Pronto MAGICARD 3649 - 0001 Maintenance Manual Download Page 35

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Ultra Electronics Ltd

Pronto Maintenance Manual

- 35 -

SECTION 10.4

SETTING THE PRINT HEAD DENSITY CALIBRATION.

CAUTION

The Print Head density programmer (PDP) is calibrated to suit the Print Head that it is supplied with. It

will not be suitable for supplied other Print Heads and therefore should only be used for a specific Print

Head

assembly.

Print Head Density

Programmer (PDP)

DONE !

Close the

Printer Lid

Whilst the

Printer Lid is open …

Summary of Contents for MAGICARD 3649 - 0001

Page 1: ...Card Printer MAGICARD Pronto Maintenance Manual Magicard Pronto single sided colour ID Card Printer 3649 0001 Magicard Pronto Mag single sided colour ID Card Printer 3649 0002 Issue 1 22 01 09 Option...

Page 2: ...ption 29 SECTION 9 PRINTER FUNCTIONS 30 section 9 1 1 printing a Test Card 30 section 9 1 2 Printer cleaning mode 30 section 9 2 1 soak test mode 31 SECTION 10 PRINT HEAD REPLACEMENT 32 section 10 1 P...

Page 3: ...standards 62 section 14 6 error checking 63 SECTION 15 FITMENTS TO THE PRINTER 64 SECTION 16 PARTS AND PART NUMBERS 65 section 16 1 external components 65 section 16 2 Top cover assembly 3633 0150 65...

Page 4: ...th 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 r...

Page 5: ...ichergestellt werden da die Geb udeinstallation mit einem 16 A berstromschalter abgesichert ist When Handling the Printer Avoid touching the thermal printing edge of the Print Head Any grease and cont...

Page 6: ...y 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 Sub...

Page 7: ...igid 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...

Page 8: ...nt 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 c...

Page 9: ...ed front Panel Button giving a clear indication of status USB interface Microsoft Certified Plug and Play Driver make the Pronto easy to install and use Secure Magicard Pronto features the patented Ho...

Page 10: ...ent Supply 3 2 Amps Output Power Rating 60 Watts Max Weight 4 4 Kilograms 10 lbs Dimensions 270mm L x 215mm W x 233mm H 17 8 L x 8 1 W x 9 2 H Dye Film loading Drop in Dye Film design Dye Film Set up...

Page 11: ...lectronics Ltd Pronto Maintenance Manual 11 USB Socket DC Power Input SECTION 3 COMPONENT LAYOUT Top Cover Opening Latch Multicoloured Button Hand Feed Entry Exit Slot Print Head Assembly Printer Conn...

Page 12: ...nual 12 Print Head Assembly Card Hand Feed Entry Exit Slot Top Cover Opening Catch Top Cover Holding Latches Print Head Cooling Fan Dye Film Sensor Bracket upper Unused Dye Film Spool Holder Used Dye...

Page 13: ...o Maintenance Manual 13 Top Cover Interlock Sensor Magnetic Encoder Roller Dye Film Sensor Bracket lower Dye Film Drive Gear Print Head Roller Front Card Opto Sensor Mid Card Opto Sensor Rear Card Opt...

Page 14: ...f the cost of colour printing The Table below is a guide to selecting the best Dye Film to use for any intended application Ribbon Layout Colour Key Full color Cards or monochrome Cards per Dye Film D...

Page 15: ...prints If it fails to read any of the data from the RFID protective Tag the Printer assumes it has monochrome Dye Film fitted Operate the top cover release Catch and lift the cover Place the two Spool...

Page 16: ...Card printing For good consistent results keep to a single variety of good quality Cards such as those available from your Magicard Dealer Card Size Card Thickness Minimum 0 51mm 0 020 Standard 0 76m...

Page 17: ...on and testing has shown that poorer quality or incorrect Card types will cause problems in the Printer These problems range from poor image quality Dye Film being cut through to Cards getting jammed...

Page 18: ...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 th...

Page 19: ...riate repair centre Ultra will at it s discretion repair or replace the defective parts at no charge to the Customer Warranty Limitations The warranty does not apply to MAGICARD Printers that have bee...

