DataCard CP60, CP60 Plus Service Manual

Datacard® CP60™ and CP60 Plus

Card Printers

Service Manual

May 2007

Part No. 539358-002, Rev C

Liability Statement

This product has been built to the high standards of Datacard Group. Please do
not attempt to operate or repair this equipment without adequate training. Any
use, operation, or repair in contravention of this document is at your own risk.
By acceptance of this system you hereby assume all liability consequent to your
use or misuse of this equipment. Datacard assumes no liability for incidental,
special, or consequential damage of any kind. Equipment specifications,
applications, and options are subject to change at the sole discretion of Datacard
without notice.

Proprietary Notice

All drawings and information herein are the property of DataCard Corporation.
All unauthorized use and reproduction is prohibited.

Trademark Acknowledgments

Datacard is a registered trademark and service mark of DataCard Corporation in
the United States and other countries. CP60 is a trademark of DataCard
Corporation.

All other product names are the property of their respective owners.

Datacard Group

11111 Bren Road West
Minnetonka, MN 55343-9015

952.933.1223
Fax: [phone]

www.datacard.com

© 2006, 2007 DataCard Corporation. All rights reserved.
Printed in the United States of America.

ii

Contents

Chapter 1: Introduction __________________________________________________________ 1-1

Intended Audience_________________________________________________________________1-2
Avoiding Electrostatic Discharge ____________________________________________________1-2
Symbol Conventions________________________________________________________________1-3

Chapter 2: Theory of Operation___________________________________________________ 2-1

Printer Components ________________________________________________________________2-2

Functional Block Diagram _____________________________________________________2-2
Sensors_______________________________________________________________________2-3
Motors _______________________________________________________________________2-5
Miscellaneous ________________________________________________________________2-6

LCD Menu Diagram___________________________________________________________2-7
Sequence of Operation_____________________________________________________________2-8
Open Card Printer Differences______________________________________________________2-10
Graphics Printing __________________________________________________________________ 2-11
Printhead Settings _________________________________________________________________2-12
Magnetic Cards___________________________________________________________________2-14

Magnetic Data Principles_____________________________________________________2-14

Encoding Format ____________________________________________________________2-19
Magnetic Stripe Primary Data Standards ____________________________________________2-22

ISO/IEC 7811 (Parts 2 and 6) __________________________________________________2-22

AAMVA DL/ID-2000 __________________________________________________________2-22

Saflok and Ving______________________________________________________________2-22

Multiple Record Format (SDS)_________________________________________________2-23

JIS X 6302 (Type I and Type II Cards)___________________________________________2-23

Magnetic Media Locations___________________________________________________2-24

Data Track Locations_________________________________________________________2-25

Summary of Specifications____________________________________________________2-26

Character Encoding _________________________________________________________2-27
Smart Card Technology____________________________________________________________2-29

Contact Smart Cards ________________________________________________________2-30

Non-Contact Smart Cards____________________________________________________2-32

Chapter 3: Routine Maintenance _________________________________________________ 3-1

Required Tools and Supplies_________________________________________________________3-2
Routine Maintenance Pro cedure____________________________________________________3-3

Clean the Interior of the Printer ________________________________________________3-3

Mechanical Inspection________________________________________________________3-5

Run the Cleaning Card________________________________________________________3-8

Visual Inspection for Card Quality______________________________________________3-8

Chapter 4: Troubleshooting_______________________________________________________ 4-1

General Notes______________________________________________________________________4-2

iii

General Troubleshooting Proced ures ________________________________________________4-2

Non-Clearing Repetitive Messages_____________________________________________4-2

Troubleshooting Sensors _______________________________________________________4-3

Troubleshooting Motors________________________________________________________4-4

Testing General DC Motors ______________________________________________4-4
Testing the Ribbon and Pick Motors_______________________________________4-5
Testing the Cam Motor __________________________________________________4-5
Testing the Printhead Fan________________________________________________4-6
Testing Transport and Duplex Motors______________________________________4-6

Troubleshooting Other Devices ________________________________________________4-6

Testing the Smart Card Solenoid__________________________________________4-6
Testing the Duplex Clutch________________________________________________4-7
Diagnosing the Duplex Interface Board___________________________________4-8
Diagnosing the Ribbon RFID Antenna_____________________________________4-8

Performance Problems______________________________________________________________4-9

Printer Initialization Errors_______________________________________________________4-9

Card Jams at Card Input_____________________________________________________4-10

Card Stalls at Output Stacker _________________________________________________4-10

Card Jams in Printing Area ___________________________________________________4-11

Ribbon Break Errors___________________________________________________________4-12
Error Codes _______________________________________________________________________4-13

Error Code Prefixes___________________________________________________________4-13

General Notes_______________________________________________________________4-13

Driver API (AP) _______________________________________________________________4-14

Printer Driver Errors (DR)_______________________________________________________4-14

Input Errors (IS) _______________________________________________________________4-17

Duplex Module Errors (DM) ___________________________________________________4-17

System Errors (SY) ____________________________________________________________4-18

Magnetic Stripe Errors (MS) ___________________________________________________4-19

Print Errors (PR)_______________________________________________________________4-24

