 1 year limited warranty.



USB Socket

DC Power Input

SECTION 3 COMPONENT LAYOUT

Top Cover Opening Latch

Multicoloured Button

Hand Feed Entry / Exit Slot

Print Head Assembly

Printer Connections



Print Head Assembly

Card Hand Feed Entry / Exit Slot

Top Cover Opening Catch

Top Cover Holding Latches

Print Head Cooling Fan

Dye Film Sensor Bracket (upper)

Unused Dye Film Spool Holder

Used Dye Film Spool Holder

Cleaning Roller Cassette



Top Cover Interlock Sensor

Magnetic Encoder Roller

Dye Film Sensor Bracket (lower)

Dye Film Drive Gear

Print Head Roller

Front Card Opto Sensor

Mid Card Opto Sensor

Rear Card Opto Sensor

Front Pinch Roller



SECTION 4 DYE FILM OPTIONS MA300YMCKO Dye-Film is the appropriate choice for colour printing with the Pronto. MA1000K & MA600KO Dye-Film – where cost is critical, monochrome printing is a fraction of the cost of colour printing. The Table below is a guide to selecting the best Dye-Film to use for any intended application.

Ribbon Layout Colour Key

Full color Cards or monochrome

Cards per Dye Film

Dye Film Panel layout

Part Number

Full Colour

300 Cards YMCKO MA300YMCKO

Monochrome: Black Red Blue Green Gold Silver White Scratch

1000 Cards K

MA1000K n (n = colour)

Black & Overcoat

600 Cards KO MA600KO

Yellow (Y) Magenta (M) Cyan (C) Resin (K) Overcoat (O)



SECTION 4.1 LOADING THE DYE FILM.

Incorporated in colour, black and clear Dye-Film is an electronic RFID protective Tag. When the Printer begins it’s initialisation process, the Printer reads the Tag and looks for the following information:

Dye-Film type. Remaining number of prints.

If it fails to read any of the data from the RFID protective Tag, the Printer assumes it has monochrome Dye-Film fitted.

Operate the top cover release Catch and lift the cover.

Place the two Spools into the front and rear cradles (left side first) and press it into place. Ensure the Gear (front right) engages with the front Spool.

Gently close the top cover until it clicks into the closed position.

The Printer will automatically recognise the type of Film that has been loaded by reading the RFID Tag

when it initialises.



CR80 85.6mm or 3.375” CR79 83.9mm or 3.303”

CR80 53.98mm or 2.125” CR79 51mm or 2.051”

CR80 – 1016 Pixels CR79 – 990 Pixels

CR80 – 642 Pixels CR79 – 601 Pixels

Recommended page size for edge to edge printing

ISO Standard Cards Sizes Printable Area of Cards

SECTION 4.2 CARDS

Card Material

Not all white plastic Cards are the same. For best image quality always use high quality grade PVC Cards. Pure PVC Card stock or laminated PVC/Polyester Cards are available. The latter are more durable and better suited to heavy use and heat lamination when required. For access control and “Smart Card” applications, your Dealer should provide the appropriate type for “Direct to Card” printing. For good consistent results, keep to a single variety of good quality Cards, such as those available from your Magicard Dealer.

Card Size

Card Thickness

Minimum 0.51mm 0.020” Standard 0.76mm 0.030” Maximum 1.02mm 0.040”

To obtain good quality prints the Cards must be :

Glossy white.

Free from dirt or grease.

Free from surface contamination, e.g. finger marks.

Free from burrs at the edge of the Card.

Free from pits or bumps in the surface.

Printable Area of the Card

The Pronto Printer offers high quality edge to edge (full bleed) printing. Thus the surface of the Card may be printed “edge to edge”. Die cut PVC Cards typically have an edge roll off (bevel) which can result in a fine white line around the edge of full bleed printed Cards. When setting up your Card design using your graphics software on your PC, you should use a maximum page size of 1016 pixels (3.375”/85.6mm) x 642 pixels (2.125”/53.98mm).



Other Card Types

Self-Adhesive Cards We recommend only self adhesive Cards supplied by Ultra Electronics via your MagiCard Dealership. There are many different types of self-adhesive Cards. Thorough investigation and testing has shown that poorer quality or incorrect Card types will cause problems in the Printer. These problems range from poor image quality, Dye Film being cut, through to Cards getting jammed in the Roller mechanism. Contact Chip Cards “Smart Cards” must conform to the ISO 7816 specification, with the chip contacts being below the surface of the Card. It is unwise to print graphics or text directly adjacent to the chip as image quality may be affected.



SECTION 5 PHILOSOPHY SECTION 5.1 REPAIR AND MAINTENANCE

The repair and maintenance philosophy for the Magicard Pronto is for repairs to be carried out by the replacement of defective modules. The Printer has been specifically designed to comprise of several major modules : The external Power Supply Unit (PSU). The Main Control PCB. The Print Engine Assembly. The Thermal Print Head.

Field Repair

Every precaution has been taken in the design of the Pronto Printer to ensure user problems are rare. We have also tried to anticipate any possible problems in the field, due to misuse, accidental failure or component failure. This Manual should enable the Service Agent to identify any module or component that has failed, replace it, and carry out the appropriate setting up and testing to ensure satisfactory operation.

Feedback

Ultra Electronics Limited is committed to the manufacture of quality products and encourages feedback of any problem or faults occurring in the field, in order that we can improve the quality of our design, manufacture and support. We would be grateful if the Service Agent would give full details of all faults when returning the Printer to us for repair. We also provide a Customer Support service to help Customers in case they are having problems with their Printer. You will find helpful information on our web-site: www.magicard.com Contact Magicard Customer Support on the following numbers : UK : Tel : +44 (0) 1305 762115 Fax : +44 (0) 1305 777904 E-Mail : [email protected] USA : Tel : +001 425 556 9708 Fax : +001 425 556 3962 E-Mail : [email protected]

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SECTION 6 WARRANTY INFORMATION

SECTION 6.1 THE WARRANTY

Coverage

Ultra Electronics Ltd warrants that the MAGICARD Printer shipped with this warranty statement will conform to the manufacturers specifications and be free from defects in materials or workmanship for a period of 24 months from the date of original purchase by the user. There are additional conditions on the Print Head warranty (see Para 2).

Limited Print Head Warranty

Ultra warrants that, under normal use and service, thermal Print Heads will be free from defects in material and workmanship for a period of 12 months from the date of original purchase or for a quantity of 40,000 printed Cards, (whichever comes first), provided that Ultra-approved card media is utilised. If a warranty claim is submitted for a defective Print Head, Ultra will have the right to inspect the Print Head and samples of the printed and blank ID Cards used with it for the purpose of verifying that the claimed defect has not been caused by non-Ultra approved media, or by foreign particles or substances which have caused chemical or physical damage. Ultra's decision in any such claims shall be final.

Warranty Claims

If the MAGICARD Printer proves defective during this period, please contact Magicard Customer Support, at the address and telephone/Fax number given below. The Customer Support personnel may first ask you to carry out certain simple checks to confirm the nature of the problem, and if a return is appropriate, they will give you a “Magicard Return Authorisation Number” (MRAN) and consignment instructions to the appropriate repair centre. Ultra will, at it’s discretion, repair or replace the defective parts at no charge to the Customer.

Warranty Limitations

The warranty does not apply to MAGICARD Printers that have been :

Damaged through physical or electrical mishandling.

Damaged through operation in environments that are outside normal office conditions in terms of corrosive atmosphere, temperature, humidity, shock or vibration.

Improperly installed or interfaced to other products which may exhibit software problems or expose the

MAGICARD to improper voltages or control signals.

Fitted with Dye Film from any source other than Ultra Electronics, or have been used to print on anything other than Card surfaces which are approved by Ultra and which will generally be made of PVC, be completely flat, and be free of harmful particles or substances.

Serviced by anyone other than an Ultra Authorised Service Provider.

Shipping

Insurance and shipping costs incurred in sending the MAGICARD printer for warranty service is the responsibility of the customer. Whenever possible, Magicard Customer Support will use the same class of shipping service selected and paid for by the customer to return the Printer. Return shipping costs from Ultra to the customer will be at Ultra's expense. After obtaining a “Magicard Return Authorisation Number” (MRAN) as described above, the Printer should be securely packed in it’s original packaging with proof of date of purchase and a note describing the problem and quoting the MRAN number. The Printer must be sent to the Service Centre address supplied with the MRAN. This address may be different to the address listed below, but will generally be closer to you. Please also mark the MRAN number on the outside of the shipping carton. All Customs Duties and Taxes, if applicable, are the responsibility of the Customer.



Applicability

The warranty and remedy provided above are exclusive and in lieu of all other warrants, either expresses or implied, including but not limited to, implied warranties of merchantability and fitness for a particular purpose. Any statements or representations made by any other person or Business are void. Neither Ultra Electronics Limited nor its affiliates shall be liable for any loss, inconvenience, or damage, including direct, special, incidental, or consequential damages, resulting from the use or inability to use the Ultra product, whether resulting from breach of warranty or other legal theory even if Ultra has been advised of the possibility of such damage or loss. This warranty is governed by English Law. Any dispute arising out of or relating to this warranty shall be submitted for arbitration of this dispute or disputes pursuant to the rules and regulations of the UK Arbitration Act. This warranty gives you specific legal rights, and you may also have other legal rights that vary from country to country so the above limitations and exclusions may not apply to all Customers. For warranty enquiries please call or Fax our Customer Support Manager : - Ultra Electronics Limited MAGICARD Service Centre Waverley House Hampshire Road Granby Estate WEYMOUTH Dorset, DT4 9XD, U.K. Tel : +44 (0) 1305 784738 Fax : +44 (0) 1305 777904

SECTION 6.2 INTERNET SUPPORT To further enhance the Customer Support already available to Magicard Customers, the Magicard Web site contains useful information on both problem solving and operation of the Pronto Printer. The web-site is available 24 hours per day at www.magicard.com

SECTION 6.3 RECOMMENDED TOOLS The following tools are recommended to support the Magicard Pronto in the field.

IBM PC or IBM Compatible Clone :

Pentium 600 MHz or faster (with USB Ports). 128 Mbytes memory or higher. 10 Gigabyte Hard Drive. 8 speed CD ROM or faster. SVGA monitor with greater than 800 x 600 screen resolution.

Recommended PC Software :

Microsoft Windows (32-Bit) software (Win 2000 onwards). Pronto Driver for Windows. Magicard Support Utility SIN1926 (loaded separately via the Driver). Graphics program such as Adobe Photoshop, Corel Draw or Paint Shop Pro. Microsoft Office. Badge Printing Application.

Engineers Tool Kit :

Anti-Static wrist strap. Pozi blade screwdriver, preferably 150mm length (min.) Torx Driver - Size 10. Long nosed pliers. Multimeter or Voltmeter.

Service Centre and Master Dealers :

McBeth Densitometer Model RD 1245 for calibration of the thermal Print Head printing density. ISO Standard Magnetic Encoding Stripe Reader.




Three Cleaning Cards and a cleaning Roller are included with each new Pronto Printer. You can purchase additional Cleaning Kits, which includeCleaning Cards, Rollers and Pens. Cleaning Kits Part Number CK1 (10 Cleaning Cards, 5 Rollers and a Cleaning Pen). Part Number 3633-0054 (Cleaning Roller Kit – 5 sleeves and 1 Roller Bar).

SECTION 7 CLEANING THE PRINTER. SECTION 7.1 CLEANING IS IMPORTANT

The most important procedure you can do to ensure Card print quality and the ongoing reliable operation of your Printer is to perform regular cleaning cycles to remove dust and debris from the print Rollers. Plastic Cards attract dust. Dust then gets ‘printed’ into the Card surface causing unsightly blemishes and possible damage to the Print Head. Your Magicard Printer has built-in cleaning Rollers to remove dust from the Card stock. These Rollers need to be replaced periodically to remove the dust and debris accumulation.

Cleaning is Easy and Inexpensive

If you have not already done so, order a Cleaning Kit – see the ‘Cleaning Supplies’ – Section 7.2. A clean Printer produces better quality Cards, as dust and dirt are not present when the Card is being printed. A clean Printer is much less likely to require factory maintenance, and the Print Head in your Printer will last for many years of normal use. Remember, large particles of dirt can damage the Print Head. Magnetic encoding also degrades rapidly if the Printer has not been cleaned.

