colour id card printer magicard rio pro maintenance manual pro maintenance manual iss.1d.pdf ·...

Issue 2 10/12/2010

Colour ID Card Printer MAGICARD® Rio Pro Maintenance Manual

Ultra Electronics Card Systems www.magicard.com

Magicard Rio Pro single sided colour ID Card Printer - 3633-9001 Magicard Rio Pro Duo double sided colour ID Card Printer - 3633-9021 Magicard Rio Pro Mag single sided colour ID Card Printer - 3652-9002 Magicard Rio Pro Duo Mag double sided colour ID Card Printer - 3652-9022 Magicard Rio Pro single sided colour ID Card Printer with Smart Encoder - 3652-9005 Magicard Rio Pro Duo double sided colour ID Card Printer with Smart Encoder - 3652-9025 Magicard Rio Pro Mag single sided colour ID Card Printer with Smart Encoder - 3652-9006 Magicard Rio Pro Duo Mag double sided colour ID Card Printer with Smart Encoder - 3652-9026 Duplex Upgrade Kit - 3633-0052

Standard Option Option Standard Standard Standard Standard Standard Option Option

Ultra Electronics Card Systems

Rio Pro 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 RIO PRO ....................................................................................... - 9 -

section 2.1 specification of the Magicard Rio Pro ........................................................................................................................................... - 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 single / double-sided upgrade. ................................................................................................................... - 18 -

section 6 PHILOSOPHY ............................................................................................................................................ - 19 -

section 6.1 repair and maintenance................................................................................................................................................................ - 19 - section 6.2 the warranty ................................................................................................................................................................................. - 20 - Section 6.3 Internet support ........................................................................................................................................................................... - 21 - section 6.4 recommended tools ..................................................................................................................................................................... - 21 -

section 7 CLEANING THE PRINTER. ....................................................................................................................... - 22 -

section 7.1 cleaning is important .................................................................................................................................................................... - 22 - section 7.2 cleaning supplies.......................................................................................................................................................................... - 22 - section 7.3 cleaning the printer Rollers ........................................................................................................................................................... - 23 - section 7.4 replacing the cleaning roller.......................................................................................................................................................... - 24 - section 7.5 cleaning the print head. ................................................................................................................................................................ - 25 -

SECtion 8 MAGICARD RIO PRO DRIVER. ................................................................................................................ - 26 -

section 8.1 installation instructions for Windows 2000/xp/2003 server & VISTA ............................................................................................. - 26 - section 8.1 installation instructions for Windows 2000/xp/2003 server & VISTA and Windows 7 continued… .............................................. - 28 - section 8.2 un-installing the driver for windows 2000 / xp / 2003 server. ......................................................................................................... - 29 - section 8.3 un-installing the driver for windows vista / windows 7. .................................................................................................................. - 30 - section 8.4 driver description .......................................................................................................................................................................... - 31 -

Section 9 PRINTER DISPLAY ................................................................................................................................... - 32 -

section 9.1 menu options ............................................................................................................................................................................... - 32 - section 9.1.1 1. clean rollers ............................................................................................................................................................................. - 33 - section 9.1.2 2. test card .................................................................................................................................................................................. - 33 - section 9.1.3 3. info .......................................................................................................................................................................................... - 34 - section 9.1.4 4. hand feed ................................................................................................................................................................................ - 34 - section 9.1.5 5. mag self test ............................................................................................................................................................................ - 35 - section 9.1.6 6. reset printer ............................................................................................................................................................................. - 35 - section 9.2 maintenance mode ....................................................................................................................................................................... - 36 - section 9.2.1 soak test mode ............................................................................................................................................................................. - 36 - section 9.2.2 Sensor test Mode ......................................................................................................................................................................... - 37 - section 9.2.3 previous menu ............................................................................................................................................................................. - 38 -

section 10 PRINT HEAD REPLACEMENT ................................................................................................................. - 39 -

section 10.1 print head damage. ..................................................................................................................................................................... - 39 - section 10.2 print head Electronic failure. ......................................................................................................................................................... - 40 - section 10.3 replacing the print head. ............................................................................................................................................................... - 41 - section 10.4 Setting the print head density calibration. ..................................................................................................................................... - 42 - Section 10.5 Print head setup and adjustment .................................................................................................................................................. - 43 -

Section 11 DISMANTLING AND ASSEMBLING THE PRINTER ................................................................................ - 44 -

section 11.1 removing & refitting the printer casing. ......................................................................................................................................... - 44 - Section 11.2 Removing & Refitting the front fascia cover .................................................................................................................................. - 44 - section 11.3 removal & refitting of the top dye film sensor ................................................................................................................................ - 45 - section 11.3 removing & Refitting of the lower dye film sensor. ........................................................................................................................ - 45 - section 11.4 removal and refitting of the Card thickness adjuster ..................................................................................................................... - 46 - section 11.5 removing & Refitting the controller pcb. ........................................................................................................................................ - 46 - section 11.6 removing & refitting of the front & rear Card sensor ...................................................................................................................... - 47 - section 11.7 removing & refitting the Lcd display .............................................................................................................................................. - 47 - section 11.8 removal & refitting of left side components ................................................................................................................................... - 48 - section 11.9 removal and refitting of right side components ............................................................................................................................. - 49 - section 11.10 removal & refitting of the Drive motors & front Card sensor. ......................................................................................................... - 50 - Section 11.11 removal of the chassis cover.................................................................................................................................................... - 51 - section 11.12 removal of the rotation unit ........................................................................................................................................................... - 52 -



section 11.13 removal of the idle rollers ............................................................................................................................................................. - 52 - section 11.14 removal and refitting of the large bearing plate ............................................................................................................................. - 53 - section 11.15 removal and refitting of steel Circlips ............................................................................................................................................ - 53 - section 11.16 Removal and refitting of rollers ..................................................................................................................................................... - 54 - section 11.17 removal & refitting of the Card guide & middle Card sensor.......................................................................................................... - 54 -

section 12 TOUBLESHOOTING .................................................................................................................................. - 55 -

Section 12.1 initialisation sequence .................................................................................................................................................................. - 55 - Section 12.2 hardware problems ...................................................................................................................................................................... - 56 - Section 12.3 image problems ........................................................................................................................................................................... - 57 - Section 12.3 image problems COnt. ................................................................................................................................................................. - 58 - Section 12.4 printer driver problems ................................................................................................................................................................. - 59 - Section 12.5 Magnetic encoding problems ........................................................................................................................................................ - 61 -

Section 13 ERROR CODE LIST .................................................................................................................................. - 62 -

Section 13 Error code list cont. ........................................................................................................................................................................... - 63 - Section 13 Error code list cont. ........................................................................................................................................................................... - 64 - Section 13 Error code list cont. ........................................................................................................................................................................... - 65 -

Section 14 MAGICARD PRINTER SUPPORT UTILITY .............................................................................................. - 79 -

section 15 MAGNETIC ENCODING ............................................................................................................................ - 88 -

section 15.1 magnetic encoding standards ....................................................................................................................................................... - 88 - SECTION 15.2 BASIC MAGNETIC ENCODING. ............................................................................................................................................. - 90 - SECTION 15.3 ENCODING USING BADGE PRINTING SOFTWARE. ............................................................................................................ - 91 - section 15.4 ASCII Character Set supported by the Rio Pro ............................................................................................................................. - 92 - section 15.5 iso standards................................................................................................................................................................................ - 92 - section 15.6 error checking. ............................................................................................................................................................................. - 93 - section 15.7 FITMENTS to the printer. ............................................................................................................................................................. - 94 -

section 16 PARTS & PART NUMBERS ...................................................................................................................... - 95 -

section 16.1 external components .................................................................................................................................................................... - 95 - section 16.2 Top cover assembly (3633-0150) ................................................................................................................................................. - 95 - section 16.3 print head assembly (FG/3633-0160) ........................................................................................................................................... - 96 - section 16.4 Rotation unit assembly (3633-0140) ............................................................................................................................................. - 96 - section 16.5 Roller Layout. ............................................................................................................................................................................... - 97 - section 16.6 Drive mechanism right hand side. ................................................................................................................................................ - 98 - section 16.7 Drive mechanism left hand side. .................................................................................................................................................. - 99 - section 16.8 Motor layout and part numbers. .................................................................................................................................................. - 100 - section 16.9 Internal wiring & sensor part numbers ........................................................................................................................................ - 101 - section 16.10 Magnetic encoding option .......................................................................................................................................................... - 102 -

section 17 PRODUCT UPDATES ............................................................................................................................. - 103 -



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, Rio Pro, Rio Pro, 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 by Magicard with the Printer. Do not to spill any liquid on the Printer.

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 its life. Before transporting the Printer, remove the dye film and Card Hoppers and pack the Printer in its original packaging.

Location Requirements for your Printer:

A clean, dry level surface.

Cable access at the rear.

Allowance for air circulation.

An adequately ventilated room.

The correct Power Supply Unit 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 set 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 its high quality photographic output. Dye Sublimation is also known as “Dye Diffusion” or “Thermal Transfer”. Inside the Dye Sublimation Printer is a roll of transparent film that resembles sheets of red, blue, yellow, and black coloured cellophane bonded together end to end. On one surface of this film are solid Dyes corresponding to the four basic colours used in printing: cyan, magenta, yellow and black. Between the solid Dye and the film, is a layer of release agent, which controls the amount of dye released at each temperature. The Print Head is heated up as it passes over the film, causing the dye to vaporise and permeate the glossy surface of the PVC Card before returning to solid form on cooling. This is sublimation.

The Clear Overcoat Layer

The Overcoat layer acts as a protective film against wear and fading and can also carry a secure image, which cannot be

photocopied – e.g. the Magicard Holokote security watermark.