Smart Card Errors (SC)________________________________________________________4-26

Chapter 5: Adjustments __________________________________________________________ 5-1

General Notes______________________________________________________________________5-3
Installing Printer Diagnostics _________________________________________________________5-3
Using Printer Diagnostics ____________________________________________________________5-5

Parts of the Diagnostics Window _______________________________________________5-5

Menu Options ________________________________________________________________5-6

Changing Printer Values_______________________________________________________5-8

Viewing and Saving Values______________________________________________5-9
Working With Scripts ____________________________________________________5-10

Setting Printer Value Parameters______________________________________________5-11

Printer ID_______________________________________________________________5-11
Card Registration Offset ________________________________________________5-11
Card Strip Offset _______________________________________________________5-12
Ribbon Type ___________________________________________________________5-12
Ribbon Offset __________________________________________________________5-12
Vertical Offset _________________________________________________________5-12
Transport Speed________________________________________________________5-13
YMC, K, T, & F Strobe Duty ______________________________________________5-13

iv

YMC, K, T, and F Power and Base Power _________________________________5-14
Duplex Infeed Offset ___________________________________________________5-14
Duplex Home Offset____________________________________________________5-15
Duplex Print Return Offset_______________________________________________5-15
Duplex Handoff Offset__________________________________________________5-15
Smart Card Registration Offset __________________________________________5-15
Image Clipping Leading and Trailing ____________________________________5-16

Setting Printer Options________________________________________________________5-17

Viewing Printer Status ________________________________________________________5-18

Testing Motors _______________________________________________________________5-19

Testing Motor Functions ______________________________________________________5-20

Setting Up Step Tests for the Printer____________________________________________5-21

Running a Magnetic Stripe Test Card__________________________________________5-22

Configuring the Magnetic Stripe Module ______________________________________5-23

Configuring Custom Track Formats____________________________________________5-25

Running Magnetic Stripe Diagnostics__________________________________________5-26

Testing the Smart Card Option________________________________________________5-27
Network Option Adjustments _______________________________________________________5-29
Software Adjustment Procedures ___________________________________________________5-33

Saving and Restoring a Printer Configuration __________________________________5-33

Start Sentinel Position_________________________________________________________5-35

Card Registration Offset Adjustment __________________________________________5-36

Ribbon Offset Adjustment ____________________________________________________5-37

Updating the Printer Firmware ________________________________________________5-38

Duplex Rotational Adjustment ________________________________________________5-39

Chapter 6: Removal and Replacement ___________________________________________ 6-1

General Notes______________________________________________________________________6-3

Symbols ______________________________________________________________________6-3

Required Tools________________________________________________________________6-3

Screw Torque Specifications ___________________________________________________6-3

Front Wire Routing ____________________________________________________________6-4

Duplex and Printhead Wire Routing ____________________________________________6-5

Functional Block Diagram _____________________________________________________6-6
Exterior Components________________________________________________________________6-7

Swingarm Cover______________________________________________________________6-7

Main Enclosure _______________________________________________________________6-8

Card Hopper _________________________________________________________________6-9

LCD Display _________________________________________________________________6-11
Swingarm Assembly________________________________________________________________6-13

Printhead Fan _______________________________________________________________6-14

Printhead Spring _____________________________________________________________6-15
Sensors____________________________________________________________________________6-16

Card Input Sensor (Without Clear Card) _______________________________________6-16

Card Input Sensor (With Clear Card) __________________________________________6-17

Swingarm Sensor_____________________________________________________________6-18

Ribbon Motion Sensor ________________________________________________________6-19

Ribbon Index Sensor _________________________________________________________6-20

v

Cam Sensor _________________________________________________________________6-21

Card Hopper Empty Sensor___________________________________________________6-22
Motors ____________________________________________________________________________6-23

Transport Motor______________________________________________________________6-23

Pick Motor___________________________________________________________________6-24

Cam Motor__________________________________________________________________6-26

Ribbon Motor and Gear______________________________________________________6-27
Transport Assembly ________________________________________________________________6-29

Main Control Board __________________________________________________________6-32

Transport Timing Belt _________________________________________________________6-36

Belt Tensioner Pulley and Tension Spring _______________________________________6-37

Drive and Idler Pulleys________________________________________________________6-38

Cleaning Rocker Assembly ___________________________________________________6-39

Front Rocker Assembly _______________________________________________________6-40

Rear Rocker Assembly________________________________________________________6-41

Ribbon Guide _______________________________________________________________6-42

Pick Roller ___________________________________________________________________6-44

Cleaning Drive Roller_________________________________________________________6-46

Front Drive Roller_____________________________________________________________6-48

Rear Drive Roller _____________________________________________________________6-50

Platen Roller_________________________________________________________________6-53

Printhead Cam ______________________________________________________________6-54

Printhead Lifter ______________________________________________________________6-55

Front Card Guide ____________________________________________________________6-56

Rear Card Guide ____________________________________________________________6-57

Static Brushes________________________________________________________________6-59

RFID Antenna________________________________________________________________6-60
Duplex Module____________________________________________________________________6-61

Duplex Entry Sensor __________________________________________________________6-63