The Magicard Cleaning System

There are three main items included in your Printer’s Cleaning Kit - a Cleaning Card, a Cleaning Roller and a Cleaning Pen :

A Cleaning Card is used to remove dirt from the print path. This should be used

after every 300 (prints per roll of Dye-Film). If you print only a few Cards a day, we recommend that you clean the Printer more often.

There is a disposable Cleaning Roller in the Printer, which should be replaced after

every 1000 prints (approx. after using 3 rolls of Dye-Film). One cleaning Roller is provided with each new roll of Dye Film.

There is also a Cleaning Pen, which is used to clean the Print Head. We recommend you use this if any lines or discolorations are seen on printed Cards. Follow the instructions on page 22 for cleaning the Printer.

SECTION 7.2 CLEANING SUPPLIES



SECTION 7.3 CLEANING THE PRINTER ROLLERS

Step 1 : Using the Cleaning Card

We recommend that you clean your Printer using a Cleaning Card after every 300 prints or each time you replace the Dye-Film. You should do this more often if you print only a few Cards a day. 1. Open the lid and lift out the Dye-Film. Leave the lid open. 2. Take a new Cleaning Card from it’s packaging. 3. Open the “Printing Preferences…” (within the Driver) and select the “Printer” Tab. Click “Clean the Printer” Button. 4. Place the narrow end of the Cleaning Card into the front Card feeder slot. The Card will automatically enter the Printer and the Rollers will be cleaned.

When the cleaning cycle is finished, the Cleaning Card will be ejected. Turn the Cleaning Card over and repeat steps 2 – 4.

5. Close all Driver windows.



SECTION 7.4 REPLACING THE CLEANING ROLLER

Step 2 Fitting a new Cleaning Roller.

There is a Cleaning Cassette inside the Printer which holds a Cleaning Roller. We recommend that this Roller is replaced after every 1000 prints, or sooner if it looks dirty. You can re-use the cassette (you simply replace the Roller within it). 1. Open the Printer Lid and remove the used Dye-Film. Pull out the Cleaning Roller Cassette. 2. Remove the “Sticky” Roller and then remove it’s central Roller Bar 3. Slide the central Roller Bar through the middle of the new “Sticky” Roller. Refit Roller to Cassette. 4. Carefully remove the protective paper layer to reveal the sticky surface. 5. Refit the Cleaning Cassette into the Printer.

Central Roller Bar

Cleaning Cassette



SECTION 7.5 CLEANING THE PRINT HEAD.

Step 3 Cleaning the Print Head.

The Print Head should be cleaned if any lines or discolorations are seen on printed Cards. It is also a good idea to clean the Print Head when you replace the Dye-Film.

1. Use the special Print Head cleaning Pen from your Magicard Printer Cleaning Kit. See Section 6.1 ‘Cleaning Supplies’.

2. Open the Printer and draw the Pen several times across the complete length of the Print Head.

Cleaning the Printer’s Print Head with a Cleaning pen



Please Note : Windows 3.11, 95, 98, ME, and NT are not supported.

Ensure the Printer is powered off.

SECTION 8 MAGICARD PRONTO DRIVER. Pronto and Pronto Mag use the new “UltraDriver”. This Driver is for use on the following Operating Systems only : Windows 2000 & Windows XP (32 bit only). Windows 2003 Server (32 bit only). Windows Vista (32 bit only). Windows 7 (32 bit only).

SECTION 8.1 INSTALLATION INSTRUCTIONS ARE THE SAME FOR ALL WINDOWS O.S. Load the Driver CD ROM into the PC you have connected to the Printer. If the CD does not run automatically, click the “START” Button, then click “Run”. Type “D:\autorun” (where D is the Drive letter for your CD Drive), then press the “Return” key. Choose the language you wish to use.



Windows Vista

NOTE If the Computer you are configuring for a USB connection to the Magicard Printer has at some time run another manufacturer’s Printer (e.g. Eltron C-Series Printer), a Windows file necessary for the Magicard installation could be missing. (The symptoms of this are that the Computer does not seem to detect the Printer’s USB connection, and the “Test Page” fails to print). Recover the file as follows :-

Navigate to c:\windows\inf (Windows XP) or c:\winnt\inf (Windows 2000). Find the file named “usbprint.in”, and then rename it to < usbprint.inf. > Reconnect the USB cable.

SECTION 8.1 INSTALLATION INSTRUCTIONS (CONTINUED…) Ensure the Printer is switched on and showing “Ready” on the front LCD Display. The Printer can now be connected to the PC.

Windows 2000 / XP / 2003 Server view



Ensure the Printer is disconnected.

SECTION 8.2 UN-INSTALLING THE DRIVER FOR WINDOWS 2000 / XP / 2003 SERVER.

On the PC, go to “START” >> “Control Panel”

Then select “Add or Remove Programs”

Classic view

Category view

Select the “Magicard Printer entry, and click on “Change/Remove”

Choose the “Magicard Printer you wish to remove (there may be more than one), and click “Next”

Lastly - simply follow the on-screen prompts !

or



Classic view

Category view

or

Choose the Windows Logo Button followed by “Control Panel”

Category View choose “Uninstall a Program…”

Classic View choose “Program and Features…”

Select the Magicard Printer and the choose the “Uninstall / Change” Button

Follow the instructions on the screen

Ensure the Printer is disconnected.

SECTION 8.3 UN-INSTALLING THE DRIVER FOR WINDOWS VISTA.

.



SECTION 8.4 DRIVER DESCRIPTION Understanding each individual Printer Driver setting : The Printer Driver contains a built-in help file (in HTML format) – this file gives an excellent, clear explanation of each Driver setting. To view the Driver’s help file, go to the Printer Preferences (as described above), and click on the “Help” Button in any of the Tabs.



SECTION 9 PRINTER FUNCTIONS

SECTION 9.1.1 PRINTING A TEST CARD The Pronto is able to print an internal Test Card independently of it’s Host Computer. This function is useful test to check the Printer is working correctly without involving any Computer software or Printer Driver settings. To print a Test Card, press the Pronto’s front panel switch twice (quickly in succession). The colour of the front pabel switch should change from green to yellow. After a short delay (whilst downloading the Test Card image), the Pronto’s Rollers should start to turn. At this point, a Card should be fed into the Printer’s front panel slot. The result should be the Test image shown below:

SECTION 9.1.2 PRINTER CLEANING MODE The Pronto can be put into a cleaning mode using the following procedure :

1. If using Windows XP, go from the “START” Button and select “Printers and Faxes”.

2. In the “Printers and Faxes” window, right-click on the Driver icon and select “Printing Preferences…”

3. Using the “Card Front” Tab, click the “Clean the Printer” Button. The Printer’s Rollers should now start to turn.

4. Finally, remove a Cleaning Card from it’s foil packet and feed the narrow end into the front of the Pronto.



The Soak Test Mode moves every mechanical part of the machine, including the Print Head cooling Fan. A blank Card will be needed (inserted from the front). There are two Soak Test Modes available on the Pronto (one with, and one without the Dye-Film fitted). No Dye-Film fitted

Power up the Printer, open the Lid and remove the Dye-Film.

Press the Multicoloured Button (on the front Panel) twice in quick sucession until the Button colour changes.

Close the Printer Lid. The front Panel Button should now begin to flash.

Next, the Printer Rollers should start to turn.

Hand feed a Card into the Printer’s front Panel slot. Dye-Film fitted Performing a Soak Test with the Dye-Film fitted is essentially identical to the steps above (the main difference is that with Dye-Film fitted, the Pronto prints a series of twenty four small squares onto the Card). When all twenty four squares have been printed, the Printer exits the Soak Test Mode.

SECTION 9.2.1 SOAK TEST MODE



SECTION 10 PRINT HEAD REPLACEMENT This section describes the action needed to replace the Print Head in the Pronto Printer.

SECTION 10.1 PRINT HEAD DAMAGE. Dust or contamination on the Card or Dye-Film is dragged below the Print Head. This causes scratches which permanently damage the printing surface. Under these circumstances the complete Print Head will have to be replaced, as it is not repairable. Some examples of Print Head damage are shown below, viewed under a microscope :

Contaminantsuch as sand, dirt, swarf.

The contaminant embeds into the PVC surface and is dragged into the Print Head.

Print direction

Card

Print Head

Dye-Film



SECTION 10.2 PRINT HEAD ELECTRONIC FAILURE. If an internal electronic component has failed inside the Print Head, then this causes the printing elements to switch on or off continuously. The Cards below show examples of electronic failure.

The Cards below show examples of electronic failure.

SECTION 10.3 REPLACING THE PRINT HEAD.

CAUTION The following procedures involve contact with Electrostatic Sensitive Devices. All precautions for handling Electrostatic Sensitive Devices should be followed at all times (including the use of a grounded wrist strap).

Switch the Printer Off !

HOLD !



Re-fit the new Print Head

Disconnect the connector Push backwards

then tilt upward

Refit the connector

SECTION 10.3 REPLACING THE PRINT HEAD (CONT).

CAUTION Care must be taken when disconnecting and connecting the Print Head Assembly. The electrical connector (located on the Print Head) is mounted on a soft flexible electronic circuit board. Damage can occur if excessive force is used at any time.

1

2

2

1



SECTION 10.4 SETTING THE PRINT HEAD DENSITY CALIBRATION.

CAUTION The Print Head density programmer (PDP) is calibrated to suit the Print Head that it is supplied with. It will not be suitable for supplied other Print Heads and therefore should only be used for a specific Print Head assembly.

Print Head Density Programmer (PDP)

DONE !

Close the Printer Lid

Whilst the Printer Lid is open …



Before leaving the factory, all thermal Print Head Assemblies are set to give optimum performance and uniform colour output. Occasionally, due to differences in tolerances between Printers, some minor adjustments may be required. The Print Head angle can be varied by a few degrees either side of vertical. This adjustment is necessary because the print elements vary slightly on each Print Head. The position of each Print Head must be optimised to ensure the correct thermal transfer through the Dye-Film onto the PVC Card. Once the Print Head angle is correct the density may need to be adjusted.

NOTE Failure to have the Print Head angle setup at the optimum position may cause the Dye-Film to wrinkle and break. Cards may also look “washed out” with unsightly marks across them.

R=128 G=128 B=128

Correct Print Head Angle Image is printed with uniform colour across the complete Card. There is little or no variation across the Card.

Print Head Angle too negative Front end of the Card will show faded colour. The image will be lighter at the front end of the Card. Front of the Card is the end that ejects out of the Printer first.

Print Head Angle too positive Rear end of the Card will show wrinkling or Dye-Film overheating. Rear of the Card is the end that ejects out of the Printer last.

SECTION 10.5 PRINT HEAD SETUP AND ADJUSTMENT The best type of image for ensuring the Print Head angle is setup at it’s optimum position is a mid grey Card (R=128, G=128 and B=128) design. It should be a constant colour with no texturing or gradients. A Card of this design can be created in any graphical design package or even MS Word.

Adjusting the Print Head.

Print a Test Card from your application and analyse the result (refer to analysing Test Card). Open the top cover and locate the Print Head assembly. Adjustment screw is located directly above the electrical connector in the center of the metal framework (see right, arrowed).

Should the Test print be too positive, adjust the Print Head angle by turning the adjustment screw clockwise.

Should the Test print be too negative, adjust the Print Head by

turning the adjustment screw anti-clockwise. Carry out a further Test print. Adjust as necessary to achieve the optimum setting.

Analysing the Test Card

NOTE It is advisable to start the Print Head setup procedure with the Print Head angle slightly negative. It can then be slowly adjusted more positive.



The Magicard Pronto Printer has been designed with a modular construction to make servicing and repair very easy. The following guidelines show you how to change the middle Card Sensor which is the most difficult component to replace. All other parts can be exchanged following this procedure.

SECTION 11 DISMANTLING AND ASSEMBLING THE PRINTER

SECTION 11.1 REMOVING & REFITTING THE PRINTER CASING.

SECTION 11.2 REMOVING & REFITTING THE FRONT FASCIA COVER

Removing & Refitting the Printer Casing.