Dye Sublimation / Inkjet Printing.

There are two factors that contribute to the quality of Dye Sublimation Printers. The first is continuous tone, and the other is un-dithered colour. In Dye Sublimation printing, colours are not laid down as individual dots, as is done in inkjet Printers. The colour produced by a dye-sub is the result of the mixing of pigments to get the actual colour. This is in contrast to most other printing methods which use a tight group of coloured dots which, when seen by the human eye from a distance, appear to be a colour (a process known as “dithering”). Under magnification, the dots are clearly different colours, and when seen close up with the naked eye the picture appears grainy. Because only one colour needs to be printed (instead of up to four), a Dye Sub can place more dots on a Card. It can take a 1200 dpi printer to get the same resolution a 300 dpi Dye Sub Printer is capable of. Another difference that helps is that because the colour sublimates on the Card instead of being laid down as little dots, the edges of each pixel are blurred. This gives the impression of blending for a more natural appearance. Dots from an inkjet leave large white gaps in between pixels, giving the impression of 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, television‟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 operates. This is compensated for in the printer Firmware but it may affect how evenly some Card designs print. Dust and debris on the Card surface will cause small white blemishes to appear in the image so keeping the Cards and tacky rollers clean is imperative. The Printer creates the Card by placing layers of dye onto the Card in the following sequence: Yellow: (Y) Magenta: (M) Cyan: (C) Black: (K) or Resin black Clear: (O) or Overcoat. The Overcoat layer acts as a protective film against wear and fading and can also carry a secure image, which cannot be photocopied (Ultra Secure). Colours appearing on the monitor will not always be exactly the same as those printed by a Printer; this 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 at the start of the Card 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 chip or aerial, 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 RIO PRO

Future Upgradable

Field upgraded from single to double sided ID Card printing, with a simple drop-in upgrade. Rio Pro Duo is pre-programmed as Double Sided, from new.

Flexible

100 Card capacity Card Feeder at the rear of the Printer / 70 Card capacity at the front Stacker. Hand Feed slot at the front of the Printer. 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. Advanced fault diagnosis using on screen fault display. Print Head cooling Fan (allowing the printer to Print continuously). Automatic adjustment for different Card thicknesses.

Smart

Attractive, compact design. Intuitive LCD with simple button menu selections. USB and Ethernet Interface. Microsoft Certified “plug and play” Driver make the Rio Pro easy to install and use.

Secure

Magicard Rio Pro 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 Rio Pro. Can be upgraded to print a custom logo Holokote and Holoflex design Holopatch is available using special Card stock to produce a highly visible logo on a gold seal stamp. Optional ISO 7811 Magnetic Stripe Encoder. Optional OmniKey 5321 Combi Contact/Contactless Encoder.



SECTION 2.1 SPECIFICATION OF THE MAGICARD RIO PRO Printing Method: Direct to Card Dye Sublimation. Feed Format: Automatic and Hand Feed. Resolution: 300 dots per inch (11.8 Dots per mm). Colour Reproduction: 256 graduations for each colour. Internal Memory Size: 16 MBytes. Printing Time: Approximately 35 seconds each side (YMCKO). Approximately 7 seconds each side for single colour. (K). Printer Interface: USB Rev 1.1 (USB 2.0 compatible), Ethernet. Operating Environment: Temperature 15 – 30 degrees Centigrade. Humidity 20% - 80% Storage Environment: Temperature 15 – 55 degrees Centigrade. Humidity 20% - 80% Power Source: External Power Supply auto-ranging. Input Voltage: AC Input 100 – 240 V AC. Input Current Consumption: 1.8 Amps. Frequency: 50 – 60 Hz Output Voltage: 24 V DC Output Current Supply: 3.75 Amps. Output Power Rating: 90 Watts (Max). Weight: 5.5 kilograms (12 lbs) including Hoppers and PSU. Dimensions: 453mm (L) x 206mm (W) x 233mm (H) incl. Hopper and Stacker. 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-Films. Software: Supplied with Windows 2000, 2003 Server, XP, Vista and Win 7 Drivers. Magstripe Encoder: Optional HICO/LOCO magnetic stripe encoder to ISO 7811 standard. Card Size: Standard ISO CR80 & CR79 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. Card Input Hopper Capacity: 100 Cards (0.76mm / 0.030”). Exit Stacker Capacity: 70 Cards (0.76mm or 0.030”). Print Length: Full Card 1016 pixels (85.6mm). Print Width: Full Card 642 pixels (54.5mm). Print Speed: Normal/High (Draft). 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). CCC approved (China) Warranty: Three years UCP (North America, EU and selected other countries only).

Elsewhere 2 year manufacturers limited warranty.



SECTION 3 COMPONENT LAYOUT

Cleaning Roller

Blank Card Hopper

Print Head Assembly

Top Cover Opening Latch

Front Card Stacker

LCD Display

Hand Feed Slot

Rear Card Hopper

DC Power Input

Network Connection

USB Connection



Top Cover Holding Latches

Print Head Cooling Fan

Print Head Assembly

Rear Card Hopper

LCD Display

Hand Feed Entry / Exit Slot

Front Card Stacker

Function Buttons

Dye Film Sensor Bracket (top)

Rio Pro component layout (viewed from front of Printer)

Card rotation Unit

Top Cover Interlock Sensor

Unused Dye-Film Spool Holder

Automatic Card Adjustment

Thermal Print Head

HoloKote/Flex Key Slot



Magnetic Encoder Roller

Dye-Film Sensor Bracket (Lower)

Flipper Unit Card Drive Roller

Cleaning Roller

Rear Idle Roller

Print Head Roller

Flipper Mechanism Rotation Motor

Flipper Mechanism Direction Motor Dye Film Drive Motor

Card Feed Motor Main Stpper Motor

Cam Motor

Rio Pro Motors (viewed from underside of Printer)

Rio Pro component layout (viewed from top of Printer)



SECTION 4 DYE FILM OPTIONS

MA300YMCKO Dye Film is the appropriate choice for colour printing with Rio Pro Printer. MA250YMCKOK Dye Film (for the double-sided models only), is more economic when printing in colour on the front side and black on the rear. 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

Included with each Dye-Film is a Cleaning Roller.

Full color Cards or monochrome

Cards Per ribbon

Ribbon Panel layout

Part Number

Full Colour

300 one side only or 150 both sides

YMCKO MA300YMCKO

Monochrome: Black Red Blue Green Gold Silver White Scratch


K

MA1000K n (n = colour)

Black & Overcoat


KO MA600KO

Colour front & Black back

250 front & back YMCKOK MA250YMCKOK

Colour front & colour back

150 Front & Back YMCKO MA300YMCKO

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



SECTION 4.1 LOADING THE DYE FILM.

Incorporated in colour (and black & clear) Dye Film is an electronic RFID protective Tag. When the Printer begins its initialisation process, the Printer reads the Tag and looks for the following info:

Ribbon Type

Remaining number of prints. If it fails to read any of the data from the RFID protective Tag, the Printer assumes it has single colour Film fitted.

Operate the top cover release catch and lift the cover.

Place the cassette into the 4 cradles (right side first) and press it into place. Ensure the gear (front right) engages with the 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 film RFID Tag as 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, stick 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.

Both the Rio Pro and Rio Pro Duo Printer offer 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 thin 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 (Pt. M9007-011) 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, failure to feed from the Card Hopper and 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 Smart Chip as image quality may be affected. Contactless (Proximity) Cards. Proximity Cards must be completely flat with no sign of the electronics or antenna being visible through the surface of the Card.



The Magicard Rio Pro Printer can be purchased in single or double-sided printing format. If you choose the Rio Pro single format model, you can purchase an upgrade from Magicard. This will change the Rio Pro to a Rio Pro Duo in the convenience of your Office allowing you to print double-sided Cards. No tools are required for this upgrade. Simply drop the Dye-Film upgrade into the machine.

1. Purchase the upgrade kit from Magicard Sales.

2. Fit the upgrade Film into the Printer.

3. Close the Lid and connect power to the machine.

4. Wait for the Printer to finish initialising (the Printer Display will change colour and show text). You are now ready to print. The upgrade is Printer specific, so once the Dye-Film upgrade has been fitted into a Rio Pro it will not work in another Printer. The Printer is now enabled for duplex printing with any type of Dye-Film, YMCK, YMCKK etc.

SECTION 5 SINGLE / DOUBLE-SIDED UPGRADE.



SECTION 6 PHILOSOPHY

SECTION 6.1 REPAIR AND MAINTENANCE The repair and maintenance philosophy for the Magicard Rio Pro 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: External Power Supply Unit The Main Control PCB The Print Engine Assembly The Thermal Print Head

Field Repair

Every precaution has been taken in the design of the Rio Pro 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 straightforward 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 lots of 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: +1 425 556 9708 Fax: +1 425 556 3962 E-Mail: [email protected]

http://www.magicard.com/

mailto:[email protected]



SECTION 6.2 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, but 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 its 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 rolls 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 or investigated 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 its 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 Firm are void. Neither Ultra Electronics Ltd. 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 the laws of England. 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 6.3 INTERNET SUPPORT To further enhance the support already available to Magicard Customers, the Magicard Web site contains useful information on both problem solving and operation of the Rio Pro Printer. The web site is available 24 hours per day at www.magicard.com

SECTION 6.4 RECOMMENDED TOOLS The following tools are recommended to support the Magicard Rio Pro in the field:

IBM PC or IBM Compatible Clone:

Pentium 600 MHz or faster (with USB support) 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 software (Win 2000 onwards). Rio Pro Windows Driver (preferably version 1.6.5.0 or later). Magicard Support Utility SIN1926 (loaded separately via the Driver CD). Graphics program such as Corel Draw, Photopaint or Paint Shop Pro. Microsoft Office. Badge Printing Application.