Duplex Home Sensor (Without Clear Card) ____________________________________6-65

Duplex Home Sensor (With Clear Card)________________________________________6-66

Duplex Interface Board_______________________________________________________6-67

Duplex Entry Rocker__________________________________________________________6-68

Duplex Motor________________________________________________________________6-69

Magnetic Clutch/Spring Clutch/Duplex Rol lers_________________________________6-71
Magnetic Stripe Option ____________________________________________________________6-75

Magnetic Stripe Circuit Board_________________________________________________6-75

Magnetic Stripe Registration Sensor (Without Clear Card) ______________________6-76

Magnetic Stripe Registration Sensor (With Clear Card)__________________________6-77

Magnetic Stripe Head________________________________________________________6-78

Magnetic Stripe Rocker Assembly_____________________________________________6-80
Smart Card Option ________________________________________________________________6-81

Smart Card Interface Board __________________________________________________6-81

Solenoid Assembly/Solenoi d Link______________________________________________6-82

Smart Card Contact _________________________________________________________6-84

Contactless Smart Card Coupler______________________________________________6-87

vi

Revision Log

Datacard CP60 and CP60 Plus Card Printers Service Manual

Revision Date Description of Changes

A March 2006 First release of this document.

B June 2006 Update part numbers for RoHS compliance.

C May 2007 Update for release of CP60 Plus printers.

Regulatory Compliance

Notice for USA (FCC Notice)

This equipment generates, uses, and can radiate radio frequency energy. If it is
not installed and used in accordance with this instruction manual, it may
interfere with radio communications. This equipment has been tested and found
to be within the limits for Class A computing devices, pursuant to Title 47 CFR
Part 15 Subpart B of FCC rules, designed to provide reasonable protection
against radio interference in a commercial environment. Operation of this
equipment in a residential environment may possibly cause interference. In the
event of interference, the user, at their own expense, will be required to take
whatever measures are necessary to correct the problem.

Notice for Canada

This digital apparatus does not exceed the Class A limits for radio noise for
digital apparatus set out in the Radio Interference Regulations of the Canadian
Department of Communications.

Le présent appareil numérique n'émet pas de bruits radioélectriques dépassant
les limites applicables aux appareils numériques de la classe A prescrites dans le
Règlement sur le brouillage radioélectrique édicté par le ministère des
Communications du Canada.

vii

Safety Issues

All Datacard products are built to strict safety and reliability specifications in
accordance with UL60950-1 and CUL requirements; therefore, safety issues
pertaining to operation and repair of Datacard equipment are primarily
environmental and human interface.

The following basic safety tips are given to ensure safe installation, operation,
and maintenance of Datacard equipment and are not to be considered as
comprehensive on all matters of safety.

Safe Environment

Connect equipment to a grounded facility power source. Do not defeat or

•

bypass the ground lead.

• Place the equipment on a stable surface (table), and ensure floors in work

area are dry and non-slip. Insulated rubber floor mats are preferred.

• Know the location of equipment branch circuit interrupters or circuit

breakers and how to turn them on and off in case of emergency.

• Know the location of fire extinguishers and how to use them. Use only ABC

type extinguishers on electrical fires.

• Know local procedures for first aid and emergency assistance at the customer

facility.

• Use adequate lighting at the equipment.

• Maintain the recommended range of temperature and humidity in

equipment area.

• Do not use this product in an environment containing volatile or flammable

compounds.

Safe Human Interface

• Use proper lifting techniques when moving or installing the equipment.

• Use standard electrostatic discharge (ESD) precautions when working on or

near electrical circuits.

• Do not defeat or disconnect safety interlocks.

• Observe standard safety precautions when servicing the system.

WARNING: To avoid a possible electric shock, always unplug the system

before servicing.

viii

Chapter 1: Introduction

This chapter provides an introduction to the Datacard® CP60
and CP60 Plus card printers.

Intended Audience______________________________________________________________
Avoiding Electrostatic Discharge _________________________________________________ 1-2
Symbol Conventions_____________________________________________________________ 1-3

1-2

CP60 and CP60 Plus Service Manual 1-1

Intended Audience

This manual is intended for use by authorized representatives of Datacard who
are responsible for the maintenance, service, and repair of the CP60 and CP60
Plus card printers. The service representatives must complete an authorized
Datacard service training course prior to servicing the printer.

Avoiding Electrostatic Discharge

While working around control boards and other sensitive components, use
proper equipment and procedures to reduce the possibility of damaging the
components. This section describes the procedure for protecting against damage
due to electrostatic discharge.

CAUTION: Static electricity can destroy components on a circuit board. Use

the following precautions when handling the board, its components, or tools
in contact with the board or its components.

Tools Required:

Procedure:

Static-grounding kit (Part Number: TUL006-006) containing:

• Static-grounding mat

• Mat-grounding cable

• Static-grounding wrist strap

1. Wear appropriate clothing. Avoid wool and synthetic fabrics.

2. Remove movable carpet and rugs.

3. Apply the grounding strap to a wrist. Ensure that there is no clothing

between the strap and skin and that the strap is snug enough to maintain
contact with the skin.