1. Remove the Dye Film. 2. Working below the Printer, gently move the two front plastics catches outwards in the direction shown above. 3. You can now lift the front end of the Printer out of the case, tilting it backwards. This will then release the two rear plastic catches and allow the

complete Print Engine to be removed. Take care to retain the connector panel. Refitting is the reverse sequence, locate the connector panel Carefully line up the two rear plastic catches first and lower the Print Engine into place. The front catches will locate and click into place (ensure no wires are trapped).

Removing & Refitting the Front Fascia 1. Remove the Printer casing as described in Section 11.1. 2. The front Fascia can now be removed by pulling this away from the

main print Assembly. 3. The two securing plastic catches are inside the area where the

printed Card collector sits. 4. The LCD Display remains attached to the main print Assembly. Refitting is the reverse sequence. Ensure the LCD Display wires are not trapped between the Fascia and Print Engine. Refit the Printer casing as described in Section 11.1.




Removal & Refitting of the Top Dye Film Sensor

1. Remove the Print Head Assembly as described in Section 10.3.

2. Disconnect the two wiring connectors attached to the

Sensor PCB, one is the Sensor and the other is the cooling Fan. Ensure they are re-connected back the same way.

3. Unclip the Sensor PCB and remove.

Removal & Refitting of the Lower Dye Film Sensor

1. Remove the Base of the Printer (see Section 11.1) and remove the Print Head Roller Drive Gear (see Page 74).

2. Unclip the plastic cross piece from the right side and slide out the cross piece (in the direction of the red arrow) that encloses the lower Dye-Film Sensor PCB. (It is clipped onto the right-side of the Printer).

3. Turn the plastic cross piece over and disconnect the Sensor cable from the small PCB.

4. The Sensor PCB can now be unclipped from the plastic cross piece. Refitting is the reverse procedure ensuring the plastic cross piece is located into the side plates.

SECTION 11.3 REMOVAL & REFITTING OF THE TOP DYE-FILM SENSOR

SECTION 11.4 REMOVING & REFITTING OF THE LOWER DYE-FILM SENSOR.

CAUTION The following procedures involve contact with Electrostatic Sensitive Devices. All precautions for handling Electrostatic Sensitive Devices should be followed at all times, including the use of a grounded wrist strap.

Top Dye Film Sensor



SECTION 11.5 REMOVING & REFITTING THE CONTROLLER PCB.


Removal & Refitting the Controller PCB

1. Disconnect all the wiring from around the outside edge of the Controller PCB. 2. Unclip the four plastic catches and remove the Controller PCB downwards. 3. On Pronto Printers with the Magnetic Encoding option, an extra PCB will need to be disconnected, it is mounted

onto the main Controller PCB. 4. The plastic moulding around the USB and Power Connector will also detach. Refitting is the reverse procedure ensuring the plastic moulding is around the USB and Power Connector is included.



SECTION 11.6 REMOVING & REFITTING OF THE FRONT & REAR CARD SENSOR

Removal & Refitting of the Front & Rear Card Sensor

1. Working inside the printing compartment, the front and rear card Sensor plastic clips can be released. The plastic clips are situated adjacent to the Card path at the front and rear of the printing area.

2. Withdraw the two plastic clips and Card Sensors from underneath the machine. The Card Sensor PCB’s can now be disconnected from the

wiring. Refitting is the reverse procedure.

Middle Card Sensor cannot be removed at this point, refer to Section 11.17 to remove.



Tacho and Sensor System

1. Carefully withdraw the Tacho Wheel plastic cover from the side of the Printer. There is a spring behind so ensure it is removed slowly (omitted for clarity).

2. The Tacho wheel can now be removed but it will also have to be tilted away from the Tacho Sensor.

3. Tacho Sensor can be removed by unclipping the outer plastic housing and sliding the Sensor outwards. Refitting is the reverse procedure but ensure the Tacho wheel passes through the Tacho Sensor before fitting the plastic cover.

Print Head Cam System 1. Cam Position Sensor can be removed by unclipping the

outer plastic housing and sliding the Sensor outwards (ensure the Pulley is rotated to the correct position). Refitting is the reverse procedure.

2. Drive Belt can be removed by sliding it off the outside of the Cam Shaft Pulley. Refitting is the reverse procedure.

3. Small Pulley can pulled from the DC Cam Motor shaft. Refitting is the reverse procedure but a new Pulley is essential unless glued into position.

SECTION 11.8 REMOVAL & REFITTING OF LEFT SIDE COMPONENTS

CAUTION The Plastic Drive pulleys attached to any of the Motors are designed to be push-fit and used only once. Magicard highly recommend new Pulleys are fitted if they are disturbed. Once pushed onto the motor shaft, the plastic deforms to produce a tight fit.



Card Drive System.

1. Remove the spring washer holding the large Pulley in place then slide the Pulley off the roller Shaft. Drive belt can also be removed. Refitting is the reverse procedure ensuring a new spring washer is used.

2. Remove the spring washer holding the small Pulley in place then slide the small Pulley from the main Stepper Motor shaft. Refitting is the reverse procedure ensuring a new spring washer and Pulley are used.

3. Idle Tension Roller pressure can be released then the large Drive Belt removed. Note how the Belt is fitted. Refitting is the reverse procedure then release the Idle Roller to tension the Belt.

4. The individual Roller Drive Pulleys can now be removed by either depressing the retaining Tabs on the shafts or releasing the spring washers. Slide the Pulleys outwards. Refitting is the reverse procedure ensuring new spring washers are used.

SECTION 11.9 REMOVAL AND REFITTING OF RIGHT SIDE COMPONENTS

CAUTION The Plastic Drive Pulleys attached to any of the Motors are designed to be push-fit and used only once. Magicard highly recommend new Pulleys are fitted if they are disturbed. Once pushed onto the Motor shaft, the plastic deforms to produce a tight fit. The following procedures involve contact with Electrostatic Sensitive Devices. All precautions for handling Electrostatic Sensitive Devices should be followed at all times, including the use of a grounded wrist strap.

RFID PCB & Top Cover Sensor

1. Sensor can be removed by unclipping the outer plastic housing and sliding the Sensor outwards. Refitting is the reverse procedure.

2. Remove the RFID PCB plastic cover and slide PCB outwards. Refitting is the reverse procedure.



SECTION 11.10 REMOVAL & REFITTING OF THE DRIVE MOTORS & FRONT CARD SENSOR.

Cam Motor. 1. Disconnect the Motor connections. 1. The Motor is held in place by two screws, remove these screws. 2. Remove the Motor out through the bottom of the Print Engine.

Refitting is the reverse procedure ensuring the Motor aligns with the screw holes.

Card Drive Motor.

1. Disconnect the Motor connector. 2. The Motor is held in place by two screws through elongated

holes. The elongated holes provide movement for Belt tension. Remove these screws.

3. Remove the Motor out through the bottom of the Print Engine. Refitting is the reverse procedure but leave the screws loose until the main Drive Belt is fitted and tensioned.



SECTION 11.11 REMOVAL OF THE CHASSIS COVER The Chassis cover can be removed from the main Print Engine, however there are no user replaceable parts inside.

Chassis Cover Removal

1. Release the front Lid catch so the Lid is partially open. 2. Release the plastic locking Tabs arrowed directly above. 3. Lift the complete Chassis cover upwards away from the Print Engine. 4. Remove the wire loom from the left hand side of the Printer (noting how it is fed

through the plastic). Refitting is the reverse procedure ensuring no wires are trapped and the Lid opens and closes freely.



SECTION 11.13 REMOVAL OF THE IDLE ROLLERS

SECTION 11.14 REMOVAL AND REFITTING OF THE LARGE BEARING PLATE

Removing the Idle Rollers 1. Remove the Idle Link Plate springs located centrally above the Idle Link Plate

from each side of the Print Engine. 2. Lift and withdraw the left and right Idle Link Plate from each side of the Printer. 3. Remove the Idle Rollers from inside the Printer. Refitting is the reverse procedure; lay the Idle Rollers inside the Print Engine. Locate one of the Idle Link Plates, align the Idle Rollers and then locate the opposite Link Plate. Springs can be located and fitted into place.

Removing the Large Bearing Plates 1. Ensure all remaining Spring Washers are removed for the metal Roller Shafts. 2. Working underneath the Printer release the four left and right plastic catches holding the Bearing Plates in position. Refitting is the reverse procedure ensuring Cam and Roller Shafts are located in the correct holes. Ensure the Bearing Plate with the Idle Roller fitted is located on the right side of the Printer.



Removal & Refitting of Rollers

1. Once the Bearing Plates have been removed the Rollers can be removed out the bottom of the Printer. Roller layout is shown below including the attached Drive Pulleys.

2. Cam linkage can also be removed, but ensure both

corresponding parts are kept together to avoid confusion when refitting.

Refitting is the reverse procedure ensuring the Cam linkage is correctly orientated.

Removal & Refitting of the Card Guide

1. Remove the two return springs from either end of the Card guide. Parts of the springs are inside the Card guide plastic assembly

2. The guide will be loose, push it against the internal side wall and lift up out of the

machine. Refitting is the reverse procedure, located the Card guide and then fit the springs.

Removal & Refitting of the Middle Card Sensor

1. Unclip the Sensor retainer from inside the centre of the printing compartment.

2. Working underneath the Printer, disconnect

the Sensor connector and withdraw the Sensor retainer and Sensor PCB.

Refitting is the reverse procedure.

SECTION 11.16 REMOVAL AND REFITTING OF ROLLERS

SECTION 11.17 REMOVAL & REFITTING OF THE CARD GUIDE & MIDDLE CARD SENSOR



SECTION 12 TROUBLESHOOTING Introduction

This Section is intended as a quick reference guide to assist Magicard Pronto users and Dealers experiencing difficulties with their Printer. The information below covers most common problems that will be encountered (compiled from the Magicard Technical Support Helpline Records).

Technical Support Web Pages

If having tried all the solutions suggested in this Guide, you are still having problems with your Printer, please visit the Technical Support pages of the Magicard Website at www.magicard.com – you will find technical information and FAQ help.

Problem Analysis

Follow the Tables and select the problem and the path that most resembles the issue that you are experiencing.

SECTION 12.1 INITIALISATION SEQUENCE The following section describes the sequence of events that occur when the Pronto is powered on. It also describes any errors that may occur and how to rectify them.

Power the Printer On

Print Head is cycled Up and Down. 1. Cam Motor is rotated. 2. Belt and Pulley system drives a Cam Shaft. 3. Optical Sensor reads Cam Motor position. 4. Cam Shaft drives Cam followers. 5. Print Head is moved Up and Down.

Dye Film. 1. Dye Film Motor rotates slightly to tension the ribbon. 2. Dye Film is tensioned to prevent it being trapped if a

Card is stuck in the printer mechanism. 3. No information about the Dye-Film is read at this

point.

Main Controller PCB is Initialised. 1. Microprocessor Boots up. 2. Flash Memory is checked. 3. Printer Firmware copied into DRAM. 4. I/O Status Checked. 5. Hardware Begins to initialise.

Possible Errors. 1. Nothing Happens : Check external Power Supply, connection into the back of the Printer. Is the green indicator on the external PSU on ? 2. Microprocessor has failed to start - replace Controller PCB. 3. Lid Open Error : When the Lid Sensor is disconnected the Printer will still initialise. However if the Lid Sensor has broken or moved the error will be shown.

Possible Errors. 1. Continuous Motor Noise is heard : Cam Motor is rotating continuously - Check Pulley and Drive Belt. Check Cam opto Sensor is functioning. 2. Error on RFID PCB : Dye-Film RFID Controller is disconnected, check the wiring connections.

Possible Errors. 1. Card or Ribbon is trapped in Printer mechanism : No Sensors are used at this point of the initialisation cycle. The Tacho wheel should rotate clockwise (viewed from left hand side) a small amount to tension the Film. If there is no movement, the Dye-Film may have run-out or Dye-Film take-up Motor is faulty/disconnected.

Card Eject. 1. Any jammed Cards are moved forward to the front

optical Card Sensor. 2. Trapped Card is ejected out the front of the Printer.

Printer Ready

Possible Errors. 1. Card Inside is not ejected, no errors are seen. Use the cleaning cycle to check if the internal Rollers are rotating. If not, then the main Drive Belt may have fallen off.