Engineers Tool Kit:

Anti-static wrist strap Pozi blade screwdriver, preferably 150mm long or greater. Torx Driver Size 10. Long nosed pliers. Multimeter or DVM.




Three Cleaning Cards and a cleaning roller are included with each new Rio Pro and Rio Pro Duo Printer. You can purchase additional Cleaning Kits, which include cleaning Cards, rollers and pens. Cleaning Kits Part Number 3633-0053 (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 cleaned 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 far 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 degrades when rollers are not clean as the Card does not move smoothly.

The Magicard Cleaning System

There are three main steps to your Printer‟s cleaning system - a Cleaning Card, a Cleaning Roller and a Cleaning Pen:

1. A Cleaning Card is used to remove dirt from the print path. This should be used after every 350 prints (every time you replace your ribbon). If you print only a few Cards a day, we recommend that you clean the Printer more often.

2. There is a disposable Cleaning Roller in the Printer, which should be replaced after every 1000 prints (approx. after using 3 rolls of ribbon). One cleaning roller is provided with a new roll of Dye Film

3. 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 instruction on page 23 for how to clean 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. Please note: the Cleaning Card is soaked in Alcohol. Do not open the packet containing the Cleaning Card until ready to use. 1. Select Menu option [1. Clean rollers], press [Ok] and follow the on-screen instructions:-

2. [Remove the Cards !] – lift out the (rear) feed Hopper and then press [Next].

And …… [Remove film] – open the lid and lift out the Dye-Film. Leave the Lid open and press [Next].

3. [Ready to clean ?] - Take a new Cleaning Card from its packaging and then press [Yes]. 4. [Insert Cleaning Card into slot] – when prompted, 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. [Clean again ?] – for maximum cleaning effect it is recommended that you turn the Cleaning Card over and select [yes], then repeat Step 4.



SECTION 7.4 REPLACING THE CLEANING ROLLER

Step 2 Fitting a new Cleaning Roller.

The Cleaning Roller is integral to the Media Preventer We recommend that this Cleaning Roller is replaced at least every 700 prints or sooner when a new Film is fitted. 1. Open the Printer lid and remove the used Dye-Film. Pull out the used cleaning spool. 2. Remove the central roller bar 3. Slide the central roller bar through the middle of the new cleaning roller. 4. Carefully remove the protective layer to reveal the sticky surface. 5. Place the new cleaning roller into the Printer. Please Note: If the steel shaft from the cleaning Roller becomes lost, a replacement can be obtained by ordering a Cleaning Roller Kit (Pt. 3633-0054) – See Section 7.2

3

1

2

4

5



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 ribbon.

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.

Please Note: The Print Head becomes hot during printing so the Cleaning Pen may need to be drawn along the face of the Print Head several times.



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

Ensure the Printer is powered off.

SECTION 8 MAGICARD RIO PRO DRIVER.

Rio Pro and Rio Pro Duo use the new “UltraDriver+”. This Driver is for use on the following Operating Systems only: Windows 2000 & Windows XP Windows 2003 Server. Windows Vista (32 and 64 bit). Windows 7 (32 and 64 bit).

SECTION 8.1 INSTALLATION INSTRUCTIONS FOR WINDOWS 2000/XP/2003 SERVER & VISTA 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 on “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 Windows 7

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 FOR WINDOWS 2000/XP/2003 SERVER & VISTA AND WINDOWS 7 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 RIO Pro” entry, and click on “Change/Remove”

Choose the “Magicard RIO Pro” you wish to remove (there may be more than one), and click “Next” Lastly - 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 Rio Pro 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 / WINDOWS 7.

.



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 DISPLAY

The front display panel has a text display and 4 push buttons. These buttons act as „soft‟ buttons – i.e. their function varies depending on the text displayed immediately above each button.

SECTION 9.1 MENU OPTIONS Press the “Menu” button…

The first menu option will be displayed. Press the “>” button (where indicated) to step through each option in the menu…

The following menu options will be displayed:

1 of 6 – Clean rollers

2 of 6 – Test card

3 of 6 – Info

4 of 6 – Hand feed

5 of 6 – Mag self test

6 of 6 – Reset printer Options 1-6 are explained on

Off Button Switches the Printer off. To switch the Printer ON again press any Button

Text Display

Menu select Buttons



SECTION 9.1.1 1. CLEAN ROLLERS IMPORTANT: To prevent the Cards slipping on the Rollers during Printing, we recommend that you clean the Printer using a Cleaning Card each time the Dye-Film roll is replaced.

SECTION 9.1.2 2. TEST CARD Follow the procedure below to clean the Card transport rollers in the Printer.

Having selected this option, you will be asked to confirm that you wish to print a Test Card. If you select “Yes” the Printer will feed a Card from the Hopper and print an internally generated Test image on it.



SECTION 9.1.3 3. INFO This option provides you with information about the Printer.

SECTION 9.1.4 4. HAND FEED Use this section to switch the Printer between “Automatic Card Feed” (Card feeder at the rear) or “Hand Feed” (front slot). OFF – This is the default setting. Cards will be fed automatically from the Card Hopper. ON – At the start of each print, the Printer will request you to feed a Card through the Card Feed slot in the front of the Printer. NOTE: Cards will NOT feed from the Card Hopper. Once the desired mode is selected press the “SAVE” Button.

Step into each option using the right-most

“arrow” button.

Use the arrow keys to toggle the mode between ON and

OFF

Λ V



SECTION 9.1.5 5. MAG SELF TEST Select “YES” on this option, if you wish to test the magnetic encoding option of the Printer. You will be asked to confirm that you wish to encode and print a Test Card. If you select the “YES” option (arrowed), the Printer will feed a Card from the Hopper, encode the magnetic stripe and print an internally generated test image on it. NOTE: If your Printer does NOT have a magnetic encoder fitted, it will be unable to perform this test and will instead display the message:- “Mag not fitted!”

SECTION 9.1.6 6. RESET PRINTER Selecting this option (“Yes”) will force the Printer to re-initialise (the same effect would be seen if the Printer‟s DC Power cable were removed and refitted).



The “Soak Test” mode moves every mechanical part of the machine, including the Print Head cooling Fan. A blank Card will be needed and inserted from the back. Remove the front and rear Card Hoppers.

SECTION 9.2 MAINTENANCE MODE The Maintenance Mode allows the User to check the functionality of the Printer. Each electronic Sensor can be checked individually. Image Start/End positions and the Dye-Film sensing system can be calibrated. It is accessed by opening the Lid and holding down the Menu Button for 3 seconds.

SECTION 9.2.1 SOAK TEST MODE

CAUTION Do not fit Dye-Film into the Printer during the “Soak Test” mode. The Dye-Film motor is advanced during the cycle. The Dye-Film drive Gear will be damaged when the Dye-Film has been fully used

and Dye-Film will be wasted.

Press and hold for three seconds



SECTION 9.2.2 SENSOR TEST MODE

C = Print head Up/Down T = Tacho Sensor (film movement) k = Dye Film Sensor L = Top Cover Sensor f = Front Card Sensor m = Middle Card Sensor r = Rear Card Sensor P = Left Hand Function Button p = Right Hand Function Button s = Chip Contact Position Up/Down

The Sensor Test mode is a useful diagnostic Tool when Sensors in the Printer may be suspect.

During the Cam Sensor test, the value above will toggle between

X and 0. The colour of the Printer‟s

Display will change to purple.

The values shown above are those measured by the Dye-Film

Sensor for each Film Panel. The colour of the Printer‟s

Display will change to purple.

Each of the above letters represents a Sensor or Button within the Printer.

The state of each Sensor or Button will toggle btween X and 0 according to the

current status of the Printer. The colour of the Printer‟s Display will

change to purple.



SECTION 9.2.3 PREVIOUS MENU Exit out of the Maintenance Menu



SECTION 10 PRINT HEAD REPLACEMENT

This section describes what action to take if you have to replace the Print Head in the Rio Pro/Rio Pro Duo 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 and permanently damages the printing surface.

contaminant

such as sand.

Print direction

The contaminant imbeds into the PVC surface and is dragged into the print

head.

Card

Dye-Film

Print Head



SECTION 10.2 PRINT HEAD ELECTRONIC FAILURE. If an internal electronic component has failed inside the Print Head, 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.

Start Switch the

Printer Off !

Remove Connector

Push backwards then tilt upward

1

2 Fit the new Print Head

1

2

Re-connect the new Print

Head

Press any Button to switch the

Printer On !

2



Print Head Density Programmer (PDP)

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 any other Print Heads and therefore should only be used for a specific Print Head Assembly.

1

Open the Printer Lid

Close the Printer Lid

Press any Button to switch the

Printer On !

Finished



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, 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 heater 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. The front of the Card is the edge that ejects out of the Printer first.

Print Head Angle too positive Rear end of the Card will show wrinkling or Dye Film overheating. The rear of the Card is the edge 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 its 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 analyzing Test Card). Open the top cover and locate the Print Head Assembly. Adjustment screw is located directly above the electrical connector in the centre 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 Rio Pro and Rio Pro Duo Printers have been designed with a modular construction to make servicing and repair of the Printer 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 front and rear Hoppers. Remove the Dye-Film. 2. Working below the Printer, gently move the two front plastic 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. Refitting is the reverse sequence. Locate the connector panel and 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 the front fascia away

from the main print assembly. (Take care to retain the white Button covers).

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. Refitting the new Sensor is the reverse procedure.

Removal & Refitting of the Lower Dye-Film Sensor

1. Gently pull upwards the plastic cross piece that encloses the lower Dye-Film Sensor in place, it is clipped into the plastic Side Plates.