4. Connect one end of the grounding cable to the wrist strap.

5. Using the grounding plug, connect the other end of the grounding cable to

the earth ground of a facility AC outlet.

6. Clear a work area, lay the static-grounding mat on the work area, and

connect the movable end of the long grounding cable to the mat.

7. Always set unshielded static-sensitive materials on the grounded anti-static

mat. Whenever possible, place components into static-shielded bags.

• Wrist strap grounding cable

• Grounding plug

8. When bringing two objects into contact (tool to circuit board or board to mat),

first simultaneously touch both objects with fingers.

1-2 Introduction

Symbol Conventions

The appearance and purpose of the symbols used in this manual are presented
below.

This symbol is used to designate a procedure that
involves electrostatic discharge sensitive components.
ESD procedures should be used.

CAUTION: This symbol indicates a strong cautionary
message to avoid serious damage to the printer.

WARNING: This symbol indicates a strong warning
message to prevent personal injury to the technician.

This symbol indicates a spring hazard. Safety glasses
should be worn when completing the procedure.



This symbol indicates a reminder message or other
additional information for the technician.

Graphic callouts with a colored background provide
incidental information about the graphic itself.

Graphic leaders with a colored background indicate a
direction of movement or similar information.

CP60 and CP60 Plus Service Manual 1-3



1-4 Introduction

Chapter 2: Theory of Operation

This chapter provides the theory of operation for the CP60 and CP60
Plus card printers.

Printer Components______________________________________________________________ 2-2

Functional Block Diagram _____________________________________________________________2-2
Sensors_______________________________________________________________________________2-3
Motors _______________________________________________________________________________2-5
Miscellaneous ________________________________________________________________________2-6
LCD Menu Diagram___________________________________________________________________2-7

Sequence of Operation__________________________________________________________ 2-8
Open Card Printer Differences___________________________________________________ 2-10
Graphics Printing _______________________________________________________________ 2-11
Printhead Settings ______________________________________________________________ 2-12
Magnetic Cards ________________________________________________________________ 2-14

Magnetic Data Principles ____________________________________________________________2-14
Encoding Format ____________________________________________________________________2-19

Magnetic Stripe Primary Data Standards _________________________________________ 2-22

ISO/IEC 7811 (Parts 2 and 6) __________________________________________________________2-22
AAMVA DL/ID-2000 __________________________________________________________________2-22
Saflok and Ving______________________________________________________________________2-22
Multiple Record Format (SDS)_________________________________________________________2-23
JIS X 6302 (Type I and Type II Cards)___________________________________________________2-23
Magnetic Media Locations___________________________________________________________2-24
Data Track Locations ________________________________________________________________2-25
Summary of Specifications ___________________________________________________________2-26
Character Encoding_________________________________________________________________2-27

Smart Card Technology_________________________________________________________ 2-29

Contact Smart Cards ________________________________________________________________2-30
Non-Contact Smart Cards____________________________________________________________2-32

CP60 and CP60 Plus Service Manual 2-1

Printer Components

Functional Block Diagram

2-2 Theory of Operation

Sensors

Name Function

All of the optical sensors in the CP60 and CP60 Plus printers are of the open
collector type, and are configured to be active-low with a pull-up resistor on the
output. When the sensor is not active (or not connected at all) the control board
sees a high voltage (5V) at the Signal input. When the sensor is active, it shorts
Signal to Ground. The diagram below is a simplified representation of an
interruption sensor.

Card Input

Printhead Cam

Swingarm Open
(Cover arm)

Ribbon Index

Ribbon Motion

The card input sensor is an interruption sensor that detects the presence
of a card at the entry of the printer and registers the trailing edge of the
card for printing.

For the clear card option, this sensor is replaced with a reflective sensor.
As the printhead cam rotates, a flag on the cam interrupts the beam of

the cam sensor. This allows the printer to know the position of the
printhead lifters. The printhead lifters lift the printhead away from the
platen roller when not printing.

The swingarm open sensor detects when the swingarm is open. The sensor
itself detects when the swingarm is closed, but the signal is inverted
elsewhere in the system.

Note: The user information and Diagnostics refer to this as a cover arm
sensor.

The ribbon index sensor is used to determine the position of the print
ribbon panels. The sensor bounces a beam off the reflective sticker on the
printhead. When the index mark or K-panel on the ribbon p a sses between
the sensor and the reflector, the beam is broken (not reflected). The Y, M,
C, & T panels do not interrupt the beam.

The ribbon motion sensor is a two-channel optical interruption sensor that
detects slots on the ribbon encoder wheel. The encoder wheel is located
on the ribbon cartridge. Internally the sensor body contains a pair of
standard interruption sensors.

CP60 and CP60 Plus Service Manual 2-3

Name Function

Magnetic Stripe
Registration

Magnetic Stripe
Optical Encoder

Duplex Entry

Duplex Home

Input Hopper
Empty (Optional)

This is a reflective sensor that locates the leading edge of the card for
magnetic stripe encoding. When no card is present, the sensor beam
reflects off a plate on the magnetic stripe rocker. When a card passes
between the sensor and the reflector, the beam is broken (not reflected).
The sensor itself is active when no card is present, but the signal is inverted
elsewhere in the system.