SECTION 12.2 HARDWARE PROBLEMS

Problem Probable Causes Possible Solutions

Cards are not being taken from the card holder at the back.

1. Cards are stuck together with static. 2. Card feed Roller may be dirty and not

gripping the Cards. 3. Card feed Roller is not rotating.

1. Separate the Cards to remove the

static charge build-up. 2. Clean the Printer using the

recommended Magicard cleaning Cards.

3. Remove the base and check the integrity of the Roller, Drive Belt and Motor.

Printer switches off automatically after a period of time.

1. Loose PSU connection on the back of the Printer.

2. Faulty external PSU.

1. Replace controller PCB or PSU if

necessary. Call Magicard Technical Support.

2. Replace PSU. Call Magicard Technical Support.

Error “Cannot lift Head” when the Printer is switched on.

1. Print Head is not being cycled up/down when the Printer is switched on.

1. Ensure the Cam components are

all fitted correctly on the left side of the Printer.

2. Check the operation of the Cam Position Sensor.

Error “Cannot Drop Head” during printing.

1. Print Head is not being moved up/down during the printing process

1. Ensure the Cam components are

all fitted correctly on the left side of the Printer.

2. Check the operation of the Cam Position Sensor.



SECTION 12.3 IMAGE PROBLEMS


White line along the length of the Card. Line is always in the same place on every Card.

1. The Print Head has some damaged heating elements.

1. Print Head will have to be replaced.

Mis-registration of colours, (3D effect, ghosting of colours and blurring).

1. Card is being positioned in slightly different

positions for each colour pass. Black Text and Overcoat are not affected.

1. Clean the rubber Rollers in the Printer. 2. Slipping Drive Belt 3. Card Print Drive Motor Belt tension loose.

White margins at one or both ends of the Card > 5mm

1. Incorrect page size set in the printing application. 2. Image Size is not large enough to completely fill

the Card.

1. Ensure the Page Layout/Setup is taken

from the installed Pronto Driver. 2. Image size must be 1016 pixels (85.6mm)

x 642 pixels (54.5mm)

White margins at one or both ends of the Card < 2mm

1. Incorrect page size set in the printing application

as above. 2. Image Size is not large enough to completely fill

the Card 3. Start & End Positions are not at default in the

Printer Driver.

1. Ensure the Page Layout/Setup is taken

from the installed Pronto Driver. 2. Image size must be 1016 pixels (85.6mm)

x 642 pixels (54.5mm) 3. Restore the default Start & End positions in

the Printer Driver

Small Areas or dots of missing colour, can be in any position on the Card.

1. Dust, Dirt or surface contamination on the Card. 2. Dust, Dirt or contamination on the Dye Film

1. Ensure the Cards are flat, clean and free

from contamination or fingerprints, replace if necessary.

2. If the Film has to be removed avoid touching it and do not place flat on the surface (static).

3. Replace the Sticky Roller inside the Printer, one is included with a new roll of Dye-Film.

Printed colours across the whole Card are too light and generally washed out.

1. Cards are not the correct type 2. Printer Head Power has been reduced too low.

1. Cards must be PVC or have a PVC

covering layer across the surface. 2. Check the driver settings and reset the

YMC Power to 50, increase if necessary.

Text or Barcodes are either missing or too light, colour is acceptable.

1. Black Resin Power is set too low. 1. Increase the Black Resin Power setting in

the Driver

Card images are fading after a few weeks.

1. High amount of surface abrasion occurring. 2. Overcoat has not been printed on the Card.

1. Cards may need extra protection like a lamination patch.

2. Ensure the Overcoat is enabled with the Driver.

Front section of the card (as its ejected) is faded compared to the rest of the Card.

1. Print Head angle is not set-up correctly. 1. Rotate the Print Head angle adjustment

screw anti-clockwise by one turn to make more positive.

Rear section of the Card (as it's ejected) has faint dark wavy lines.

1. Print Head angle is not setup correctly. 1. Rotate the Print Head angle adjustment

screw clockwise by one turn to make more negative.



SECTION 12.3 IMAGE PROBLEMS CONT.


Vertical lines across the image (always in the same place on each Card).

1. Card striking something during the

printing cycle. 2. Card striking the Magnetic Encoding

Head during printing. 3. Card not running smoothly through the

sprung-loaded Card guide system

1. Check the print path is clear and all Rollers are turning. 2. Reduce the Magnetic Encoding Head height by tightening

the rear grub-screw. 3. Ensure the sprung-loaded Card Guide moves in and out

smoothly

Vertical lines across the image (different place on each Card).

1. Incorrect belt tension between the main

Stepper Motor and large drive Pulley. 2. Stepper Motor is not rotating smoothly. 3. Damaged or faulty controller PCB.

1. Re-tension the main stepper Drive Belt (Belt should rotate

through 90 degrees along the length of it’s longest travel). 2. Compare the rotational resistance to another Stepper

Motor. 3. Swap if necessary for testing. 4. Call Magicard Technical Support.

Background colour changes at edges of dark or light objects

1. Poor Print Head colour compensation. Usually a fault with either the Print Head or Controller PCB.

1. Replace Print Head. 2. Replace controller PCB, call Magicard Technical Support.

Light faded edge along the length of the Card.

1. Raised area or burr along the same edge to the Card.

2. Poor contact between the Print Head printing surface and the Card.

1. Flip the card over and print on the reverse (if applicable)

otherwise rotate the card through 180 degrees. Does the faded edge remain on the same side ?

2. Ensure the Print Head moves up and springs back down smoothly.

3. Ensure the Print Head shield has not slipped downwards.

Printed image is not very clear or sharp.

1. Poor quality PVC cards. 2. Card is being mis-positioned slightly for

each colour pass. 3. Low resolution picture. 4. Incorrect Driver settings.

1. Try using a higher quality PVC Card. 2. Clean the Printer using the recommended Magicard

cleaning consumables. 3. Ensure the original artwork is a high resolution image. 4. Increase the sharpness setting in the Printer Driver.



SECTION 12.4 PRINTER DRIVER PROBLEMS


When a document is sent, nothing happens at the Printer.

1. Printer is “Offline”. 2. Incorrect Printer selected

within the Operating System.

3. Incorrect Port selected in the Driver settings.

4. Corrupted or deleted Driver within the Operating System.

1. Re-initialise the Printer ensuring Dye-Film is fitted and it

reports “Ready”. 2. Ensure the printing Application is set to print to the

Pronto. (Set as the default Printer ?) 3. USB printing Port should be selected to USB001. 4. Remove the current Driver and re-install the latest

version.

When a document is sent to the printer it appears in the print queue (Spooler) but nothing happens at the Printer.

1. Printer is “Off-Line”. 2. Windows Spooler is

Paused.


reports “Ready”. 2. Right Click on the Printer Driver and choose “Unpause

Printer”.

Print document is jammed in the print queue (Spooler).

1. Corrupted Print Job sent to Printer.

2. Printer is “Off-Line”. 3. Incorrect Port selected in

the Driver settings.

1. Delete the Print Job from the queue and resend the

document. 2. Re-initialise the printer ensuring Dye-Film is fitted and it

reports “Ready”. 3. USB printing Port should be selected to USB001.

When a document is sent to the Printer it appears in the print queue (Spooler) and disappears immediately.

1. Incorrect port selected in the Driver settings.

2. Corrupted Printer Driver.

1. USB printing Port should be selected to USB001. 2. Remove the current Driver and re-install the latest

version.

Unable to open the Printer settings within “Printers and Faxes”.

1. Corrupted Printer Driver 1. Remove the current Driver and re-install the latest

version.

After installing the Driver and connecting the Pronto, nothing happens, Printer is not detected.

1. Printer is “Off-Line”. 2. Problem with the USB Port 3. Problem with the USB

cable. 4. Corrupted Printer Driver. 5. Damaged Controller PCB.

1. Re-initialise the Printer ensuring Dye-Film is fitted and

Display indicates “Ready”. 2. Try connecting to another spare USB Port. 3. Try a known working USB cable. 4. Contact Magicard Technical Support for replacement

Controller PCB.

After installing the Driver and connecting, Windows registers the Printer but nothing appears in the printer list.

1. Printer is “Off-Line”. 2. Corrupted Printer Driver 3. Conflicting Printer Driver

files. 4. Damaged Controller PCB.


reports “Ready”. 2. Remove the current Driver and re-install the latest

version. 3. Remove all other Card Printer Drivers. 4. Contact Magicard Technical Support for another

Controller PCB.

After installing the Driver and connecting the Printer “Found New Hardware” Wizard appears.

1. “Beta” Driver is/has been installed.

2. Partitioned Hard Drive.

1. Contact Magicard Technical Support for advice about

removing “Beta” Drivers. 2. Install the Driver onto the partition where the Operating

System is loaded. You may have to copy files from one partition to another.



SECTION 12.5 MAGNETIC ENCODING PROBLEMS


Magnetic Encoding is inconsistent, some Cards swipe and others do not.

1. Cards are not moving smoothly over the

Magnetic Encoder Head during the encoding cycle.

2. Feed Rollers are slipping or not moving the Card efficiently.

3. Magnetic Verification is deselected.

1. Clean the Printer using the recommended Magicard Cleaning Cards.

2. See number 1. 3. Select Verification option in the Printer Driver.

Cards are not encoded.

1. Blank Cards have been placed in the

Hopper the wrong way round and magnetic Verification is deselected.

2. Magnetic Encoded data is in the wrong place on the Magnetic Stripe.

3. Magnetic Encoded data is not the correct format for the swipe Reader.

4. Magnetic Encoding Head is either mis-aligned or faulty.

1. Position the Card in the Hopper with the magnetic stripe

underneath and to the left side of the Printer. Ensure Magnetic Verification is selected in the Printer Driver.

2. Clean the Printer using the recommended Magicard Cleaning Cards.

3. Ensure the Driver settings reflect the type of magnetic stripe cards being used, e.g. HICO or LOCO.

4. Contact Magicard Technical Support

Cards are not encoded (individual Tracks missing data).

1. Magnetic Encoding Head is dirty. 2. Magnetic Encoding Head is either mis-

aligned or faulty.

1. Clean the Printer using the recommended Magicard

Cleaning Cards. 2. Contact Magicard Technical Support.



It is recommended that the user does not change the settings within the Magicard Support Utility unless requested by Magicard Technical Support or trained Magicard Dealerships. Serious damage can occur if the configuration settings are changed by inexperienced users.

SECTION 13 MAGICARD SUPPORT UTILITY This Utility provides advanced diagnostic and configuration Tools for use when setting up and testing Magicard Printers. Install the Magicard Support Utility from the Driver CD. Alternatively, it can be found in “Program Files” in a Folder called “Ultra Electronics Ltd”. It is also available from our website using the following link: http://www.magicard.com/support/technical-support/?R=&L=&id=&lang=1&printerID=39&supportOption=3 Once installed, a Shortcut will appear on your Desktop. Open the “Support Utility” and choose the USB Port. When it has connected to the first Magicard Printer a number of extra Tabs will appear. If the connection fails, an error will be shown.

http://www.magicard.com/support/technical-support/?R=&L=&id=&lang=1&printerID=39&supportOption=3�



SECTION 13.1 PRINTER IDENTITY

Print Sequence

Y M C K O

Image Outline

Start Position End Position

Previous Image Next Image

The Printer configuration can only be changed when the Printer is in “Dealer Service Mode”. The mode is switched on by sending a special command to the Printer – DEALERSERVICEON (see Section 14.2). Before adjusting any configuration settings it is important to understand the printing cycle. Both the “Image Start” and “Image End” can be adjusted in both directions and can lead to confusion as to what is changing. Image Start Card is moved to this calibrated position directly over the Print Roller, prior to lowering the Print Head and printing the first colour pass.

(Increasing the number in the “Support Utility” moves the image “Start” position further onto the card, thus increasing the width of the white line at the front of the Card. A numerical change of 8 digits moves the “Start” position a distance of 1 pixel width).

Image End The Pronto has printed the colour panel and the Print Head is lifted off the Card at this point. (Increasing the number makes the image length longer, closer to the rear of the Card, thus decreasing the width of the white line at the rear of the Card. A numerical change of 1 moves the “End” position a distance of 1 pixel width). Print Head Density Every Print Head has a different resistance which means they will print at different colour depths.