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

PCB. 3. 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 11.3 REMOVING & REFITTING OF THE LOWER DYE FILM SENSOR.


Top Dye Film Sensor PCB



Removal & Refitting of Card Thickness Adjuster

1. Remove the cleaning roller and the rubber cleaning / feed roller below it. 2. Remove the return spring from the plastic locating pin from the back of the Printer. 3. The complete plastic Assembly will be loose, unclip from the plastic Side Plates and

withdraw from the Printer. Refitting is the reverse procedure. Locate the assembly into position and refit the return spring into position.

SECTION 11.4 REMOVAL AND REFITTING OF THE CARD THICKNESS ADJUSTER

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. Take care not to damage the small PCB connctors.

2. Unclip the four plastic catches and remove the

Controller PCB downwards. 3. On Rio Pro and Rio Pro Duo Printers with the Magnetic

Encoding and OmniKey options 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 fall away. Refitting is the reverse procedure ensuring the plastic molding is around the USB and power connector is included.

Spring fits between moulded plastic parts.




Removing & Refitting the LCD Display.

1. Disconnect the electrical connections to the printer‟s front LCD (Liquid Crystal Display). 2. LCD is held in position by the plastic catch (arrowed above, right) in the centre of its top edge. Gently push upwards and remove the

LCD from the main print engine.

Refitting is the reverse procedure.

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

SECTION 11.7 REMOVING & REFITTING THE LCD DISPLAY

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 11.16 to remove

Card Sensor locations in the Rio Pro (Printer viewed from underside)

Front

Mid Front Rear



Flipper Rotation System. 1. Flipper 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 inside of the bottom Pulley. It can then be removed from the top Pulley. Refitting is the reverse procedure.

3. Large Pulley can be removed by carefully removing the small silver Star Washer. Refitting is the reverse procedure.

4. Small Pulley can pulled from the Stepper motor shaft. Remove the spring washer by bending the release Tabs outwards. The spring washer cannot be re-used after this. Refitting is the reverse procedure but a new pulley is essential unless glued into position.

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.

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 (not shown here).

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

Ensure long groove on pulley aligns with plastic pin (arrowed)

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.



RFID PCB & Top Cover Sensor

1. Cam Position 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.

Flipper Drive System.

1. Drive Belt can be removed by sliding it off the inside of the bottom Pulley. It can then be removed from the top Pulley. Refitting is the reverse procedure.

2. Large pulley can be removed by first removing the small silver Star Washer. Refitting is the reverse procedure.

3. Small Pulley can removed from the Stepper motor shaft. Remove the spring washer by bending the release tabs outwards. The spring washer cannot be re-used after this. Refitting is the reverse procedure but a new pulley is essential unless glued into position.

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 is used.

3. Idle tension roller pressure can be released then the large drive Belt removed. Note how the belt is fitted and which Pulleys it fits around. 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.

Card Feed System.

1. Slide the drive Belt off the top Pulley the remove completely from the bottom Pulley. Refitting is the reverse procedure.

2. Top Pulley is removed by depressing the locking Tabs in the centre of the roller shaft. Slide the pulley outwards and remove. Refitting is the reverse procedure.

3. Bottom pulley can be removed by sliding it outwards off the DC motor. Refitting is the reverse procedure but it is essential a new Pulley is used unless it is glued into position.

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.



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 Flipper Motor.

1. Disconnect the motor connector. 2. The motor is held in place by two screws, remove these screws. 3. Remove the motor out through the bottom of the print engine. Refitting is the reverse procedure. Record where the Motor screws are fitted. Replace these screws in the same 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.

Card Feed Motor.

1. Disconnect the motor connections. 2. The motor is held in place by two screws,

remove these screws. 3. 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 Rotation Motor.

1. Disconnect the motor connector 2. The motor is held in place by two screws, remove these

screws. 3. Remove the motor out through the bottom of the print engine. Refitting is the reverse procedure.

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



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 (note it‟s route

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

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.



SECTION 11.12 REMOVAL OF THE ROTATION UNIT

SECTION 11.13 REMOVAL OF THE IDLE ROLLERS

Rotation Unit Removal 1. With the Pulleys removed as outlined in Sections 11.7 and 11.8. 2. Remove the white plastic Bushes (holding the Flipper Shaft) from each side . 3. Complete Rotation Unit can now be lifted out the front end of the Printer.

Refitting is the reverse procedure, drop the rotation unit into position ensuring the correct orientation and then fit the Bearing Plates.

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.



WARNING Personal injury could result if the appropriate safety measures are not followed.

SECTION 11.14 REMOVAL AND REFITTING OF THE LARGE BEARING PLATE

SECTION 11.15 REMOVAL AND REFITTING OF STEEL CIRCLIPS Steel Circlips are used throughout the Rio Pro (including the mounting of the Large Bearing Plate). When Removing and refitting these, always wear approved eye protection.

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.

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 Rio Pro and Rio Pro Duo user and Dealers when 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 lots of 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 Rio Pro 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.

Flipper Unit. 1. The Flipper Unit is rotated by the Flipper Stepper

Motor. 2. Flipper Unit Position Optical Sensor reads the

position 3. Flipper Unit should now be horizontal

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

optical Card Sensor. 2. Flipper is rotated so it is aligned with the Card feed

mechanism. 3. Trapped Card is ejected out the front of the Printer.

Printer Ready

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. LCD is on but information corrupted: 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 mechanism. Check Cam Opto Sensor is functioning (see section 9.2.2 Sensor Test). 2. Error on display RFID PCB Missing: 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 ribbon. If there is no movement then the Dye-Film may have run-out or Film take-up motor has a problem/disconnected.

Possible Errors. 1. Flipper Error 18:01: Check the flipper mechanism is not obstructed by a Card. Flipper mechanism is initialised using an optical Sensor on the left side of the Printer at the front. Check connections and functionality using the Sensor test (see section 9.2.2). Flipper mechanism Drive Belts can be checked.

Possible Errors. 2. Flipper Card Jam 04:07: The front Sensor is blocked or not working, check the Sensor functionality or wiring using the Sensor test (see section 9.2.2). 3. Flipper Card Jam 04:11: A trapped Card has not passed through the front Sensor, into the Flipper mechanism before ejecting out the front. Check the Flipper mechanism Card drive motor and Drive Belt. This can be found on the right hand side of the Printer at the front. 4. 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 (right hand side of Printer).




SECTION 12.2 HARDWARE PROBLEMS

Problem Probable Causes Possible Solutions Reference Section

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 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.

1. Section 4.2 2. Section 7 3. Section 16.8

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.

1. Section 6.1

Cards are jamming in the Flipper Unit.

1. Drive pulley or Belt has become

detached. 2. Sensor is not positioning the Rotation

Unit 3. Early Firmware version.

1. Ensure the Flipper Unit

components are fitted correctly. 2. Ensure the rotation position Sensor

is connected and functioning correctly.

3. Ensure the Printer has the latest Firmware installed.

1. Section 11.8 2. Section 9.2.2 &

11.8. 3. Section 18

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.

3. Check the correct Power Supply is used.

1. Section 11.8 2. Section 9.2.2

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.

3. Check the correct Power Supply is used.

4.

1. Section 11.8 2. Section 9.2.2



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. 1. Section 10

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.

1. Section 7 2. Section 11.9

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 Rio Pro Driver.

2. Image size must be 1016 pixels (85.6mm) x 642 pixels (54.5mm)

1. Section 4.2

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 Rio Pro 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.

1. Section 4.2

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 ribbon 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.

1. Section 4.2 & 7.4.

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.

1. Section 4.2 2. Section 8.4

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

1. Black Resin Power is set too low or too high.

1. Increase the Black Resin Power setting in the Driver.

1. Section 8.4

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.

1. Section 8.4

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.

1. Section 10.5

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.

1. Section 10.5



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.

1. Section 11.9 2. Section 16.10

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, e.g. Flipper driver/rotation motor. Swap if necessary for testing.

3. Call Magicard Technical Support.

1. Section 11.9 2. Section 11.9 3. Section 6.1

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.

1. Section 4.2 2. Section 16.2 3. Section 16.2

Page 1 is printed on one Card and page 2 is printed on a second Card when both pages should appear on the same Card automatically.

1. Single-sided Printer being used. 2. Incorrect Driver settings.

1. Ensure Rio Pro Duo has been

purchased or Printer has been upgraded to the Duo model.

2. Ensure the Duplex mode has been enabled in the Printer Driver.


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.

1. Section 4.2 2. Section 7. 3. Section 1 4. Section 8.4



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 Rio Pro. Perhaps it should be 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”.



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


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 Rio Pro nothing happens, Printer is not seen.

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.



2. Try connecting to another spare USB Port.

3. Try a known working USB cable. 4. Contact Magicard Technical

Support for another 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.



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 not switched on.

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

2. See number 1. 3. Switch on Verification in the Printer

Driver.

1. Section 7 2. Section 7 3. Section 8.4

Cards are not encoded.

1. Blank Cards have been placed in the

Hopper the wrong way round and magnetic verification is switched off.

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 to understand.

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 switched on 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.

1. User Manual 2. Section 7 3. Section 8.4 4. Section 6.1

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.




SECTION 13 ERROR CODE LIST

Error Number Displayed Error Error Code Description of Problem

01 Lid Open. Please close to continue 01:00

Error is shown if the lid is opened while trying to feed a Card from the Hopper. It will not be shown if the Printer is in Soak Test mode (in which case the lid is ignored, and this error cannot occur).

01:01 Error is shown if it detects that there is a pending print job and the Lid is opened during the download.