For the clear card option, this sensor is replaced with another reflective
sensor.

This encoder monitors the rotation of the idler roller in the magnetic stripe
module. It provides positional feedback to the module to ensure proper
magnetic encoding.

The duplex e ntry senso r i s an o p tical interruption se n s or that det e cts the
presence of a card as it enters and leaves the duplex module.

For the clear card option, this sensor is replaced with a reflective sensor.
The duplex home sensor determines the ro tational position of the duplex

flipper. The flipper has three flags that pass through the sensor.
This reflective sensor detects when the card hopper has no cards left. It

functions only when special software is created to use it.

2-4 Theory of Operation

Motors

Name Function

The CP60 and CP60 Plus printers have up to five motors depending on the
configuration. The three DC motors are all similar, with an integral reduction
geartrain and 24-volt operation. The speed of the motors is controlled by pulse
width modulation. While the motors are reversible, some are wired to operate in
one direction only. The duplex step motor operates at 24 volts, but the transport
step motor operates at 40 volts.

Pick Motor

Transport Motor

Cam Motor

Ribbon Motor

Duplex Motor

The pick motor drives the pick roller to bring a card into the system. The
motor is wired for unidirectional operation and cannot be reversed by
the control board. One wire is tied to ground and the other wire is the
control. This motor is driven by a single channel in the motor driver.

The transport motor drives the platen roller through a gear, which also
drives the main transport belt. This is a 2-phase (4-wire), 40-volt stepper
motor.

The cam motor rotates the printhead cam, which operates the
printhead lifters. This raises and lowers the printhead into position for
printing or permitting a card to pass beneath. This motor is wired bi­directional and uses two channels from the motor contr o ller so that it
can be reversed. (However at this time, the mot or is not operated in
reverse.)

The ribbon motor drives the gear train of the ribbon cartridge to
advance the ribbon during printing. The motor is wired for
unidirectional operation and cannot be reversed by the control board.
One wire is tied to ground and the other wire is the control. This motor is
driven by a single channel in the motor driver.

The duplex motor drives a gear on the duplex clutch. The clutch
permits a single motor to either oper ate the rollers, or rotate the entire
flipper assembly (this is discussed in more detail on page
2-phase (4-wire), 24-volt stepper motor.

2-6). This is a

CP60 and CP60 Plus Service Manual 2-5

Miscellaneous

Name Function

Smart Card Solenoid

Duplex Clutch

RFID Antenna

The smart card solenoid retracts the smart card rocker downward
so the contacts touch the card. When relaxed, a return spring lifts
the rocker and contacts away from the card.

The duplex clutch controls whether the duplex motor operates the
drive rollers or rotates the whole flipper assembly. The clutch
contains two concentric axes that are free to rotate
independently when the clutch is relaxed. When the clutch is
active, a magnetic field pulls the two axes together and friction
forces the two to rotate in unison. Because the clutch is engaged
magnetically, the rotation of either axis is independent from the
body of the clutch.

Operation: The duplex motor rotates the outer axis (large gear),
which is coupled to the two duplex drive rollers. The flipper
assembly is coupled to the inner axis. When the clutch is relaxed,
the outer axis (gear) rotates independently from the flipper
assembly, and this causes the drive rollers to rotate. When the
clutch is engaged, the whole flipper assembly rotates in unison
with the large gear, which keeps the d r ive rollers from rotating.

The RFID antenna circuit board is a simple loop antenna that
communicates with the supplies ID chip in the ribbon supply spool.
The bi-directional communication method is similar to

Contact Smart Cards (p. 2-32) using load-modulation, although

the specific details may vary.

Non-

Duplex Interface
Board

Magnetic Stripe
Daughter Board

Smart Card Daughter
Board

The duplex interface board contains a step motor driver for the
duplex motor, and a 24-volt driver circuit for the clutch. The sensor
signals are passed through directly from the main control board.

There are two types of magnetic stripe daughter boards: 3-track
and single track. The circuit board controls the magnetic stripe
head and provides an interface for the optical encoder. The
optical encoder data is passed back to the main control board
without modification.

The smart card daughter board provides a communica ti o n
interface between the application computer and the smart card.
Most of the communication aspects and the da ta transfer are
controlled by an external software application, and are
transparent to the printer. The daughter board also provides a
connection to control the smart card solenoid.

2-6 Theory of Operation

LCD Menu Diagram

CP60 and CP60 Plus Service Manual 2-7

Sequence of Operation

Power-on Initialization

1. When the printer is plugged in, it begins its initialization routine. (There is no

On/Off switch.)

2. As the main control board initializes itself, the status light on the front of the

printer will be steady amber.

3. After the control board is initialized, the status indicator will cycle through

Red, Amber, and Green.

4. While the control board examines and initializes external components, the

indicator will flash green.

A. It checks for smart card, magnetic stripe, and duplex modules.
B. The duplex module is initialized, and the rollers are operated for

sufficient time to ensure no cards are present in the module.

C. The printhead cam motor is cycled and homed.
D. The transport is initialized and then operated for sufficient time to ensure

that the card track is clear.

E. The ribbon type is identified. This may or may not result in the ribbon

motor being energized for a short time to detect a ribbon encoder change.