To ensure each Pronto will print at a calibrated density the adjustment is calibrated at time of manufacture. Once this calibration is carried out, the Pronto can print a wide variety of image designs. If the density is set too high, the Dye-Film will be overheated and wrinkle or break. When it is set too low the images look faded and washed out. Adjustments should be made in increments of 25 or 50 before you see any change in the printed image.

(As a datum point, the setting should be close to the resistance that is printed on the Print Head assembly (e.g. R=3893)). Print Position Adjustment of the image vertically across the Card (when the card is held in landscape).

The setting changes which group of Print Head elements are used during the printing cycle.

Information about the Printer, the Serial Number is unique and set during manufacturing. Firmware can be updated by the user. This can be downloaded from : www.magicard.com

Printer configuration settings, see below.




SECTION 13.2 STATISTIC AND COMMANDS

SECTION 13.3 UPGRADE FIRMWARE

This Tab contains three separate areas: Statistics Shows valuable information on Printer usage. Quick Commands Enables the user to send special commands to the Printer (usually used for fault diagnosis). Print *.PRN file Enables the user to send previously saved print data to the Printer. Use this Tab to upgrade the Printer Firmware. The latest Firmware can be downloaded from www.magicard.com as an “executable” file.




SECTION 13.4 QUERY PRINTER

SECTION 13.5 ETHERNET

Collects advanced diagnostic data from the Printer. If you experience a problem, you may be asked to email the results of the query to Magicard Technical Support for analysis. Ethernet connection is not available with the Pronto Printer. (The settings are visible because this Support Utility is also used for Magicard Rio 2e, Tango 2e and Tango +L Printers which have this capability).



SECTION 13.6 MAG ENCODE

SECTION 13.7 MAG READ

Self Test Magnetic Encode Button – enables the user to confirm the integrity of the Printer’s Magnetic Encoding operation. Direct Magnetic Encoding – the user can encode Cards directly from this Tool. To use this Tool :-

Ensure Magnetic Stripe Cards are loaded into the Card Hopper. Select the Track(s) that you wish to encode and enter the data to be encoded. Click on the ‘Encode’ Button.

“Mag Read function” enables you to read ISO Standard magnetic encoding using the Printer hardware. To use this Tool :-

Ensure a magnetic encoded Card is loaded into the Card Hopper. Select the Track(s) that you wish to read using the Tool. Click on the ‘Read’ button. If successful the data will be displayed with a ‘green’ indicator. If it fails, no data will

be displayed. A ‘red’ indicator will show. Choose “Eject” to feed the Card out the front of Printer.

NOTE For use with Magnetic Encoding Models only.

NOTE For use with Magnetic Encoding Models only.



SS FC PAN FS NAME FS ADDITIONAL DATA DISCRETIONARY DATA ES LRC

76 Alphanumeric Data Characters

Primary Account No. 19 digits maximum

Name 26 alphanumeric characters

Expiry Date (YYMM) (Characters = 4) Service Code (Characters = 3)

PVKI 1 character PVV or Offset 4 characters CVV or CVC 3 characters Some or all the above field may be found in discretionary data.

SS Start Sentinel % FS Field Separator ^ ES End Sentinel ? FC Format Code LRC longitudinal redundancy check character

PVKI Pin Verification Key Indicator PVV Pin Verification Value CVV Card Verification Value CVC Card Validation Code

SECTION 14 MAGNETIC ENCODING SECTION 14.1 MAGNETIC ENCODING STANDARDS

MAGTEK

DIMENSIONS – FINANCIAL TRANSACTION CARDS. Hi-Co = 2750 - 4000 Oersteds. ISO 7810 Properties of Card Size Document 7811-1 Embossing 7811-2 Magnetic Stripe 7811-3 Location of Embossed Characters 7811-4 Location of Tracks 1 and 2 7811-5 Location of Track 3 7813 Financial Transaction Cards For Copies of Specifications contact : AMERICAN NATIONAL STANDARDS INSTITUTE 11W. 42nd Street New York, New York 10036 001 (212) 642-4900.

MAGNETIC STRIPE ENCODING – FINANCIAL TRANSACTION CARD

CARD DATA FORMAT FOR TRACK ONE

EMBOSSED INFORMATION

Magnetic Stripe

85.6mm / 3.375 inches 0.76 mm / 0.030" Thick

54.5 mm 2.125 inches

Track 1 IATA 210 7 bits per character 79 alphanumeric characters

Track 2 ABA 75 5 bits per character 40 numeric characters

Track 3 THRIFT 210 5 bits per character 107 numeric characters

ISO Range for start sentinel: 0.273 to 0.313 inches 6.93 to 7.97 mm

5.66mm / 0.223 inches

Track Recording Density (Bits per inch)

Character Configuration (including parity bit)

Information Content (including control characters)



CARD DATA FORMAT FOR TRACK TWO

CARD DATA FORMAT FOR TRACK THREE

The Track formats used in this document are based on ISO Standards, however, other formats may be used. Contact your Card issuer for your exact requirements. MAGTEK 20725 South Annalee Ave Carson, California 90746 TEL: 001 (310) 631-8602 FAX: 001(310) 631-3956

SS PAN FS ADDITIONAL DATA ES LRC

37 Numeric Data Characters


Expiry Date (YYMM) (Characters = 4) Service Code (Characters = 3)

PVKI 1 character PVV or Offset 4 characters CVV or CVC 3 characters Some or all the above fields may be found in discretionary data.

SS Start Sentinel Hex B ; FS Field Separator Hex D = ES End Sentinel Hex F ? LRC longitudinal redundancy check character

PVKI Pin Verification Key Indicator PVV Pin Verification Value CVV Card Verification Value CVC Card Validation Code

DISCRETIONARY DATA

SS PAN FS USE & SECURITY DATA ES LRC

104 Numeric Data Characters


Country Code (opt.) 3 characters Currency Code 3 characters Currency Exponent 1 character Amount Authorised / Cycle 4 characters Amount Remaining this cycle 4 characters Cycle Begin (Validity Date) 4 characters Cycle Length 2 characters Retry Count 2 characters PIN control parameters (opt.) 6 characters Interchange Controls 1 character PAN Service Restriction 2 characters SAN – 1 Service Restriction 2 characters SAN – 2 Service Restriction 2 characters Expiry Date (opt.) 4 characters Card Sequence Number 1 character Card Security Number (opt.) 9 characters

First Subsidery Account Number (opt.) Second Subsidery Account Number (opt.) Relay Marker 1 character Cryptographic Check 6 characters Digits (opt.) Discretionary Data A field separator (FS) must be used if an optional field is not used.

SS Start Sentinel Hex B ; FS Field Separator Hex D = ES End Sentinel Hex F ? FC Format Code Two digits LRC longitudinal redundancy check character

ADDITIONAL DATA FC



SECTION 14.2 BASIC MAGNETIC ENCODING. The Magicard Pronto may have the Magnetic stripe encoder fitted as an enhancement and for added security. To ensure the encoding is compatible with your Card Readers, it has the ability to meet I.S.O STD 7811. The Printer is capable of encoding, both CR80 HI-CO and LO-CO Cards using the standard 3 Track format. All Magnetic Encoding data must be typed using a True Type font in Black, all text must be in “Upper Case”. To produce a basic encoding document, follow the instructions below :

Bring the image you require to print, onto the Computer’s Display Screen.

Ensure that the Image you are printing is using a Rastagraphic Program (i.e. such as a word processing application, DTP package, or proprietary badge making application).

Type in your data to be magnetically encoded anywhere on the face of the “Card” (within the Application) using

the following format :

Type your code in a black, True Type font only.

All Tracks of the code must start with a ‘tilde’ < ~ > followed by the Track number and a comma < , > Example : ~1,

Type in your code.

Track 1 may be a combination of numbers and uppercase letters (alphanumeric). (Tracks 2 and 3 numeric only).

Example : To encode the data “12345XYZ” on Track 1 of a Magnetic Strip Card : ~1,12345XYZ? The Printer

Driver will add the Sentinels (in red).

Print the Card.



SECTION 14.3 ENCODING USING BADGE PRINTING SOFTWARE. Magnetic Track data is sent in the form of text strings from the Application software to the Printer Driver, along with all of the other printable objects within your Card design. For the Printer Driver to differentiate between magnetic Track data and the rest of the printable objects, the magnetic Track data strings must be uniquely tagged and be formatted using the System font. In other words, specific characters must be added to the magnetic Track data for the Printer Driver to know which data is to be encoded, which Tracks to encode, when the Track data stops and starts and so on. When using the Generic Printer Driver, you 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 most likely appear as printed text on the Card. To avoid this, Track information must be entered as described below. When entering Track data, the “~” character is entered first, followed by the Track number 1, 2, or 3 on which you intend to encode the data, the data to be encoded should then follow. There must be no spaces between these encoding characters. The first character of this data string must be the Track specific “SS” (Start Sentinel), and the last character must be Track specific ES (End Sentinel). The characters or data in between the SS and the ES can include all of the valid characters specific to each Track format. The number of these characters, however, is limited by each Track’s maximum character capacity. When segmenting Track data, the appropriate FS (Field Separator) must be used. The following table shows the SS, ES, FS, and valid characters defined for each Track. TR-1, TR-2, and TR-3/NNT format options selected in the Magnetic Encoding properties, enforce Track character limits. The following example illustrates how Track data should be entered for Tracks 1, 2, and 3 under Windows Operating Systems:

Windows 2000 / 2003 SERVER/ XP / VISTA / Windows 7

It should be noted that testing independently from an application could be carried out in “WordPad”.

Sample Encoded Data.

~1%MAGICARD MAGTEST^24-07-2003? ~2;0123456789? ~3;0123456789? However, after the page set-up has been carried out, the text must fit within the Card; “Carriage Returns” could be automatically inserted if the “magnetic string” continues over the page edge. The text must be of “True Type Font” and in capital letters.

TRACK START SENTINEL END SENTINEL FIELD SEPARATOR

VALID CHARACTERS

~1 % ? ^ ASCII CHAR 32-95

~2 ; ? = ASCII CHAR 48-63

~3 ; ? = ASCII CHAR 48-63

NOTE Magnetic Encoding Data must always appear on Page One of your Badge Design.



SECTION 14.4 ASCII CHARACTER SET SUPPORTED BY THE PRONTO

SECTION 14.5 ISO STANDARDS

Track 1

Recorded information can be of alphanumeric type (ASCII Char 32-95). Bit density of the recorded information shall be 210 Bits per inch. Number of data bits making up each character is 6 plus 1 Parity Check Bit. The total number of data characters, control characters and Longitudinal Redundancy Check (LRC) characters

together must not exceed 79, including ‘Start’ and ‘End’ Sentinels.

Track 2

Recorded information can only be numeric type. (ASCII Char 48-63). Bit density of the recorded information shall be 75 Bits per inch. Number of data bits making up each character is 4 plus 1 Parity Check Bit. The total number of data characters, control characters and LRC characters together must not exceed 40,

including ‘Start’ and ‘End’ Sentinels.

Track 3

Recorded information can only be numeric type. (ASCII Char 48-63). Bit density of the recorded information shall be 210 Bits per inch. Number of data bits making up each character is 4 plus 1 Parity Check Bit. The total number of data characters, control characters and LRC characters together must not exceed 107,

including “Start” and “End” Sentinels.

ASCII CHAR. DETAIL ASCII CHAR. DETAIL ASCII CHAR. DETAIL 32 space 53 5 74 J 33 ! 54 6 75 K 34 “ 55 7 76 L 35 # 56 8 77 M 36 $ 57 9 78 N 37 % 58 : 79 O 38 & 59 ; 80 P 39 ‘ 60 < 81 Q 40 ( 61 = 82 R 41 ) 62 > 83 S 42 * 63 ? 84 T 43 + 64 @ 85 U 44 , 65 A 86 V 45 - 66 B 87 W 46 . 67 C 88 X 47 / 68 D 89 Y 48 0 69 E 90 Z 49 1 70 F 91 [ 50 2 71 G 92 \ 51 3 72 H 93 ] 52 4 73 I 94 ^ 95 _



SECTION 14.6 ERROR CHECKING. The data has two checking systems to ensure accuracy. The Longitudinal Redundancy Check and the Parity check. They can be set to odd or even. Even Parity makes the number of I’s in the data being checked total an even number (2,4,6…). Odd Parity makes the number of I’s in the data being checked total an odd number (1,3,5…). If 123 was encoded in 5 MPC on Track 2 with ODD Parity and EVEN LRC would look thus: II0I0 I0000 0I000 II00I IIIII 00I0I ; 1 2 3 ? LRC

The first 4 bits of each group (except the LRC) represent the information ( 2 = 0I00 ). The 5th bit of each group (except the LRC) is the parity bit for its group ( 0 or I ). The LRC consist of a parity bit for all of the information groups (each bit in the LRC is the parity bit for the same coloured bits in all the other groups).