Page 20: ...tomer Support Manager Ultra Electronics Limited MAGICARD Service Centre Waverley House Hampshire Road Granby Estate WEYMOUTH Dorset DT4 9XD U K Tel 44 0 1305 784738 Fax 44 0 1305 777904 SECTION 6 2 IN...

Page 21: ...ing Kit see the Cleaning Supplies Section 7 2 A clean Printer produces better quality Cards as dust and dirt are not present when the Card is being printed A clean Printer is much less likely to requi...

Page 22: ...Open the lid and lift out the Dye Film Leave the lid open 2 Take a new Cleaning Card from it s packaging 3 Open the Printing Preferences within the Driver and select the Printer Tab Click Clean the P...

Page 23: ...ks dirty You can re use the cassette you simply replace the Roller within it 1 Open the Printer Lid and remove the used Dye Film Pull out the Cleaning Roller Cassette 2 Remove the Sticky Roller and th...

Page 24: ...ations are seen on printed Cards It is also a good idea to clean the Print Head when you replace the Dye Film 1 Use the special Print Head cleaning Pen from your Magicard Printer Cleaning Kit See Sect...

Page 25: ...ng Systems only Windows 2000 Windows XP 32 bit only Windows 2003 Server 32 bit only Windows Vista 32 bit only Windows 7 32 bit only SECTION 8 1 INSTALLATION INSTRUCTIONS ARE THE SAME FOR ALL WINDOWS O...

Page 26: ...ymptoms 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...

Page 27: ...OR WINDOWS 2000 XP 2003 SERVER On the PC go to START Control Panel Then select Add or Remove Programs Classic view Category view Select the Magicard Printer entry and click on Change Remove Choose the...

Page 28: ...on followed by Control Panel Category View choose Uninstall a Program Classic View choose Program and Features Select the Magicard Printer and the choose the Uninstall Change Button Follow the instruc...

Page 29: ...ch 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 fil...

Page 30: ...t delay whilst downloading the Test Card image the Pronto s Rollers should start to turn At this point a Card should be fed into the Printer s front panel slot The result should be the Test image show...

Page 31: ...ured Button on the front Panel twice in quick sucession until the Button colour changes Close the Printer Lid The front Panel Button should now begin to flash Next the Printer Rollers should start to...

Page 32: ...Dye Film is dragged below the Print Head This causes scratches which permanently damage the printing surface Under these circumstances the complete Print Head will have to be replaced as it is not re...

Page 33: ...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 invo...

Page 34: ...upward Refit the connector SECTION 10 3 REPLACING THE PRINT HEAD CONT CAUTION Care must be taken when disconnecting and connecting the Print Head Assembly The electrical connector located on the Prin...

Page 35: ...The Print Head density programmer PDP is calibrated to suit the Print Head that it is supplied with It will not be suitable for supplied other Print Heads and therefore should only be used for a speci...

Page 36: ...the Card is the end that ejects out of the Printer first Print Head Angle too positive Rear end of the Card will show wrinkling or Dye Film overheating Rear of the Card is the end that ejects out of...

Page 37: ...out of the case tilting it backwards This will then release the two rear plastic catches and allow the complete Print Engine to be removed Take care to retain the connector panel Refitting is the reve...

Page 38: ...d remove the Print Head Roller Drive Gear see Page 74 2 Unclip the plastic cross piece from the right side and slide out the cross piece in the direction of the red arrow that encloses the lower Dye F...

Page 39: ...ap Removal Refitting the Controller PCB 1 Disconnect all the wiring from around the outside edge of the Controller PCB 2 Unclip the four plastic catches and remove the Controller PCB downwards 3 On Pr...

Page 40: ...t 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 Senso...

Page 41: ...tem 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...

Page 42: ...ng the retaining Tabs on the shafts or releasing the spring washers Slide the Pulleys outwards Refitting is the reverse procedure ensuring new spring washers are used SECTION 11 9 REMOVAL AND REFITTIN...

Page 43: ...m of the Print Engine Refitting is the reverse procedure ensuring the Motor aligns with the screw holes Card Drive Motor 1 Disconnect the Motor connector 2 The Motor is held in place by two screws thr...