01:02 Error is shown if the Lid is opened while printing a colour panel, either yellow, magenta or cyan.

01:03 Error is shown if the Lid is opened while printing the resin black panel, or if the Lid is opened while printing with continuous single colour resin Film.

01:04 Error is shown if the Lid is opened while printing the clear Overcoat panel.

01:05

01:06

Error is shown if the Lid is opened while advancing the ribbon on to the start of the next coloured panel. This may be either during printing or initialisation.

01:07

Error is shown if the Lid is opened while aligning the start of a coloured Dye panel with the edge of the Print Head prior to printing.

01:08

Error is shown if the Lid is opened when the print job is being validated against the parameters in the Printer Driver. This can also happen if a print job is sent to the Printer while the Lid is open.

01:09

Error is shown if the Lid is opened while trying to take up the loose Dye-Film. Note that this function is carried out after resetting the Print Head position on initialisation or re-initialisation.

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 _nished successfully.


02 Out of Cards. Please refill the Hopper and

press retry. 02:00

Error is shown if the rear Card Sensor has not been blocked by a Card passing through it. It will try to feed a Card three times from the Hopper.



SECTION 13 ERROR CODE LIST CONT.


03 Hand Feed error please select retry to try

again. 03:00

Error is shown if the front Card Snsor has not been blocked by a Card after trying to hand-feed a Card for 10 seconds.


04 Flipper Card Jam. Pease clear Printer

mechanism 04:00

Error is shown if the front Card Sensor becomes blocked when trying to hand – feed a Card, but does not unblock within 5 seconds. Card is trapped in between the Flipper and front Card Sensor.

04:01

Error can be shown while trying to retrieve a Card out of the Smart encoding module. If the front Card Sensor remains unblocked for more than 5 seconds it will be displayed. This is reserved for further use.

04:02

Error can be shown while trying to retrieve a Card out of the Smart encoding module. If the front Card Sensor remains blocked for more than 5 seconds it will be displayed. This is reserved for future use.

04:03

Error can be shown while moving a Card from the Flipper mechanism into the print engine module. If the front Sensor remains unblocked for more than 3 seconds it assumes a Card is trapped in the Flipper mechanism.

04:04

Error can occur while moving a Card from the print engine module to the Flipper mechanism. If the front Sensor remains blocked for more than 5 seconds it assumes a Card is trapped in the Flipper mechanism. The Flipper will try to intialise but the Flipper Sensor will not change as a Card is trapped.

04:05

Error can occur while moving a Card towards the back of the Printer to the standby position. Standby position is a Card in the middle Card Sensor. If the front Sensor has remained unblocked for 2 seconds the error will occur. This sequence is performed during the magnetic verification cycle while the Card is moving forwards.

04:06

Error can occur while trying to move a Card towards the back of the Printer to the standby position. Standby position is a Card in the middle Card Sensor. If the middle Sensor has remained unblocked for 2 seconds the error will occur. This sequence is performed after the magnetic verification cycle while the Card is moving forwards.

04:07

Error can be shown if the front Sensor is blocked when trying to initialise the Flipper. If it fails to unblock by rewinding the main Stepper motor) and block the mid Sensor within 4 seconds the error will be shown.





04 Flipper Card Jam. Please clear Printer

mechanism 04:08

Error is shown while trying to return the Card to the print engine after rotating the Flipper unit. If the front Sensor is not obscured within 5 seconds the error is seen.

04:09

Error is shown while trying to return the Card to the print engine after rotating the Flipper unit. If the front Card sensor fails to clear within 5 seconds then the error is seen. Note that the front Card Sensor has already been obscured by the Card at this stage.

04:10

Error is shown while trying to feed a Card into the Flipper mechanism for rotation. If the front Card Sensor is not unblocked within 5 seconds the error is seen. By this point the Card has already moved forwards to block the front Card Sensor.

04:11

Error is shown while trying to eject the Card out of the Printer. If the front Sensor remains blocked for more than 3 seconds the error is seen. At this stage the Card has already moved towards the Flipper mechanism and has blocked the front Sensor.

04:12

This error is raised if the Flip Sensor is always blocked after smart encoding. The printer is attempting to rotate

the card to the horizontal position.


05 Encoder Jam. Please clear Printer mechanism 05:00

Error is shown 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 the error is displayed. Reserved for future use.

05:01

Error is shown 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 the error is displayed. Reserved for future use.





06 Card Jam. Please clear Printer mechanism 06:00

06:01

06:02

Error is shown while trying to feed a Card into the Flipper mechanism for rotation. If the front Card Sensor is not unblocked within 5 seconds the error is seen. By this point the Card has already moved forwards to block the front Card Sensor.

06:03

06:04

06:05

Error can be shown while trying to feed a Card from the Hopper and the middle Card Sensor remains unblocked for more than 6 seconds. Note that by this point in the cycle the rear Sensor has already been obscured by a Card.

06:06

Error is shown while attempting to return the Card to the standby position (over the middle Card Sensor) from in the rear Card Sensor. It occurs if the rear Sensor is not unblocked within 3 seconds.

06:07

This error can occur while trying to hand-feed a Card to the standby position (over the middle Card Sensor). If we fail to see the mid Sensor block within 5 seconds the error will be seen. Note, by this point a Card has already been seen in the front Sensor (block and then unblock).

06:08

Error can be seen while trying to move a Card from the Smart encoding position to the standby position (over the middle Sensor). Normally occurs if the middle Sensor is not blocked within 5 seconds. At this point the Card has already successfully moved out of the encoder and Flipper. At this point in the cycle the Card has been seen by the front Sensor (suggesting that the Card is between the front and middle Sensors).

06:09

Error is shown while trying to move the Card from over the front Sensor to the standby position (over the middle Sensor) if the front Sensor does not unblock within 3 seconds.






Error can be shown while trying to move the Card from within the front Sensor to the standby position (over the middle Sensor). If the middle Sensor is not blocked within 3 seconds by a Card the error will be displayed. Note that by this point the front Sensor has become unblocked by a Card.

06:11

Error is shown while trying to move the Card from the Flipper to the standby position (over the middle Card Sensor). If the middle Sensor is not blocked within 3 seconds the error will be displayed. Note by this point a Card has passed through the front (suggesting that the Card is between the front and mid Sensors).

06:12

Error is shown while trying to move the Card from the main print area into the rotation mechanism. If the front Card Sensor is not obscured within 5 seconds the error is displayed.

06:13

Error is shown while trying to move the Card into the magnetic encoding standby position (this is where the rear edge of the Card just blocks the rear Card Sensor). If the rear Sensor is not obscured within 4 seconds the error is displayed.

06:14

Error can be shown during the magnetic encoding cycle. If a Card fails to unblock the rear Card Sensor within 4 seconds the error is displayed. At this point the Card is already in the magnetic encoding standby position and has begun to move the Card forwards towards the magnetic encoding Head.

06:15

Error is shown while moving the Card forward towards the front Sensor during the soak test routine. If the front Card Sensor is not blocked within 6 seconds the error will be displayed.

06:16

Error is shown while moving the Card backward towards the rear Sensor during the soak test routine. If the rear Card Sensor is not blocked within 6 seconds the error will be displayed.

06:17 Error is shown while moving the Card towards the Flipper ready for rotation. If the front Card Sensor does not block within 5 seconds the error is displayed.

06:18

Error is shown while trying to position the Card so that its rear edge just covers the rear Card Sensor (ready for printing). If the rear Sensor does not block within 3 seconds the error is displayed.

06:19

Error is shown while trying to position the Card so that its rear edge just covers the rear Card Sensor (ready for printing). If the rear Sensor is not unblocked within 3 seconds the error will be displayed. At this point the rear Sensor has already been blocked by the Card moving backwards and the Printer is moving the Card forward again until the rear Sensor unblocks.






Error is shown while feeding a Card from the Hopper into the standby position (covering the middle Card Sensor). If the front Sensor fails to block within 6 seconds the error is displayed. By this point the Card has been successfully taken from the rear Card Hopper and the Rio Pro is trying to move it to the front Card Sensor, before returning it to the standby position.


07 No Film detected. Please load a new roll of

Film to continue. 07:00

Error is displayed while initialising the Dye Film. If the Rio Pro cannot validate the electronic RFID Tag on the Dye Film the error is displayed. Note that this RFID validation process is not performed when no Tag is present the printer assumes that a roll without a Tag is monochrome (single colour ribbon). This error is only displayed when the Tag is detected but invalid.


08 Out of Dye Film. Please load a new roll of

Film to continue. 08:00

Error is shown while trying to advance the Film to the start of the next panel. If no Tacho Sensor pulses or Dye Sensor transitions are seen for at least 5 seconds the error is displayed.

08:01

Error is shown while trying to advance the Dye Film by a certain fixed offset (for example, to line up the start of the panel with the printing position). If no Tacho Sensor pulses or Dye Sensor transitions are seen for at least 5 seconds the error will be displayed.

08:02

08:03

Error can be shown while running a Tacho Sensor test (via the “TAC” quick command). If no Tacho Sensor pulses are seen for at least 4 seconds an error will be displayed.

08:04

Error can be seen while printing a colour panel. If no Tacho Sensor pulses or Dye Sensor transitions are seen for at least 150 printed lines (this equates to roughly 150ms) an error will be displayed.

08:05

Error can be seen during printing of the black panel. If no Tacho Sensor pulses or Dye Sensor transitions are seen for at least 150 printed lines (this equates to roughly 75ms) an error will be displayed.




08:06

Error can be seen during printing of the Overcoat panel. If no Tacho Sensor pulses or Dye Sensor transitions are seen for at least 150 printed lines (this equates to roughly 150 ms) an error will be displayed.