SECTION 15 FITMENTS TO THE PRINTER. To ensure maximum flexibility the Magnetic Controller PCB is “added-on” to the main Controller PCB. It connects directly into the main PCB and is not Printer specific. Although it is relatively straightforward to fit the Magnetic Encoding components into the Printer, it is extremely difficult to calibrate (to meet ISO specifications). To do this requires a specialist Card Analyser and a thorough knowledge of data encoding methods. It is therefore recommended that Printers are not upgraded from Standard to Magnetic Encoding types.

Magnetic Encoder PCB

Surface Connector on reverse side of PCB



Feet x2 (Front only) E9070

Print Head Assembly FG/3633-0160

Print Head Cooling Fan E9092

Chassis Top Cover 3649-0150-001

Print Head Cable

3633-0400

Print Head Springs x 2 E9041

Lid Latch 3649-0150-003

Spring Lid Latch x 2

E9246

Top Cover 3649-0150-002

SECTION 16 PARTS AND PART NUMBERS The following section lists the main assemblies and their relative Part Numbers.

SECTION 16.1 EXTERNAL COMPONENTS

SECTION 16.2 TOP COVER ASSEMBLY (3633-0150)

Pronto Base 3649-0100-001

Pronto Front Fascia 3649-0100-002



Print Head Mount 3633-160-002

Support Plate 3633-160-002

3 x 6mm Dowel Pin

E9090

Print Head Shield M9005-820

M3 x 6mm Torx Screw x 2

E9091

Heatsink 3649-0160-001

Spring E9042

M3 x 20mm Torx Adjustment Screw

E9165

Thermal Print Head P1-0001/R

Side Plate 3633-160-002

3 x 6mm Dowel Pin

E9090

SECTION 16.3 PRINT HEAD ASSEMBLY (FG/3649-0160)



Camshaft 3633-0300-001

SECTION 16.4 ROLLER LAYOUT

110 Teeth Pulley 3633-0200-010

Grip Washer Rio/0055/R

30 Teeth Pulley 3633-0200-007

30 Teeth Pulley 3633-0200-007

Cam Drive Assembly

Grip Washer Rio/0055/R

Bearing Plate 3649-0300-001

Belt- Drive Train E9057

Belt Tensioner Bracket 3633-0200-013

Tension Pulley 3633-0200-013

Print Head Roller

3633-0180

Rear Idler Roller

3633-0183



SECTION 16.5 DRIVE MECHANISM RIGHT HAND SIDE.

RFID PCB M9500-853

Cable – RFID

3633-0403



SECTION 16.6 DRIVE MECHANISM LEFT HAND SIDE.

H Frame Assembly 3649-0300-002

115 Teeth Drive Belt E9056

Camshaft Pulley 3633-0200-005

Camshaft Motor Pulley 3633-0200-006

80 Teeth Cam Belt

E9055

Cam Sensor 3633-0502



SECTION 16.7 MOTOR LAYOUT AND PART NUMBERS.

Card Print Motor (Stepper) Rio/0112/R

Cam Motor (DC) Rio/0043/R

Dye Film Motor (DC) Rio/0043/R



USB Connector Power Connector

Main Controller PCB FG/3633-0500 (S/N’s –A----) FG/3633-0511 (S/N’s –C----) Magnetic Controller PCB 3633-0501

SECTION 16.8 INTERNAL WIRING & SENSOR PART NUMBERS

Connector Wiring Loom Part Number Connected Hardware Hardware Part Number(s)

CN1 3633-0174 LCD Display LCD Display – E9038

CN2 3633-0170

Cam Sensor Dye Film Sensor (Lower) Tacho Sensor

Cam Sensor – 3633-0502 Dye Film Sensor (Lower) – 3633-0505 Tacho Sensor – 3633-0502

CN3 3633-0177 Cam Motor

Cam Motor – Rio/0043/R

CN5 3633-0178

Card Front Sensor Card Middle Sensor Card Rear Sensor

Card Front Sensor – 3633-0502 Card Middle Sensor – 3633-0502 Card Rear Sensor – 3633-0502

CN12 3633-0179

Dye Film Motor

Dye Film Motor – Rio/0043/R

CN15 3633-0171

Card Feed Motor Card Print Motor

Card Feed Motor – Rio/0043/R Card Print Motor – Rio/0112/R

CN16 3633-0172

RFID PCB Top cover Sensor

RFID PCB – 3633-0300 Top cover Sensor – 3633-0502

CN17 3633-016

Print Head Top Dye Film Sensor Fan

Print Head – 3633-0160 Top Dye Film Sensor – 3633-0502 Fan – E9092

Flipper Position Sensor Cam Sensor Dye Film Sensor (lower) Tacho Sensor

Cam Motor (DC)

Card Front Sensor Card Middle Sensor Card Rear Sensor

Dye Film Motor (DC)

Card Feed Motor (DC)

Card Print Motor (Stepper)

RFID Controller

Top Cover Sensor

Print Head Wiring

Dye Film Sensor (Upper)

Print Head Cooling Fan



SECTION 16.9 MAGNETIC ENCODING OPTION

Holes for Screw P1-0038/R

Magnetic Head Aperture

3633-0110

Washer M1560-110/R

Magnetic Head 3633-0110

Spring E9147

Screw P1-0038/R



Part Numbers:

3633-0100-011 Brush Strip E9243 Pop Rivet 3633-0403 Modified Wire Loom

SECTION 16.10 GENERAL INFORMATION

RFID Reader PCB

Dye-Film Drive Motor

Anti Static Brush Strip

Prontoo Stepper Motor pulleys are now held in place by Push-On fastener (P/N RIO/0465), LS also.



Card Feed Roller

Print Head Roller Drive Gear

Print Head Roller

Printer Cam

Cam Drive Assembly

Bearing Plate Left Side

Bearing Plate Right Side

Cam Pulley (Print Head Up/Down) is now glued onto the motor shaft with Loctite 422 adhesive.



Tacho Wheel

Bearing Plate – Left Side

Dye-Film Sensor (Lower)

Cam Sensor



SECTION 17 PRONTO SPARES LIST

Part Number Description

3649-0100-002 Front Bezel

3649-0503 Switch PCB

3649-0100-003 Front button (blue plastic)3649-0100-004 Light Guide (clear plastic)

3649-0150-001 Chassis Cover (note: this is the main black plastic lid component)

3649-0150-002 Top Cover

3649-0150-003 Lid Latch

E9092 Printhead Fan Assembly

3633-0504 Dye film Sensor PCB

3633-0400 Cable Assembly - Dye Film Sensor & Printhead Fan (Latching Connectors)FG/3649-0160 Printhead Assembly

FG/3649-0500 Main PCB (Latching Connectors)

3633-0501 Magnetic encoding PCB

M9500-853/R RFID PCB Assembly

3649-0505 Dye Film LED Emitter PCB

3633-0502 Opto Sensor PCB

3633-0401 Cable Assembly - Dye LED & Tacho+Cam+Flip Sensors (Latching Connectors)

3633-0402 Cable Assembly - Cam Motor & Stepper Motor (Latching Connectors)

3633-0406 Cable Assembly - Card Sensors -Front, Middle & Rear (Latching Connectors)

3649-0050 Cable Assembly - Dye Film Take-up (Latching Connectors)

3633-0403 Cable Assembly RFID & Lid Sensor (Latching Connectors)

RIO/0112/R Stepper Motor

RIO/0043/R DC Motor 9 N/CM

3633-0100-011 Anti-Static Brush StripP1-0034/R PSU Assembly

3633-0180 Print Roller

3633-0182 Mag Drive Roller

3633-0188 Card Feed Roller

3633-0185 Cleaning Roller (black rubber roller)

3633-0183 Idle Roller Assembly

3633-0184 Rear Idler Roller Assy (Mag printers)

3633-0200-012 Tacho Encoder Wheel

3649-0100-001 Base (external moulding)3633-0300-008 Cam Pivot Bar

Pronto Spring Kit contents:- Spring (Lid Latch) x6 Spring (Printhead) x6 Spring Retention Plate x6 Spring, Idler Link Plate x6 Spring, Belt Tensioner x6 Spring, Card Guide x6 Compression Spring (Tacho & Media preventer) x6

Pronto Transmission Kit contents:- Pulley 30T 5mm Bore x4 Pulley 30T 3mm Bore x4 Pulley 30T 6mm Bore x4 Pulley, 110T, 6mm Bore x4 Pulley (Smooth) Belt Tensioner x4 Pulley (Toothed) Belt Tensioner x4 Belt Tensioner Bracket x4 Belt, Stepper Drive, 144T x4 Belt, Drive Train, 184T x4 Belt, Card Feed, Cam, 80T x4 Push-On Fastener, 5mm Shaft x10 Grip Washer x10

Pronto Low-cost Miscellaneous Items Kit contents:- Retaining Clip (Opto Sensor) x3 Rear Connector Panel x1 Cable Clip, Large x5 Spring Dampeners (used on lid latch springs) x10 Circlip x10 Idler Link Plate x2 Bearing Plate, Large x2 Mounting braket for Dye Film LED Emitter PCB x2 Card Guide x2 Cam Shaft x2 Cam Linkage, Long x2 Cam Linkage, Short x2 Tacho Plunger x2 Tacho Retainer x2 RFID PCB Retainer x2 Dye-Film Take-Up Gear x2 Feet, Self Adhesive x6 Pop Rivet (used on Anti-static brush strip) x10 Screw M3X8 POZI Pan-head SEMS x10 M3 x 10mm Countersunk Screw x10

Pronto Spring Kit

Pronto Transmission Kit

Pronto Low-cost Miscellaneous Items Kit

Front Bezel

Lid Assy

Print Engine - Electrical

Print Engine - Mechanical



SECTION 18 FIRMWARE RELEASE HISTORY

Introduction This is the amendment record for the Magicard Pronto printer Firmware (Software Identifcation Number 2221). This document is updated whenever a new version of the Firmware is released. 6-Oct-2009 | Release V1.09 1. Re-release of previous version due to Compiler fault. 6-Oct-2009 | Release V1.07 1. Updated the executable Firmware updater. This now handles multiple Printers connected at once. 23-Sep-2009 | Release V1.06 1. Added some extra debouncing to the sensor signal from the encoding module. 2. Updated dye LED calibration process to permit the use of either 5 or 6 panel Film. 3. Fixed soft power-off. 3-Sep-2009 | Release V1.05 1. Fixed a misregistration issue which affects some machines when photographs are printed against primary colour backgrounds. 2. Leave fan on for longer for the 'RUNFAN' diagnostic command. 12-Aug-2009 | Release V1.04 1. Printer now avoids unnecessary Film usage when waking from sleep mode. 2. Reduced the occurrence of a resin line where the Head is dropped onto the Card. 3. Fixed problem where Firmware version was not being displayed corectly in the Printer query. 23-Jun-2009 | Release V1.03 1. Ensure printhead fan is switched off while waiting for the printed card to be removed from the exit slot. 2. Improved Resin Black printing method. 3-Jun-2009 | Release V1.02 1. Reduce the occurrence of a rogue Black Resin line. 2. Fixed bug in which sometimes caused the first Card to be blank when printing Resin-only images. 26-May-2009 | Release V1.01 1. Improved Print Head temperature control during Overcoat panel. 22-May-2009 | Release V1.00 1. Initial production release.



SECTION 19 PRONTO ERROR CODES

01 - LID OPEN

Please close Lid to continue.

01:00 01:00

This error is raised if the Lid is opened while trying to feed a Card from the Hopper, unless the Printer is in feed-soak mode (in which case the Lid is ignored, and this error cannot occur).