5. When the printer has finished its initialization procedure and is ready to

process cards, the status light will turn green.

Default Card Production Sequence

1. After the card data has been sent to the printer, it begins the card

personalization process.

2. The card is picked and passes through the cleaning rollers.

3. After the leading edge of the card passes through the cleaning rollers, the

card is detected by the input sensor. The trailing edge of the card is registered
for positioning.

4. The card is first sent to the smart card area.
A. When the card is approaching the location of the smart card contacts, the

solenoid engages and pulls the contacts down.

B. The leading edge of the card makes contact with the smart card sensor

(mechanical switch in the contact block) and the transport stops.

C. The card is programmed by an external application. The printer acts only

as an interface to the card.

D. The external application notifies the printer that smart card interaction is

complete, and control is returned to the printer.

2-8 Theory of Operation

5. The card is then sent back toward the entry of the printer before being sent to

the magnetic stripe module.

A. The leading edge of the card is registered by the magnetic stripe sensor.
B. The optical encoder measures the distance the card is traveling during the

encoding process.

C. All tracks of the card are written simultaneously.
D. On the return pass, the card data is verified.

6. The card is then returned to the input sensor and registered for graphics

printing.

A. When the leading edge of the card reaches the platen roller, the printhead

cam engages and lowers the head onto the card.

B. The ribbon motor is engaged. The motor is over-driven, and the spindle

clutch slips as needed to match the speed of the card.

C. After printing a panel, the printhead is raised and the card is returned to

the input sensor.

D. The ribbon motor advances to the next panel by examining the ribbon

encoder.

E. The process is repeated for the remaining panels.

7. The card is passed to the duplex module.
A. The duplex entry sensor detects the card and determines the position

within the flipper.

B. With the magnetic clutch relaxed, the drive rollers pull the card into the

module.

C. The clutch is engaged and the motor rotates the flipper to the return

position.

D. The clutch is released, and the motor drives the rollers to move the card

back into the printer. (The rollers always move in the forward direction,
but since the flipper assembly is inverted, the card is moved back into the
printer.)

8. The card is re-registered by the input sensor and printing is completed on the

back of the card in the same fashion as the front.

9. After printing, the card is moved to the front of the printer and placed into

the output hopper.

CP60 and CP60 Plus Service Manual 2-9

Open Card Printer Differences

There are several Datacard printers that support the Open Card format, but not
all printers support the same functions. The table below lists the differences by
printer model.

Item

CP60

CP60 Plus

Printer Model

SE48 220 280 310

@S character spacing    
@L line spacing    
@T graphics template 
@@ hex character control   
Allow format characters in print field     
More than 11 dummy emboss lines    
Special font spacing for fonts 1, 2, 3    
Characters not on emboss wheel
permitted

    

Graphics data control  

2-10 Theory of Operation

Graphics Printing

The information presented in the following section is not required for servicing
the CP60 and CP60 Plus printers but is presented to augment the customer
engineer’s training and knowledge base.

The printhead is made up of 672 microscopic heating elements. Each of these
thermal elements is made from a printed circuit conductor etched into the
printhead substrate (metallic-like foil). The elements are spaced 0.0035 inch apart,
and represent a single pixel at 300 DPI resolution.

To transfer pigment from the print ribbon to the card, the respective thermal
element (pixel) heats up until the temperature reaches the transfer threshold. At
this point, pigment from the print ribbon will adhere to the card. The longer the
element remains on, the more material gets applied.

• At temperatures below the transfer threshold, no pigment is transferred to

the card.

• If the temperature of an element is too high, the area surrounding the

element may also get hot enough to transfer pigment. This will lead to
reduced resolution, blotching, and ribbon breaks.

• The intensity of the printed pixel is controlled by the length of time that the

pixel’s thermal element is turned on. The longer the pixel is on, the darker
(more intense) the color will be.

CP60 and CP60 Plus Service Manual 2-11

Printhead Settings

A printed card is made up of 1013 discrete vertical (short edge of the card)
columns printed across the length of the card. As each column is printed, the
printhead circuitry activates the necessary pixels to transfer pigment from the
ribbon to the card.

Controlling when and how these pixels heat up is determined by several
parameters: power, base power, and strobe.

Power

In the past, printhead pixels were controlled by varying the voltage to the pixel
element. On the newer generation of printheads, the power to the pixel is
controlled by pulsing the voltage, commonly referred to as Pulse Width
Modulation (PWM). This concept is also known as Duty-Cycle.

The heat of a thermal element on the printhead is controlled by how long it is
turned on versus how long it is turned off. In a sense, the printhead control was
analog but is now digital.

To increase the temperature, or heat, on a single element, it is turned On more
than it is turned Off. The higher the duty-cycle, the hotter the element becomes.
Because the printhead now receives full voltage from the power supply,
swapping the power supply for another power supply will have an impact on
printing intensity. The printer can easily be adjusted to compensate when a new
power supply is required.