08:07 Error can be shown during Dye-Film initialization. If the print counter on the Dye-Film RFID Tag has reached its limit the error will be displayed.

08:08

Error can be shown while carrying out the validation checks that are done prior to printing a Card. If the print counter on the Dye-Film RFID Tag has reached its limit the error will be displayed. Note the printer has already determined that the fitted Film is capable of being used for the downloaded print job (for example, it has the required colour format). Also note that this error can never occur during magnetic encoding only jobs.

08:09

Error is shown while trying to advance the Dye Film to the start of the next panel. If Tacho pulse are seen, but no Dye Film sensor transitions occur for at least 5 seconds the error will be displayed.

08:10

Error is shown while trying to advance the Dye Film to the start of the next colour panel. If Dye Film Sensor transitions are seen, but no Tacho pulses occur for at least 5 seconds the error will be displayed.

08:11

Error can be shown while trying to advance the Film to the start of the next colour panel. If Tacho and Dye Film sensor transitions are seen, but the Dye Film Sensor change does not stabilize within 5 seconds the error is displayed. This could be due to counterfeit ribbon, or an uncalibrated Dye Film Sensor (in which case the Dye Film Sensor should be calibrated using the Printer menu).


09 Unsupported Film, please load different Film to

continue. 09:00

Error can be shown while initialising the Dye Film. If the fitted Dye Film has an unsupported configuration of colour panels an error will be shown. A list of supported Dye Films are: Colour, Resin and Overcoat for full-colour prints MA300YMCKO Continuous single-colour Resin or scratch Film MA1000K Resin and Overcoat for monochrome prints, for example MA600KO Colour, Resin and Overcoat for colour/monochrome duplex printing MA250YMCKOK. Note, this error means that the Dye-Film's RFID Tag was successfully validated. The most likely scenario for this error is the introduction of a new Film type which is unknown to older Printer Firmware versions.





10 Wrong Film type. Please load different Film to

continue or press cancel to clear print job. 10:00

Error is shown while advancing the Dye-Film to a specific position within a certain colour 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, a colour panel was requested when black only Film was loaded the error will be displayed. This error should never arise in practice, as print jobs are rejected if they are not compatible with the loaded Film.

10:01

Error can be shown while determining the print cycle sequence for the current print job using a colour type Film. In other words, Film having a YMCKO configuration, if the image cannot be printed using the loaded Film this particular error will be displayed. It may not arise in practice unless short panel colour Film is supported in the future, and the user attempts to print an image which contains too many lines of data in a particular colour.

10:02

Error can be shown while determining the print cycle sequence for the current print job using single colour type Film. In other words, continuous resin only type Film, if the image cannot be printed using the loaded Film this particular error will be displayed. This particular error may arise if the user manages to send a print job file requiring either colour or Overcoat to a machine which has single colour only Film fitted.

10:03

Error can be shown while determining the print cycle sequence for the current print job using black and Overcoat type Film. In other words, Film with a KO configuration, if the image cannot be printed using the loaded Dye Film this error will be displayed. This particular error may arise if the user somehow manages to send a print job file requiring colour to a machine which has MA600KO Dye Film fitted.

10:04

Error can be shown while determining the print cycle sequence for the current print job using colour film with the extra black resin panel type film. In other words, film with a YMCKOK configuration. If the image cannot be printed using the loaded Dye Film, this error will be shown. This particular error may not arise in practice unless short-panel colour Dye Film is supported in the future, and the user attempts to print an image which contains too many lines of data in a particular colour.

10:05

Error is shown while validating the downloaded print job against the capabilities of the Dye-Film. If colour data is sent while monochrome fFlm (K or KO) is fitted an error will be displayed. The Printer Driver should normally prevent this from happening, but it is possible to by pass the Driver by sending PRN‟s directly to the Printer.

10:06





11 Can‟t find panel. Please check Dye Film and Printer mechanism, or press cancel to clear

print job. 11:00

Error is shown while trying to align the Dye-Film to a chosen offset within a chosen panel (for example, prior to printing) if the Printer can not find the requested panel within 8 panels of its starting point. This error often indicates that either the Dye-Film LED is poorly positioned, or that the Dye-Film LED needs to be calibrated using the FCL command. This error is similar to 11:01, but the surrounding context is slightly different. 11:00 can occur whenever the Dye 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 Film panel misalignment by skipping an entire panel set.

11:01

Error is shown while trying to align the Dye-Film to a chosen offset within a specific 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 Film LED is poorly positioned, or that the Dye-Film LED needs 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 Film panel misalignment by skipping an entire panel set.


12 RFID PCB missing. Reconnect PCB to

continue. 12:00

Error is shown during Printer initialization. If the RFID PCB cannot be detected the error is displayed.


13 Print Head Error, switch Printer off and

reconnect Print Head. 13:00

Error is shown while checking the print head temperature in standby. If the measured temperature is out of range an error is displayed. This indicates that either the print Head is not connected, or that the thermistor on the Print Head is not functioning correctly.


14 Overheat error, switch Printer off and allow

Print Head to cool. 14:00

Error is shown while waiting for the Print Head temperature to fall before printing a Card. If the measured temperature is out of range the error is displayed.





15 Image too dark. Please cancel print job and

reduce Driver Print Head power settings to try again.

15:00

Error can be shown 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 Print Head temperature is very low, causing the Print Head strobe widths to be come too long.


16 Can‟t Lift Head, check Printer Mechanism 16:00

Error is shown while resetting the Cam to the “Head Up" position. If the Printer does not see the Cam Sensor become obscured within 5 seconds the error is displayed.

16:01

Error is shown 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 the error is displayed. By this point the Cam Sensor is already unblocked.

16:02

Error is shown while trying to lift the Print Head. If the Cam Sensor does not block within 5 seconds an error is displayed. Note, this function is only used by the HEAD quick command and the Cleaning Routine.

16:03

Error is shown while trying to lift the Head at the end of printing a panel. If the Cam Sensor does not clear within 5 seconds the error is shown. By this point the Sensor has already been blocked.

16:04

Error is shown while trying to move the Cam in the “Head-Up" position. If the Cam Sensor does not block within 5 seconds the error is seen. This function only happens during Printer Boot-up and print job cancellation.

16:05

Error is shown 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 the error is seen. Note that the Sensor has already been blocked by this point. This function only happens during Printer Boot-up and print job cancellation.

16:06

Error is shown 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 the error is shown. Note that by this point the Sensor has already made a dark-to-light transition. This function only happens during Printer Boot-up and print job cancellation.

16:07 Error is shown while lifting the Print Head and the Cam Sensor does not block within 5 seconds.





16 Can‟t Lift Head, check Printer Mechanism 16:08

Error is shown while trying to lift the Print Head. If the Cam Sensor does not block within 5 seconds the error is displayed. By this point the Head has been lifted and the Cam Sensor has just unblocked. The Printer is pulsing the Cam Motor backwards to prevent overrun.


17 Can‟t Drop Head, check Printer Mechanism 17:00

Error is raised while trying to lower the Print Head. If the Cam Sensor does not unblock within 5 seconds the error is displayed. This function is called by the HEAD quick command, the Cleaning routine and the Soak test routine.

17:01

Error is shown while lowering the Print Head and analyzing the image data. If the Cam Sensor does not unblock within 3 seconds this error is displayed. Note 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.


18 Flipper Error, cannot initialise the Flipper.

Please clear Printer mechanism 18:00

Error is shown while trying to initialise the Flipper mechanism. If the Flipper Position Sensor is not blocked within 4 seconds the error is displayed. By this point the Printer has already cleared any Card jam away from the Flipper mechanism, if the front Sensor was found to be blocked.

18:01

Error is shown while trying to initialise the Flip mechanism. If the Flipper Position Sensor is not unblocked within 4 seconds the error will be displayed. By this point the Printer has already cleared any Cards away from the Flipper mechanism if the Front Sensor was found to be blocked. Also the Flipper Position Sensor has been cleared (In other words, the Sensor is in the slot).


19 Mag Verify Fail. Press Retry or Cancel to

continue. 19:00

Error is shown after carrying out the Magnetic Verification cycle. If the data read back from the Card on the final attempt does not match the data that was sent in the print job the error is displayed. This error cannot occur if either “Perform Verification” is switched off in the Printer Settings or another error (e.g. Lid Open or Card Jam) occurs during encoding/verification cycle.





19 Mag Verify Fail. Press Retry or Cancel to

continue. 19:01

Error is shown while processing a “Magnetic Self Verify” command from the Support Utility (e.g. a pre-encoded Card is read back by the Printer and the results displayed in the Support Utilty). If the data read back from the Card cannot be determined the error is displayed (e.g. could be in a Non-ISO format).


20 Mode Unsupported. Cannot print requested image with this printer model. Please cancel

print job and adjust Driver settings to try again. 20:00

Error can be shown 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 the error is displayed. Note that this type of Printer does not yet exist and this feature is reserved for future development.

20:01

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 the error is displayed. Note that this type of Printer does not yet exist and this feature is reserved for future development.


21 CLEAN REQUIRED. Please clean the Rollers

to avoid deterioration 21:00

Error can be shown if the cleaning prompt is enabled. This prompt is displayed when the number of Cards printed since the last clean exceeds the user configurable threshold (by default 700). Note that this check is only performed at Printer boot-up.


22 Test Results 22:00

Error is shown after executing a Sensor Test, initiated using an SNS command. If the Printer found that the Cam Sensor never changed then the error is displayed.

22:01 Error is shown after completing a Sensor Test, initiated using an SNS command. If the Cam Sensor changed but the Flip Sensor failed to unblock the error is displayed.

22:02

Error is shown after completing a Sensor test, initiated using an SNS command. If the Cam Sensor changed but the Flip Sensor never changed the error is displayed.