01:01

This error is raised by the Printer User Interface Module if it detects that there is a pending print job while the Lid is open.

01:02

This error is raised if the Lid is opened while printing a colour panel.

01:03

This error is raised if the Lid is opened while printing the resin black panel, or if the Lid is opened while printing with continuous resin Film.

01:04

This error is raised if the Lid is opened while printing the overcoat panel.

01:05

This error is raised if the Lid is opened during the Dye LED calibration process.

01:06

This error is raised if the Lid is opened while winding the Film on to the start of the next panel. This may be either during printing or initialisation.

01:07

This error is raised if the Lid is opened while aligning the start of a Dye panel with the edge of the PrintHead. This may be either during printing or initialisation.

01:08

This error is raised if the Lid is open when we are vaLidating the print job parameters against the Printer setup. This can happen if we send a print job to the Printer while the Lid is open.

01:09

This error is raised if the Lid is opened while we are trying to take up the slack in the Dye-Film. Note that this function is called after resetting the Cams on initialisation or reinitialisation, and also after printing each panel.

01:10

This error is raised by the Pronto user interface module if it detects that there is a pending print job while the Lid is open.

01:11

This error is raised by Pronto models if the Lid was opened while the Printer was waiting for an ejected Card to be removed from the Card slot.



01:12

This error is raised if, at the end of a print job, we detect that the Lid is open. This will usually mean that the print job aborted early due to the Lid being opened, but could also mean (in extremely rare circumstances) that the Lid was opened just after the point when the job actually finished successfully.

01:13

This error is raised while trying to hand-feed a Card on Pronto Engines, if the Lid is opened during the hand feed process. This error only occurs if the Lid is opened before a Card has been seen at the front Sensor, during the phase where the motor is still running.

01:14

This error is raised while trying to hand-feed a Card on Pronto Engines, if the Lid is opened during the hand- feed process. This error only occurs if the Lid is opened before a Card is seen at the front Sensor, during the phase where the motor is `resting' (waiting for the front Sensor to block before starting again).

01:15

This error is raised while trying to hand-feed a Card on Pronto Engines, if the Lid is opened during the hand feed process. This error only occurs if the Lid is opened after the front Sensor is blocked, but before the mid Sensor is blocked.

02 - OUT OF CARDS

Applicable to Hopper fed Cards.

02:00 02:00

Not applicable to the PRONTO.

03 - HAND FEED ERROR

Please select Retry to try again.

03:00 03:01

This error is raised in Pronto Engines during hand-feeding if the Printer could not feed a Card into the Engine within 3 attempts.

04 - CARD JAM 1

Please clear Printer mechanism.

04:00 04:00

This error is raised if the front Sensor becomes blocked when trying to hand-feed a Card, but does not unblock within 5 seconds.

04:01

This error is raised while trying to get a Card out of the Smart Encoding unit if the front Sensor remains clear for more than 5 seconds.

04:02

This error is raised while trying to get a Card out of the Smart Encoding unit if the front Sensor stays blocked for more than 5 seconds.

04:03


04:04


04:05

This error is raised while trying to rewind the Card to the standby position (i.e. Over the mid Sensor) if the front Sensor stays clear for more than 2 seconds. This function is called to reposition the Card after performing mag verification in the forwards direction.



04:06

This error is raised while trying to rewind the Card to the standby position (i.e. Over the mid Sensor) if the mid Sensor stays clear for more than 2 seconds. This function is called to reposition the Card after performing mag verification in the forwards direction.

04:07


04:08

This error is raised while trying to return the Card to the print Engine after rotating it if the front Sensor is not obscured within 5 seconds.

04:09

This error is raised while trying to return the Card to the print Engine after rotating it if we fail to clear the front Sensor within 5 seconds. Note that the Sensor has already been obscured by the Card at this stage.

04:10

This error is raised while trying to feed a Card into the flip mechanism for rotation if the front Sensor is not cleared within 5 seconds. By this point, the Card has already moved forward to block the Sensor.

04:11

This error is raised while trying to eject the Card from the Printer if the front Sensor remains blocked for more than 3 seconds. At this stage, the Card has already been moved towards the flip mechanism and has blocked the front Sensor.

05 - ENCODER JAM


05:00 05:00

This error is raised while trying to move the Card from the smart encoding position to the standby position if the Card present Sensor does not register the Card leaving within 3 seconds.

05:01

This error is raised while trying to place the Card into the smart encoding position if the Card present Sensor does not register the arrival of the Card within 2 seconds.

05:02

This error is raised while trying to roll a Card backwards to the smart encoding position if it takes more than 2 seconds for the encoder contact switch to be made.

06 - CARD JAM 2


06:00 06:00

This error is raised while measuring the positions of the resin calibration marks on the image position setup Card if we fail to see the trailing edge of a dark bar within 10 seconds. Note that we have already detected the edge of the Card and a light-to-dark bar transition by this point.

06:01

This error is raised in Pronto print Engines while trying to rewind a Card to the "ready-to-mag-encode" position if the rear Sensor is not obscured within 4 seconds.

06:02

This error is raised while positioning the Card at the front Sensor during image position calibration if we fail to see the Card arrive at the Sensor within 5 seconds.

06:03

This error is raised while measuring the positions of the resin calibration marks during image position calibration if we fail to see the leading edge of the Card arrive at the front Sensor within 10 seconds. Note that the Card is moving backwards at this point, so the leading edge is actually the back edge.



06:04

This error is raised while measuring the positions of the resin calibration marks during image position calibration if we fail to see a light-to-dark bar transition at the mid Sensor within 10 seconds. Note that we have already detected the edge of the Card by this point.

06:05

This error is raised while trying to feed a Card from the Hopper if the mid Sensor remains clear for more than 6 seconds. Note that by this point the rear Sensor has already been obscured (hopefully by a Card).

06:06

This error is raised while trying to return the Card to the standby position (over the mid Sensor) from over the rear Sensor if we fail to see the rear Sensor unblock within 3 seconds.

06:07

This error is raised while trying to hand-feed a Card to the standby position (over the mid Sensor) if we fail to see the mid Sensor block within 5 seconds. Note that by this point we have already seen the front Sensor block and then unblock.

06:08

This error is raised while trying to move a Card from the smart encoding position to the standby position (over the mid Sensor) if we fail to see the mid Sensor block within 5 seconds.

06:09

This error is raised while trying to move the Card from over the front Sensor to the standby position (over the mid Sensor) if the front Sensor does not unblock within 3 seconds.

06:10

This error is raised while trying to move the Card from over the front Sensor to the standby position (over the mid Sensor) if the mid Sensor does not block within 3 seconds. Note that by this point we have already seen the front Sensor unblock.

06:11


06:12


06:13

This error is raised while trying to move the Card into the magnetic encoding standby position (which is where rear edge of the Card just blocks the rear Sensor) if the rear Sensor does not block within 4 seconds.

06:14

This error is raised during magnetic encoding if we fail to unblock the rear Sensor within 4 seconds. By this point we have already successfully placed the Card into the magnetic encoding standby position (where the rear edge of the Card just blocks the rear Sensor) and have begun to move the Cards forwards towards the mag head.

06:15

This error is raised while moving the Card forwards towards the front Sensor during the soak test routine if we fail to see the front Sensor block within 6 seconds.

06:16

This error is raised while moving the Card backwards towards the rear Sensor during the soak test routine if we fail to see the rear Sensor block within 6 seconds.

06:17

This error is raised while moving the Card towards the Flipper ready for rotation if the front Sensor does not block within 5 seconds.



06:18

This error is raised while trying to position the Card so that its rear edge just covers the rear Sensor (ready for printing) if we fail to see the rear Sensor block within 3 seconds.

06:19

This error is raised while trying to position the Card so that its rear edge just covers the rear Sensor (ready for printing) if we fail to see the rear Sensor unblock within 3 seconds. By this point the rear Sensor has already been blocked by the Card moving backwards, and the Printer is moving the Card forwards again until the Sensor just unblocks.

06:20

This error is raised in Pronto print Engines during the forward motion part of the soak test routine if the Card cannot be seen to arrive at the front Sensor within 6 seconds.

06:21

This error is raised in Pronto print Engines during the backward-motion part of the soak test routine if the Card cannot be seen to arrive at the rear Sensor within 6 seconds.

06:22

This error is raised while feeding a Card from the Hopper into the standby position (covering the mid Sensor) if we fail to see the front Sensor block within 6 seconds. By this point the Card has already been successfully extracted from the Hopper, and the Printer is trying to move it all the way to the front Sensor before returning it to the standby position.

06:24


06:25


06:26

This error is raised in Pronto Engines while rewinding the Card to the standby position (after mag encoding) if the mid Sensor does not block within 5 seconds.

06:27


07 - NO DYE-FILM DETECTED

Please load valid Film to continue.

07:00 07:00

This error is raised while initialising the Dye-Film if the Printer cannot vaLidate the information in the header of the Dye-Film's RFID tag. Note that this tag vaLidation process is not performed when no tag is present|the Printer just assumes that a roll lacking a tag is monochrome. Thus, this error is only raised when the tag is detected but invaLid.

08 - OUT OF DYE-FILM

Please load a new roll of Film to continue.

08:00 08:00

This error is raised while trying to advance the Film to the start of the next panel if no tacho or Dye Sensor transitions are seen for at least 5 seconds.

08:01

This error is raised while trying to advance the Film by a certain fixed offset (for example, to line up the start of the panel with the printing position) if no tacho or Dye Sensor transitions are seen for at least 5 seconds.

08:02

This error is raised while collecting data for the calibration of the Dye LEDs if no tacho transitions are seen for at least 5 seconds while trying to move the Film between measurements.



08:03

This error is raised while running a Tacho Sensor test (via the "TAC" quick command) if no Tacho Sensor transitions are seen for at least 4 seconds.

08:04

This error is raised while printing a colour panel if no Tacho or Dye Sensor transitions are seen for at least 150 printed lines (this equates to roughly 150 ms).

08:05

This error is raised while printing a black panel if no Tacho or Dye Sensor transitions are seen for at least 150 printed lines (this equates to roughly 75 ms).

08:06

This error is raised while printing an overcoat panel if no Tacho or Dye Sensor transitions are seen for at least 150 printed lines (this equates to roughly 150 ms).

08:07

This error is raised during Dye-Film initialisation if the print counter on the Dye-Film's RFID tag has reached its limit.

08:08

This error is raised while carrying out the vaLidation checks that are done just prior to printing each Card if the print counter on the Dye-Film RFID tag has reached its limit. Note that by this point the Printer has already determined that the fitted Film is in principle capable of being used for the downloaded print job (for example, it has the required colours).

08:09

This error is raised while trying to advance the Film to the start of the next panel if tacho transitions are seen, but no Dye Sensor transitions are seen for at least 5 seconds.

08:10

This error is raised while trying to advance the Film to the start of the next panel if Dye Sensor transitions are seen, but no tachos are seen for at least 5 seconds.

08:11

This error is raised while trying to advance the Film to the start of the next panel if tacho and Dye Sensor transitions are seen, but the Dye panel Sensor change does not stabilise within 5 seconds. This could be due to glitches, or an uncalibrated Dye LED (in which case the "FCL" command should fix it).

08:12

This error is raised just prior to commencing printing if the black end-of-Film marker tape has been detected.

09 - UNSUPPORTED DYE-FILM

Please load different Film to continue.

09:00 09:00

This error is raised while initialising the Dye-Film if the fitted Film has an unsupported configuration of Dye panels. The currently supported configurations are: colour, resin and overcoat for full-colour prints. Note that this error means that the Dye-Film's RFID tag was successfully vaLidated.

10 - WRONG DYE-FILM TYPE

Please load different Film to continue, or press Cancel to clear the print job.

10:00 10:00

This error is raised while advancing the Dye-Film to a specific position within a specific panel (for example, moving the Film into a position where it can be used for printing) if the panel requested is not present in the loaded Film type. For example, if a colour panel was requested when KO Film was loaded.

10:01

This error is raised while determining the print event sequence for the current print job using LC1 type Film (in other words, Film having a YMCKO configuration) if the image cannot be printed using the loaded Film.



10:02

This error is raised while determining the print event sequence for the current print job using LC3 type Film (in other words, continuous resin-only Film) if the image cannot be printed using the loaded Film.