Base Power

The Base Power sets the upper limit to the power PWM. In simple terms, this sets
the bandwidth (gamut) of the printing. Increasing the base power darkens the
available colors in the printer, but does not impact the lighter colors. Note that
there is an upper threshold after which increasing the base power has little or no
effect on the final printing. At this point, the image is saturated and cannot be
increased in gamut any further. However, note that this is not the same as
darkening the image in the SmartDriver control panel. This will darken the
whole image, including the lighter areas.

2-12 Theory of Operation

Strobe

If an entire column of thermal elements (pixels) needs to be activated, the overall
power to the printhead will drop due to the current draw. The strobe setting
compensates for this drop in voltage by increasing the time that the pixels are
active.

For example, if all 672 pixels were turned on, it would take longer for each pixel
to reach the threshold temperature than it would if only 300 pixels were turned
on. This would result in a lighter image if more pixels are needed, and a darker
image if only a few pixels are needed.

The Strobe setting is a time factor that compensates for this reduction in power
by increasing the "on-time" for each pixel based on how many pixels are required
for the printed column. The strobe setting value is a baseline number for a
look-up table that the printer calculates for each printed column.

The gray test card is used to detect strobe misadjustment. This test card is
available only to the Advanced User in Diagnostics.

CP60 and CP60 Plus Service Manual 2-13

Magnetic Cards

The information presented in the following section is not required for servicing
the CP60 and CP60 Plus printers but is presented to augment the customer
engineer’s training and knowledge base.

Magnetic Data Principles

This discussion is intended to be a primer for those who are not completely
familiar with the principles of writing data to and reading data from a magnetic
stripe. It covers some advanced theory, but is not intended to be a
comprehensive discussion into the physics of electromagnetism. Those wishing to
delve deeper into the physics of electromagnetism should be able to find
additional information on the Internet or from their local library (Search Topics
include: Electromagnetism, Gauss, Magnetic Stripe).

Magnetism

All magnets, including the Earth, have a North Pole and a South Pole. These
poles always appear in North/South pairs, and there will never be one without
the other. A magnetic field is comprised of Magnetic Lines of Force, or Magnetic
Flux, which travel from North to South between the poles. Even though magnetic
flux is invisible, the effects of these lines can be seen as they interact with
particles of iron. If a piece of paper is placed over a common bar magnet, and
iron filings are sprinkled across the paper, the iron particles will line up in a
fashion similar to the drawing below
stronger the magnetism. From the drawing below, we can see that the magnetic
field is strongest near the poles.

1

. The greater the density of these lines, the

1 This is the same principle used with magnetic stripe developing fluid. The fluid contains magnetic particles in an

evaporative fluid. When the fluid evaporates, the particles align on the strongest magnetic areas.

2-14 Theory of Operation

Magnetic Media

Magnetic media (stripe material) contains small magnetic particles. Before
information is encoded on the stripe, the poles of the magnetic particles are
randomly oriented (top image below). To encode information, the poles of the
individual particles are oriented in the same direction (middle image below). The
effect of having all of the small particles oriented in the same direction is the
same as having one large magnet with a single North pole and single South pole
(bottom image below).

Electrical Current and Magnetism

There is an interrelationship between magnetic fields and electrical current.
When an electrical current moves through a wire, a magnetic field is generated
around the wire

3

current

will be generated (induced) in the wire.

2

. Reciprocally, when a magnetic field moves past a wire, a

Note that in the case of magnetic stripe cards, a static (non-changing) magnetic
field is physically moving past the conductor. This would be analogous to flying
over the mountains in an airplane. The hills and valleys make the distance
between the airplane and the ground increase and decrease, but the landscape
itself does not change.

If the magnetic field (landscape) were changing, the result would be the same,
and induction would occur. What is important is that the magnetic field is either
changing or moving for induction to occur.

2 From Ampere's Law.

3 Mathematically, Faraday's Law of Induction states that a voltage is induced in the conductor. However, for reasons

of symmetry with Ampere's Law, it is common practice in discussion to refer to the energy transfer as "induced
current." This is appropriate as long as the conductor forms a closed circuit and Ohm's Law can be applied.

CP60 and CP60 Plus Service Manual 2-15

Writing Data

To write data to the magnetic material on a card, it is necessary to create a
magnetic field near the stripe. This aligns all of the magnetic particles nearby in
the same orientation (polarity). The Magnetic Write Head contains a small coil of
wire wrapped around a semicircular iron core

4

. (The head coil and iron core are
used to focus and concentrate the magnetic field.) When electrical current passes
through the head coil, a small but concentrated magnetic field is generated across
the open ends of the core. The magnetic stripe on the card is magnetized with the
opposite magnetic polarity from the head. This is shown in the image below.

To change the polarity of the magnetic stripe under the magnetic head, the
polarity of the current in the head coil is reversed. This reverses the magnetic
polarity of the iron core, which in turn reverses the polarity of the magnetic
stripe.

4 Other materials may also be used for magnetic cores.

2-16 Theory of Operation

Reading Data

To read the magnetic information from a card, the magnetic field on the card is
used to generate a current in the magnetic head. This is possible because a
moving magnetic field induces a current (or voltage) in a conductor.

The magnitude of the current is dependant on the rate of change of the magnetic
field passing by the head. The greater the change, the larger the current. A simple
way of understanding this is that current will be induced when the read head
cuts through a line of flux. When the read head is traveling parallel to a flux line,
no current will be induced.