22:03 Error is raised after completing a Sensor Test, initiated using an SNS command. If the Cam and Flip Sensors both change the error is displayed.



22:04

Error is shown after completing a Sensor Test, initiated using a SNS command. If the Flip Sensor result is ”Invalid" the error is displayed.





23 Wrong PSU. Please switch the Printer off and

check the Power Supply. 23:00

Error can be shown after intialising the Cam at switch on. If the time taken to rotate the Cam mechanism by half a turn was longer than 2.5 seconds the error is displayed. This is designed to indicate a low level output from the external PSU (PSU looks very similar to other IT equipment).


24 General Error. Please contact Magicard

Technical Support quoting code. 24:00

Error is shown while processing a downloadable Firmware Binary File. If the file length is greater than 1170432 bytes (1143kB) the error is displayed.

24:01

Error is shown while attempting to write a downloaded Firmware Binary File into Flash memory. If the format ID string in the downloaded file is not the correct one for the Rio Pro (e.g. Rio/Tango 2E) the error is displayed.

24:02

24:03 Error is shown after printing a Card. If it fails to increment the printed Card count in the RFID Tag this error will be displayed.

24:04

Error is shown while trying to feed a Card from the Hopper to the printing area. If the Printer sees the middle Card Sensor block before the rear Card Sensor does the error is displayed. This could possibly indicate that the rear Sensor has dropped out of position, but could also mean that the middle Card Sensor is faulty.

24:05

Error is shown while trying to feed a Card from the Hopper to the printing area. If the Printer sees the front Card Sensor block before the rear and middle Card Sensors the error is displayed. This could possibly indicate that both the rear and middle Card Sensors have dropped out of position, but could also mean that the front Card Sensor is faulty.

24:06

Error is shown while trying to feed a Card from the Hopper to the print engine if the Printer sees the front Card Sensor block before the middle Card Sensor the error is displayed. This could possibly indicate that the middle Card Sensor has dropped out of position, or that the front Card Sensor is faulty.

24:07

Error is shown while trying to hand feed a Card into the printing area. If the Printer sees the middle Card Sensor block before the front Card Sensor the error is displayed. This could possibly indicate that the front Card Sensor has dropped out of position, or that the middle Card Sensor is faulty.



SECTION 13 ERROR CODE LIST CONT


24 General Error. Please contact Magicard Technical Support quoting Error code.

24:08

Error is shown while trying to hand feed a Card into the printing area. If the Printer sees the rear Card Sensor block before the front and middle Card Sensors the error is displayed. This could possibly indicate that both the front and middle Card Sensors have dropped out of position, or that the rear Sensor is faulty.

24:09

Error is shown while trying to hand feed a Card into the printing area. If the Printer sees the middle Card Sensor block before the front one clears the error is displayed. This could possibly indicate that the front or middle Card Sensor is faulty.

24:10

Error is shown while trying to hand feed a Card into the printing area. If the Printer sees the rear Card Sensor block before the front or middle Card Sensor the error is displayed. This could possibly indicate that the front Card Sensor has failed, that the middle Card Sensor has dropped out of position or that the rear Sensor is faulty.

24:11

Error is shown while trying to hand feed a Card into the printing area. If the Printer sees the rear Card Sensor block before the middle Card Sensor the error is displayed. This could possibly indicate that the middle Card Sensor has dropped out of position, or that the rear Card Sensor is faulty.

24:12

Error is shown while attempting to write a downloaded Firmware file into Flash memory. If the encrypted checksum of the file is invalid the error is displayed. This would mean that the Firmware file has been either corrupted during transmission, or modified by a third party.

24:13

Error is shown while attempting to move the Card into the standby position. If the Firmware data relating to the current position of the Card is invalid the error is displayed. This should never happen.

24:18

24:19

24:20





26

27

28

29

30

31

32

33

34

35



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 14 MAGICARD PRINTER 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 short cut 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 14.1 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 Rio Pro 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 Rio Pro will print at a calibrated density the adjustment is calibrated at time of manufacture. Once this calibration is carried out the Rio Pro 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 Head 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, firmware can be downloaded from

www.magicard.com

Printer configuration settings, see below.




SECTION 14.2 “DEALER” SERVICE MODE As mentioned in Section 14.1, the configuration settings can only be adjusted in “Dealer Service Mode”. The mode is switched on by sending a command to the Printer: DEALERSERVICEON The parameters can be adjusted (within defined limits) using the configuration settings in the „Printer Identity‟ Tab of the Magicard Support Utility. To activate “Dealer” Mode, enter DEALERSERVICEON as a quick command from the „Statistics/Commands‟ Tab. The LCD backlight will change to yellow in response.

To deactivate “Dealer” mode, enter DEALERSERVICEOFF as a quick command (or re-boot the Printer). The LCD backlight will change back to it‟s normal colour.

Description of “Dealer” Mode features:

After boot-up, the Printer is not in “Dealer” Mode and the image parameters cannot be modified.

After entering “Dealer” Mode, the LCD backlight becomes yellow. The image parameters may be modified within the permitted limits (shown in the table below).

If the entered values are outside of the permitted limits, they will be reduced to the upper or lower limit, as appropriate.

After leaving “Dealer” Mode, the LCD backlight returns to it‟s normal colour. The image parameters retain their dealer-modified values and cannot be further modified.

After rebooting the Printer, the image parameters retain their Dealer-modified values.

If the Printer is placed into “Dealer” Mode and then re-booted, it will not boot up in “Dealer” Mode.

If the Printer receives a „Reset‟ command (from the „Reset‟ button on the „Printer Identity‟ tab), it will reload the original factory settings.

Parameter Maximum deviation from factory setting

Print Head density calibration ±500

Image start position ±192 (equivalent to ±1.04 mm)

Image end position ±24 (equivalent to ±2.08 mm)

Print Head position ±12 (equivalent to ±1.04 mm)



SECTION 14.3 STATISTIC AND COMMANDS

This tab contains three separate areas: Statistics Shows information on Printer usage. Quick Commands Enables the user to send special commands to the Printer (usually used for fault diagnosis).

See table below. Print *.PRN file Enables the user to send previously saved print data to the Printer.

Quick Command Function

CAM Function called upon receiving a CAM command. The function will cause the Printer to Reset the Print Head Cam Mechanism Position.

CHP

Function called upon receiving a CHP command. The function takes a single parameter (either UP or DOWN). If the parameter is DOWN, a Card is fed into the Smart Encoding Unit. If the parameter is UP, the Card is moved to the standby position (over the Middle Sensor).

CLN Function is called upon receiving a CLN command. The function will cause the Printer to execute its Cleaning Cycle.

DYE Function is called upon receiving a DYE command. The function re-initialises the Dye-Film.

EJT Function is called upon receiving an EJT command. The function causes the Printer to eject a Card if there is one in the Print Engine.

ENC Function is called upon receiving an ENC command. The function initiates the Magnetic Encoding Test Cycle.

FEED

Function is called upon receiving a FEED command. This function feeds a Card into the Standby Position (over the Middle Sensor). It takes a Single Numeric Parameter: if this is Zero or One, the Card is left in the Standby Position, but if it is greater than one it will eject the Card and feed another in, repeating however many times the parameter specifies.




FLIP

Function is called upon receiving a FLIP command. If Duplex Printing is Enabled, and there is a Card in the Print Engine, this function will Feed the Card into the Flipper Mechanism, rotate it, and return it to the Printer.

FRN

Function is called upon receiving a FRN command. The function enables/disables the Film Saving Feature (required for printing with Short Colour Panels). It takes a single parameter of either ON or OFF.

HEAD

Function is called upon receiving a HEAD command. This function takes a Single Parameter, either UP or DOWN, and raises or lowers the Print Head accordingly.

RAMP Function is called upon receiving a RAMP command. The function sets the Density Ramp adjustment according to the given numeric parameter (between 0 and 100 where 50 is the Default Setting).

SET Function is called upon receiving a SET command. This function saves the current printer settings into the Protected Memory Area.

TST Function is called upon receiving a TST command. This function initiates an Internal Test Print.

STN Function is called upon receiving a STN command. This function causes the printer to re-initialise the Internal Holokote Images.

SNS Function is called upon receiving a SNS command. Operates a single “Soak Cycle” and checks all Sensors.

SHW

Function is called upon receiving a SHW command. This function enables the Sensor Status to be reflected at the front panel LEDs. It takes a single parameter, which specifies the sensor to be tested. The possible values for the parameter are:

CAM - to test the cam sensor TACHO - to test the tacho sensor FLIP - to test the flip sensor DYE - to test the dye film sensor LID - to test the lid sensor FRONT - to test the front Card sensor MID - to test the mid Card sensor REAR - to test the rear Card sensor BUTTON1 - to test button 1 on the front panel BUTTON2 - to test button 2 on the front panel SMART - to test the encoder Card sensor TEMP - to test the printhead temperature sensor ON - to test all the optosensors at once OFF - to terminate sensor test mode

Sending an invalid parameter is equivalent to SHWOFF.