Page 44: ...ssis 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 En...

Page 45: ...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 fitt...

Page 46: ...move 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...

Page 47: ...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...

Page 48: ...f 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 PS...

Page 49: ...f 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 contam...

Page 50: ...er Stepper Motor 3 Swap if necessary for testing 4 Call Magicard Technical Support Background colour changes at edges of dark or light objects 1 Poor Print Head colour compensation Usually a fault wit...

Page 51: ...orrect 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...

Page 52: ...tion is deselected 2 Magnetic Encoded data is in the wrong place on the Magnetic Stripe 3 Magnetic Encoded data is not the correct format for the swipe Reader 4 Magnetic Encoding Head is either mis al...

Page 53: ...guration 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 Ele...

Page 54: ...g 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...

Page 55: ...ics Shows valuable information on Printer usage Quick Commands Enables the user to send special commands to the Printer usually used for fault diagnosis Print PRN file Enables the user to send previou...

Page 56: ...the Printer If you experience a problem you may be asked to email the results of the query to Magicard Technical Support for analysis Ethernet connection is not available with the Pronto Printer The s...

Page 57: ...o encode and enter the data to be encoded Click on the Encode Button Mag Read function enables you to read ISO Standard magnetic encoding using the Printer hardware To use this Tool Ensure a magnetic...

Page 58: ...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...

Page 59: ...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 Currenc...

Page 60: ...the image you require to print onto the Computer s Display Screen Ensure that the Image you are printing is using a Rastagraphic Program i e such as a word processing application DTP package or propr...

Page 61: ...g 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...

Page 62: ...its making up each character is 4 plus 1 Parity Check Bit The total number of data characters control characters and LRC characters together must not exceed 40 including Start and End Sentinels Track...

Page 63: ...akes the number of I s in the data being checked total an odd number 1 3 5 If 123 was encoded in 5 MPC on Track 2 with ODD Parity and EVEN LRC would look thus II0I0 I0000 0I000 II00I IIIII 00I0I 1 2 3...

Page 64: ...ter specific Although it is relatively straightforward to fit the Magnetic Encoding components into the Printer it is extremely difficult to calibrate to meet ISO specifications To do this requires a...

Page 65: ...Head Cable 3633 0400 Print Head Springs x 2 E9041 Lid Latch 3649 0150 003 Spring Lid Latch x 2 E9246 Top Cover 3649 0150 002 SECTION 16 PARTS AND PART NUMBERS The following section lists the main ass...

Page 66: ...e 3633 160 002 3 x 6mm Dowel Pin E9090 Print Head Shield M9005 820 M3 x 6mm Torx Screw x 2 E9091 Heatsink 3649 0160 001 Spring E9042 M3 x 20mm Torx Adjustment Screw E9165 Thermal Print Head P1 0001 R...

Page 67: ...ey 3633 0200 010 Grip Washer Rio 0055 R 30 Teeth Pulley 3633 0200 007 30 Teeth Pulley 3633 0200 007 Cam Drive Assembly Grip Washer Rio 0055 R Bearing Plate 3649 0300 001 Belt Drive Train E9057 Belt Te...

Page 68: ...Ultra Electronics Ltd Pronto Maintenance Manual 68 SECTION 16 5 DRIVE MECHANISM RIGHT HAND SIDE RFID PCB M9500 853 Cable RFID 3633 0403...

Page 69: ...ntenance Manual 69 SECTION 16 6 DRIVE MECHANISM LEFT HAND SIDE H Frame Assembly 3649 0300 002 115 Teeth Drive Belt E9056 Camshaft Pulley 3633 0200 005 Camshaft Motor Pulley 3633 0200 006 80 Teeth Cam...

Page 70: ...Ultra Electronics Ltd Pronto Maintenance Manual 70 SECTION 16 7 MOTOR LAYOUT AND PART NUMBERS Card Print Motor Stepper Rio 0112 R Cam Motor DC Rio 0043 R Dye Film Motor DC Rio 0043 R...