10:03

This error is raised while determining the print event sequence for the current print job using LC6 type Film (in other words, Film with a KO configuration) if the image cannot be printed using the loaded Film. This particular error may arise if the user somehow manages to send a PRN requiring colour to a machine which has MA600KO Film fitted.

10:04

This error is raised while determining the print event sequence for the current print job using LC8 type Film (in other words, Film with a YMCKOK configuration) if the image cannot be printed using the loaded Film.

10:05

This error is raised while vaLidating the downloaded print job against the capabilities of the loaded Dye-Film if colour data is sent while monochrome Film (K or KO) is fitted. The Driver should normally prevent this from happening, but it is possible to bypass the Driver by sending PRNs directly to the Printer.

10:06

This error is raised while preparing to calibrate the Dye LEDs if the Printer detects that anything other than colour Film (YMCKO or YMCKOK) is loaded.

11 - CANNOT FIND PANEL

Please check Film and Printer mechanism, or press Cancel to clear the print job.

11:00 11:00

This error is raised while trying to align the Dye-Film to a chosen offset within a chosen panel (for example, prior to printing) if the Printer cannot find the requested panel within 8 panels of its starting point. This error often indicates that either the Dye LED or Sensor is poorly positioned, or that the Dye LEDs need to be calibrated using the "FCL" command.

11:01

This error is raised while trying to align the Dye-Film to a chosen offset within a chosen panel (for example, prior to printing) if the Printer cannot find the requested panel within 8 panels of its starting point. This error often indicates that either the Dye LED or Sensor is poorly positioned, or that the Dye LEDs need to be calibrated using the "FCL" command.

This error is similar to 11:00, but the surrounding context is slightly different. 11:00 can occur whenever the Film position is being set, whereas 11:01 can only occur when the Film position is being set and the Printer has had to recover from a Dye-panel misalignment by skipping an entire panel set.

11:02

This error is raised if the Printer is in factory mode and the requested Dye Film panel offset is less that the current offset (e.g. The Film has overshot).

12 - RFID PCB MISSING

Reconnect PCB to continue.

12:00 12:00

This error is raised during Printer initialisation if the RFID PCB cannot be detected.

13 - PRINTHEAD ERROR

Switch Printer off and reconnect PrintHead.

13:01 13:01

This error is raised if no change in the GPIO input attached to the PrintHead thermistor is detected while trying to calibrate the analogue-to-digital conversion module. This probably means that the thermistor is not connected.

14 - OVERHEAT ERROR

Switch Printer off and allow PrintHead to cool.



14:00 14:00

This error is raised while waiting for the PrintHead temperature to fall before printing a Card if the measured temperature is out of range.

14:01

This error is raised while waiting for the PrintHead temperature to fall before printing a Card if it takes more than 2 minutes for the temperature to drop below 68 C.

15 - IMAGE TOO DARK

Please cancel print job and reduce Driver PrintHead power settings to try again.

15:00 15:00

This error is raised during the print cycle, while waiting for the main Stepper motor to reach the appropriate position for the next printing pass, if the Printer detects that the motor has already passed that position. This can sometimes occur when the image being printed is very dark, and/or the PrintHead temperature is very low.

16 - CANNOT LIFT HEAD

Check Printer mechanism.

16:00 16:00

This error is raised while resetting the Cam to the "head up" position if the Printer does not see the Cam Sensor block within 5 seconds.

16:01

This error is raised while trying to reset the Cam to the "head up" position if the Printer does not see a light-to-dark Cam Sensor transition within 5 seconds. By this point the Cam Sensor is already unblocked.

16:02

This error is raised while trying to lift the PrintHead if the Cam Sensor does not block within 5 seconds. Note that this function is only used by the "HEAD" quick command and the cleaning routine.

16:03

This error is raised while trying to lift the head at the end of printing a panel if the Cam Sensor does not clear within 5 seconds. By this point the Sensor has already been blocked.

16:04

This error is raised while trying to place the Cam in the "head up" position if the Cam Sensor does not block within 5 seconds. This function is only called during Printer Boot-up and print job cancellation.

16:05

This error is raised while trying to place the Cam in the "head up" position if the Cam Sensor does not make a dark-to-light transition within 5 seconds. Note that the Sensor has already been blocked by this point. This function is only called during Printer boot-up and print job cancellation.

16:06

This error is raised while trying to place the Cam in the "head up" position if the Cam Sensor does not make a light-to-dark transition within 5 seconds. Note that by this point the Sensor has already made a dark-to-light transition. This function is only called during Printer Boot-up and print job cancellation.

16:07

This error is raised while lifting the PrintHead if the Cam Sensor does not block within 5 seconds.

16:08

This error is raised while trying to lift the PrintHead if the Cam Sensor does not block within 5 seconds. By this point the head has been lifted and the Cam Sensor has just unblocked, and the Printer is pulsing the Cam motor backwards to prevent overrun.

17 - CANNOT DROP HEAD

Check Printer mechanism.



17:00 17:00

This error is raised while trying to lower the PrintHead if the Cam Sensor does not unblock within 5 seconds. This function is called by the "HEAD" quick command, the cleaning routine and the soak test routine.

17:01

This error is raised while lowering the PrintHead and analysing the image data if the Cam Sensor does not unblock within 3 seconds. (Note that by this point the image data has been completely analysed. This function is used during the printing routine before starting to print each colour panel).

19 - MAG VERIFY FAIL

Press Retry or Cancel to continue.

19:00 19:00

This error is raised after carrying out magnetic verification if the data read back from the Card on the final attempt does not match the data that was written. This error cannot occur if either verification is switched off, or some other error (such as Lid open or Card jam) occurs during encoding/verification.

19:01

This error is raised while processing an "MSV" command if the data read back from the Card does not match the data written within 4 attempts.

20 - MODE UNSUPPORTED

Cannot print requested image with this Printer model.

20:00 20:00

This error is raised while determining the format of the downloaded print job if colour printing has been requested for the front of the Card but the Printer does not support colour printing.

20:01

This error is raised while determining the format of the downloaded print job if colour printing has been requested for the back of the Card but the Printer does not support colour printing.

21 - CLEAN REQUIRED

Please clean Rollers to avoid deterioration.

21:00 21:00

This error is raised if the cleaning prompt is enabled and the "clean required" ag has been set. This ag gets set when the number of Cards printed since the last clean exceeds the user configurable threshold (by default - 700). (Note that this check only gets performed at Printer Boot-up).

22 - TEST RESULTS

This error is raised after executing a Sensor

22:00 22:00

Test, initiated using an "SNS" command, if the Printer found that the Cam Sensor never toggled.

22:01

This error is raised after completing a Sensor test, initiated using an "SNS" command, if the Cam Sensor toggled but the flip Sensor never saw the light.

22:02

This error is raised after completing a Sensor test, initiated using an "SNS" command, if the Cam Sensor toggled but the flip Sensor never got obscured.

22:03

This error is raised after completing a Sensor test, initiated using an "SNS" command, if the Cam and flip Sensors both toggled.



22:04


22:05

This error is raised when performing the Sensor test routine on a Pronto Engine upon completion of the test.

22:06

This error is raised when performing the Sensor test routine on a Pronto Engine if the Cam Sensor does not toggle.

23 - WRONG PSU

Please switch Printer off and check the Power Supply.

23:00 23:00

This error is raised after initialising the Cam at boot up if the time taken to rotate the Cam by half a turn was longer than 2.5 seconds, indicating a low level output from the PSU.

24 - GENERAL ERROR

Please contact Technical Support, quoting Error Code.

24:00 24:00

This error is raised while processing a downloaded Firmware binary file if the file length is greater than 1170432 bytes (1143 kB).

24:01

This error is raised while attempting to write a downloaded Firmware binary into ash memory if the embedded ID string in the downloaded file is incorrect. This would happen if, for example, a Pronto binary was somehow sent to an Enduro Printer.

24:02

This error is raised while trying to erase an ash memory sector if there is a timeout waiting for the operation to complete.

24:03

This error is raised after printing a Card if the postprint Dye-Film RFID Tag check (which involves incrementing the Tag's print counter) fails.

24:04

This error is raised while trying to feed a Card from the Hopper to the print Engine if the Printer sees the mid Sensor block before the rear one does. This could possibly indicate that the rear Sensor has dropped out of position, but could also mean that the mid Sensor is faulty.

24:05

This error is raised while trying to feed a Card from the Hopper to the print Engine if the Printer sees the front Sensor block before the rear and mid ones do. This could possibly indicate that both the rear and mid Sensors have dropped out of position, but could also mean that the front Sensor is faulty.

24:06

This error is raised while trying to feed a Card from the Hopper to the print Engine if the Printer sees the front Sensor block before the mid one does. This could possibly indicate that the mid Sensor has dropped out of position, or that the front Sensor is faulty.

24:07

This error is raised while trying to hand feed a Card into the print Engine if the Printer sees the mid Sensor block before the front one does. This could possibly indicate that the front Sensor has dropped out of position, or that the mid Sensor is faulty.

24:08

This error is raised while trying to hand feed a Card into the print Engine if the Printer sees the rear Sensor block before the front and mid ones do. This could possibly indicate that both the front and mid Sensors have dropped out of position, or that the rear Sensor is faulty.



24:09

This error is raised while trying to hand feed a Card into the print Engine if the Printer sees the mid Sensor block before the front one clears. This could possibly indicate that the front Sensor has failed, or that the mid Sensor is faulty.

24:10

This error is raised while trying to hand feed a Card into the print Engine if the Printer sees the rear Sensor block before the front one clears and the mid one blocks. This could possibly indicate that the front Sensor has failed, and that the mid Sensor has dropped out of position, or that the rear Sensor is faulty.

24:11

This error is raised while trying to hand feed a Card into the print Engine if the Printer sees the rear Sensor block before the mid one does. This could possibly indicate that the mid Sensor has dropped out of position, or that the rear Sensor is faulty.

24:12

This error is raised while attempting to write a downloaded Firmware file into ash memory if the encrypted checksum of the file is invaLid. This would mean that the Firmware file has been either corrupted during transmission, or modified by a third party.

24:13

This error is raised while attempting to move the Card into the standby position if the Firmware data relating to the current position of the Card is invaLid. This should never happen.

24:15

This error is raised in Pronto Engines while hand-feeding a Card to the standby position, while trying to block the front Sensor, if the rear Sensor blocks first.

24:16

This error is raised in Pronto Engines while hand-feeding a Card to the standby position, while trying to block the front Sensor, if the mid Sensor blocks first.

24:18

This error is raised if the UNEXPIRE command fails.

25 - CALIBRATE FAILED

Could not calibrate the Dye-Film LEDs.

25:00 25:00

This error is raised while calibrating the Dye LED if the cluster analysis is unable to find the black panel. This means that light was always able to shine through the Film, regardless of which panel the Printer was looking at.

25:01

This error is raised while calibrating the Dye LED if the Printer never sees either green or blue light shine through the Film, regardless of which part of the Film it looks through. (Note that the Printer was able to see red light shine through).

25:02

This error is raised while calibrating the Dye LED if the Printer never sees blue light shine through the Film, regardless of which part of the Film it looks through. (Note that the Printer was able to see red and green light shine through).

25:03

This error is raised while calibrating the Dye LED if the Printer never sees red, green or blue light shine through the Film, regardless of which part of the Film it looks through.

25:04

This error is raised while calibrating the Dye LED if the Printer never sees red or blue light shine through the Film, regardless of which part of the Film it looks through. (Note that the Printer was able to see green light shine through).



25:05

This error is raised while calibrating the Dye LED if the Printer never sees green light shine through the Film, regardless of which part of the Film it looks through. (Note that the Printer was able to see red and blue light shine through).

25:06

This error is raised while calibrating the Dye LED if the Printer never sees red light shine through the Film, regardless of which part of the Film it looks through. (Note that the Printer was able to see green and blue light shine through).

25:07

This error is raised while calibrating the Dye LED if the Printer never sees red or green light shine through the Film, regardless of which part of the Film it looks through. (Note that the Printer was able to see blue light shine through).

29 - UPGRADE FIRMWARE

A Firmware upgrade is required.

29:00 29:00

This error is raised if the Dye-Film is of a type or format not supported by the current Firmware version. Upgrading the Firmware will prevent this error from occurring.

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