LNG

Function is called upon receiving a LNG command. The function takes a single numeric parameter, which is used to set the Boot Up Language for Status and Error Messages. The possible parameter values are as follows:

0 - ENGLISH 1 - PORTUGUESE 2 - FRENCH 3 - GERMAN 4 - SPANISH 5 – ITALIAN

RUN

Function is called upon receiving a RUN command. The function takes a single parameter, and enables various tests to be performed The possible parameter values are as follows: CAM - Runs the Cam Motor while displaying the Cam Sensor State FEED - Runs the Feed Motor Backwards DYE - Runs the Dye Motor while displaying the Tacho Sensor State MAIN - Runs the Main Stepper Motor FLIPPER - Runs the Flipper Rotation Motor while displaying the Flipper Position Sensor State FLIPROLL - Runs the Flipper Card Drive Motor FAN - Runs the Print Head Cooling Fan PANEL - Displays the current state of the Dye Film Sensor POUT - Raises the P-OUT line for 5 seconds CAL - Sets the LEDs in the Middle and Rear Card Sensors to Bright Mode for 5 seconds LCD - Cycles the LCD backlight through its entire range of Colours OFF - Turns Off all Motors

FLM

Function is called upon receiving a FLM command. The function takes a Single Parameter, which may be either Y,M,C,K or O, and Aligns the Ribbon at the Corresponding Panel.

FCL

Function is called upon receiving a FCL command. The function, with no parameter, initiates the Dye LED Calibration Routine. If a parameter is supplied, it must be in the form of a # sign followed by a Six Digit Hexadecimal Number, which is then used to set the dye LED Colour directly.



SECTION 14.4 UPGRADE FIRMWARE

SECTION 14.5 QUERY PRINTER

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.

Use this Tab to upgrade the Printer‟s Firmware.

The latest Firmware can be downloaded from www.Magicard.com as an “executable” file.




SECTION 14.6 ETHERNET

Ethernet connection is available with Rio Pro and Rio Pro Duo Printers. The settings are visible because this Support Utility is also used for Magicard Rio 2e, Tango 2e and Tango +L Printers which do have this capability.

SECTION 14.7 MAG ENCODE

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 correctly 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.

NOTE For use with Magnetic Encoding Models only.



SECTION 14.8 MAG READ

“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, your data will be displayed together with an accompanying „green‟ indicator. If it fails, no data will be displayed together with an accompanying „red‟ indicator.

Choose „Eject‟ to feed the Card out the front of Printer. PLEASE NOTE:- The Magnetic Reader function is NOT a reliable indicator of magnetic Encoding quality. It contains no error correction functions and so is not a substitute for a Magnetic Swipe Reader.

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 maximum

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 15 MAGNETIC ENCODING

SECTION 15.1 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 (ANSI) 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

EMBOSSED INFORMATION

MAGNETIC STRIPE

3.375" 0.030" Thick

2.125"

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 USA TEL: 001 (310) 631-8602 FAX: 001(310) 631-3956

SS PAN FS ADDITIONAL DATA ES LRC

37 Numeric Data Characters

Primary Account No.

19 digits maximum 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

Primary Account No.

19 digits maximum 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 15.2 BASIC MAGNETIC ENCODING. The Magicard Rio Pro and Rio Pro Duo 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. To change between the two, there is a setting in the Printer menu. The Printer display will tell you whether it has a magnetic encoder fitted by showing an “M”. 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 screen.

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

Type in your magnetic code anywhere on the face of the Card 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. Example: ~1

Type in your code.

Track 1 may be a combination of numbers and uppercase letters, Tracks 2 and 3 numbers only.

Example: To encode the data “12345XYZ” on track 1 of a magnetic strip Card: ~1%12345XYZ?

Print the Card.



SECTION 15.3 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 etc. 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 / XP / VISTA / Windows 7 / 2003 SERVER.

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

Sample Encoding Data.

~1%MAGICARD MAGTEST^24-07-2013? ~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 15.4 ASCII CHARACTER SET SUPPORTED BY THE RIO PRO

SECTION 15.5 ISO STANDARDS

Track 1.

Recorded information can be of the 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 of numeric type. (ASCII Char 48-63)



The total number of data characters, control characters and Longitudinal Redundancy Check characters together must not exceed 40, including Start and End sentinels.

Track 3.

Recorded information can only be of numeric type. (ASCII Char 48-63)



The total number of data characters, control characters and Longitudinal Redundancy Check 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 15.6 ERROR CHECKING. The data has two checking systems to ensure accuracy. The Longitudinal Redundancy Check (LRC) and the Parity check. They can be set to odd or even. Even Parity makes the number of 1‟s in the data being checked total an even number (2,4,6…) Odd Parity makes the number of 1‟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 5

th bit of each group (except the LRC) is the parity bit for it‟s 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 15.7 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 specialist equipment and a thorough knowledge of data encoding techniques. It is therefore not recommended that Printers are upgraded from Standard (STD) to Magnetic encoding (MAG) types.

Connector for the Magnetic writing head

USB

Ethernet

DC Power



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)

Front Card Hopper 3652-0100-001

Rio Pro Front Fascia 3652-0100-003

Rio Pro Front Label

3652-0100-008

Rio Pro Base 3652-0100-001

Feet x 4 E9070

Rear Card Hopper 3652-0100-005

Metallic Collar 3652-0100-002

Top Cover 3652-0150-005

Top Cover Latch 3652-0150-003

Top Cover Latch Spring

E9319

Dye Film Sensor (Upper) 3652-0505

Print Head Assembly FG/3652-0160

Print Head Cooling Fan (24v) E092

Chassis Top Cover 3652-0150-005

Print Head Cable

3633-0400

Print Head Springs x 2 E9041

Latch Button E9319



SECTION 16.3 PRINT HEAD ASSEMBLY (FG/3633-0160)

SECTION 16.4 ROTATION UNIT ASSEMBLY (3633-0140)

Spring E9165

M3 x 20mm Torx Adjustment Screw

E9091

M3 x 6mm Torx Screw x 2 E9091

Support Plate x2 3652-0160-001

3x8mm Dowel x2

E9368

Print Head Mount 3652-0160-002

Guide Bar (Dye-Film) x2 3633-0160-007

Thermal Print Head E9312

Heatsink 3652-0160-003

Card Feed Rollers x4

Roller Spring Plate x2

Flipper Unit Housing (Left side)

Flipper Unit Housing (Right side)

Idler Pulley x2

Rotation Drive Gear x2

Star Washer x2

The Rotation Unit is now assembled externally as one complete unit so individual items are not available, a complete unit will be sent if required. The external Pulleys on the Rotation Unit are now considered a permanent fixture and the locking pin holds the Pulley Assembly in place. If the Rotation Unit is to be removed and replaced it should exchanged as a complete item.



SECTION 16.5 ROLLER LAYOUT.

Camshaft 3633-0300-001

Star Washer x 2 Rio/0055/R

Bearing Plate x 2 3633-0300-004

Print Head Roller 3633-0180

Cam Linkage Long x 2 3633-0300-002

Cam Linkage Short x 2

3633-0300-001

Rotation Unit 3633-0140

Flipper Pulley 3652-0140

110 Teeth Pulley 3633-0200-010

Card Feed Roller 3633-0204

30 Teeth Pulley x 3 3633-0200-005



SECTION 16.6 DRIVE MECHANISM RIGHT HAND SIDE.

80 Teeth Belt E9055

115 Teeth Belt E9056

30 Teeth Pulley 3633-0200-006

RFID PCB M9500-853/R

30 Teeth Pulley 3633-0200-005

Top Cover Assembly 3652-0150-005

144 Teeth Belt E9058

H Frame Assembly



SECTION 16.7 DRIVE MECHANISM LEFT HAND SIDE.

Cam Sensor 3633-0502

Camshaft Pulley 3633-0200-005

30 Teeth Pulley 3633-0200-005

115 Teeth Drive Belt E9056

Camshaft Motor Pulley 3633-0200-006 80 Teeth Cam Belt

E9055

Rotation Unit Position Sensor 3633-0502



SECTION 16.8 MOTOR LAYOUT AND PART NUMBERS.

Flipper Unit Motor (Stepper)

Flipper Card Feed Motor (Stepper)

Dye-Film Motor (DC)

Card Feed Motor (DC) Print Head Roller

Motor (Stepper) Cam Motor

(DC)



SECTION 16.9 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

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

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

CN3 3633-0177

Flip Rotation Motor Cam Motor

Flip Rotation Motor – Rio/0112/R 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 Flip Card Motor

Dye Film Motor – Rio/0043/R Flip Card Motor – Rio/0112/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

USB Connector Power Connector

LCD Display

Flipper Position Sensor

Cam Sensor

Dye Film Sensor (lower)

Tacho Sensor

Flip Rotation Motor (Stepper)

Cam Motor (DC)

Card Front Sensor

Card Middle Sensor

Card Rear Sensor

Dye Film Motor (DC)

Flip Card Motor (Stepper)

Card Feed Motor (DC)

Card Print Motor (Stepper)

RFID Controller

Top Cover Sensor

Print Head Wiring

Dye Film Sensor (Upper)

Print Head Cooling Fan

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



Magnetic Encoding Head 3633-0110 x1

Tension Spring E9147 x1

Mounting Washer M1560-110/R x2

Mounting Grubscrew P1-0038/R x2

3 x 6mm Grub Screws x 2 M1550-140/R

Location of mounting screws for Magnetic Head - Rio Pro

SECTION 16.10 MAGNETIC ENCODING OPTION



SECTION 17 PRODUCT UPDATES

Rio Pro Printhead Roller Pulley

The Large Drive Pulley is now fitted with a black Flange to prevent Belt slippage.

Please Note: The large Drive Pulley Flange is fitted here (attached at four points).

3652-0145 Large Drive Pulley



Part Numbers:

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

Anti Static Brush Strip is fitted here.

Rio Pro Stepper Motor pulleys are now held in place by Push-On „Star Washer‟ (P/N RIO/0465), left side also.



Rio Pro Cam Pulley

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



Fig 1

Additional Plastic Flange now fitted to all Rio Pro printers to prevent Rotation Belt

and Rotation Drive Belt slipping off. Fitted to both pulleys on each side.

colour id card printer magicard rio pro maintenance manual pro maintenance manual iss.1d.pdf ·...

Documents