Page 71: ...iddle Sensor Card Rear Sensor Card Front Sensor 3633 0502 Card Middle Sensor 3633 0502 Card Rear Sensor 3633 0502 CN12 3633 0179 Dye Film Motor Dye Film Motor Rio 0043 R CN15 3633 0171 Card Feed Motor...

Page 72: ...tronics Ltd Pronto Maintenance Manual 72 SECTION 16 9 MAGNETIC ENCODING OPTION Holes for Screw P1 0038 R Magnetic Head Aperture 3633 0110 Washer M1560 110 R Magnetic Head 3633 0110 Spring E9147 Screw...

Page 73: ...rs 3633 0100 011 Brush Strip E9243 Pop Rivet 3633 0403 Modified Wire Loom SECTION 16 10 GENERAL INFORMATION RFID Reader PCB Dye Film Drive Motor Anti Static Brush Strip Prontoo Stepper Motor pulleys a...

Page 74: ...anual 74 Card Feed Roller Print Head Roller Drive Gear Print Head Roller Printer Cam Cam Drive Assembly Bearing Plate Left Side Bearing Plate Right Side Cam Pulley Print Head Up Down is now glued onto...

Page 75: ...Ultra Electronics Ltd Pronto Maintenance Manual 75 Tacho Wheel Bearing Plate Left Side Dye Film Sensor Lower Cam Sensor...

Page 76: ...ck rubber roller 3633 0183 Idle Roller Assembly 3633 0184 Rear Idler Roller Assy Mag printers 3633 0200 012 Tacho Encoder Wheel 3649 0100 001 Base external moulding 3633 0300 008 Cam Pivot Bar Pronto...

Page 77: ...istration issue which affects some machines when photographs are printed against primary colour backgrounds 2 Leave fan on for longer for the RUNFAN diagnostic command 12 Aug 2009 Release V1 04 1 Prin...

Page 78: ...ess 01 06 This error is raised if the Lid is opened while winding the Film on to the start of the next panel This may be either during printing or initialisation 01 07 This error is raised if the Lid...

Page 79: ...opened during the hand feed process This error only occurs if the Lid is opened after the front Sensor is blocked but before the mid Sensor is blocked 02 OUT OF CARDS Applicable to Hopper fed Cards 02...

Page 80: ...ard from the smart encoding position to the standby position if the Card present Sensor does not register the Card leaving within 3 seconds 05 01 This error is raised while trying to place the Card in...

Page 81: ...to the standby position over the mid Sensor if the front Sensor does not unblock within 3 seconds 06 10 This error is raised while trying to move the Card from over the front Sensor to the standby po...

Page 82: ...g to move it all the way to the front Sensor before returning it to the standby position 06 24 Not applicable to the PRONTO 06 25 Not applicable to the PRONTO 06 26 This error is raised in Pronto Engi...

Page 83: ...is error is raised while trying to advance the Film to the start of the next panel if Dye Sensor transitions are seen but no tachos are seen for at least 5 seconds 08 11 This error is raised while try...

Page 84: ...n the Dye Film to a chosen offset within a chosen panel for example prior to printing if the Printer cannot find the requested panel within 8 panels of its starting point This error often indicates th...

Page 85: ...hin 5 seconds Note that this function is only used by the HEAD quick command and the cleaning routine 16 03 This error is raised while trying to lift the head at the end of printing a panel if the Cam...

Page 86: ...20 00 20 00 This error is raised while determining the format of the downloaded print job if colour printing has been requested for the front of the Card but the Printer does not support colour print...

Page 87: ...nvolves incrementing the Tag s print counter fails 24 04 This error is raised while trying to feed a Card from the Hopper to the print Engine if the Printer sees the mid Sensor block before the rear o...

Page 88: ...Engines while hand feeding a Card to the standby position while trying to block the front Sensor if the rear Sensor blocks first 24 16 This error is raised in Pronto Engines while hand feeding a Card...

Page 89: ...Film regardless of which part of the Film it looks through Note that the Printer was able to see green and blue light shine through 25 07 This error is raised while calibrating the Dye LED if the Prin...

Page 90: ...Ultra Electronics Ltd Pronto Maintenance Manual 90...

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