Because the flux density is greatest at the poles of a magnet, the current will also
be greatest as the magnetic pole passes below the head. This is illustrated in the
drawing below. If the magnetic stripe were comprised of a single North-to-South
magnet, no current would be induced in the magnetic head for the majority of
the length of the card.

When two North Poles or two South Poles are adjacent to one another, the
magnetic field is compressed and becomes even more dense. The higher the
density of the magnetic field, the larger the current that is induced in the
magnetic head.

For this reason, magnetic data is comprised of Transition Points where the
polarity of the magnetism reverses, which results in North-to-North or South-to­South polarity.

CP60 and CP60 Plus Service Manual 2-17

Magnetic Data

The method for recording information on a magnetic stripe is called two­frequency, coherent phase encoding (also known as F/2F). Although the name is

complex, the concept is simple: two signals are merged together and written as a
single signal. The significance of this format is that a timing signal is embedded
in the data stream (called self-clocking data). This method allows the data to be
read properly regardless how fast or slow a person swipes the card past a read
head.

The clock signal is evenly spaced pulses that are recorded for the whole length of
the stripe. The binary data is written between each of the clock pulses. These two
signals are merged together into a serial data stream and sent to the magnetic
head as an alternating current of varying frequency.

In the example below, the binary data to be written to the card is “011001.” When
this is merged with alternating clock pulses, the result is “1011111010111.” To
write this merged data string to the magnetic stripe, the polarity of the magnetic
head is reversed when a “1” is in the data stream, and left unchanged when a “0”
is in the data stream.

When this information is read back from the magnetic stripe, the current in the
magnetic head appears as alternating pulses. This is shown as the bottom graph
in the figure above.

2-18 Theory of Operation

Encoding Format

As described in the preceding section, the data on a magnetic stripe is nothing
more than a series of binary 1’s and 0’s. However, for this data to be usable, it is
necessary to know how to extract and interpret the information. By specifying
how information is recorded to the stripe, it can be assured that the read device
will extract and interpret the information correctly.

Bit Density

The lowest level encoding format is the recording density. This is typically
specified as bits per millimeter, or bits per inch. A high bit density will allow
more information to be stored on the magnetic track.

Word Length

Each piece of information written to the magnetic stripe is a binary coded
character. These characters (numeric or alphanumeric) are represented by a
binary number known as a binary word. Typically, these binary words are
between 4 and 8 bits in length.

The number of bits per word is determined by how many possible characters
there are in a character set. The common alphanumeric character set requires 6
bits for the binary character code, but a numeric character set requires only 4 bits
for the character code. Once the number of bits per word has been specified, all
characters in the same data string will have the same number of bits per word.

Record Length

The record length is the total number of binary words (characters) that can be
stored on a magnetic track. Bit density, word length, and the physical length of
the stripe determine the maximum record length.

CP60 and CP60 Plus Service Manual 2-19

Parity Check

A parity check is a method of determining if an error has occurred. This is
accomplished by adding one extra bit to the end of a binary character code. The
purpose of the parity bit is to make the sum of data bits in a binary word either
even or odd. This way, all words throughout the data string will have the same
parity. In the table below, note that the sum of all the bits in each row is an odd
number. This is called odd parity. With even parity, the sum of the rows would be
an even number.

Char

$ 0 0 0 0 1 0 0 1

A 1 1 0 0 0 0 1 3

B 1 1 0 0 0 1 0 3

C 0 1 0 0 0 1 1 3

S 1 1 1 0 0 1 1 5

W 0 1 1 0 1 1 1 5

Z 1 1 1 1 0 1 0 5

Data String

Regardless what type of information is written on a magnetic stripe, there is a
basic layout that is followed. This basic layout is shown below.

Leading

Clock

Pulses

Start

Sentinel

Leading/Trailing Clock Pulses

Parity

Specific Data

Binary Char Code

Bit

5

2

2

4

3

2

2

Sentinel

2

End

Bit

1

2

Sum

0

2

Longitudinal

Redundancy Check

Trailing

Clock

Pulses

The actual information written to a magnetic stripe cannot extend fully to the
edges of the stripe. The main reason for this is because the card reader needs to
synchronize its timing to the speed at which the card is swiped through the
reader. Leading and trailing clock pulses permit the reader to gauge the speed of
the card without losing data. (The timing is continuously updated as the whole
card is read, but the leading and trailing clock pulses provide a starting point
without data loss.)

Specific Data

This is the actual data that personalizes the card. This data can represent a
person’s name, birth date, account number, etc. The actual content of this data is
determined by the card issuer or one of the many international standards. (Refer
to the

Magnetic Stripe Primary Data Standards section for a description of some

common standards.)

2-20 Theory of Operation

Start Sentinel/End Sentinel

4 5

The specific data on a card is bracketed by a Start Sentinel and an End Sentinel.
These are used to identify where valid data begins and ends. These two sentinels
are reserved characters and cannot be used for any other reason on the magnetic
stripe. For this reason, the sentinel characters will not be standard letters or
numeric characters. (Just like any other character written to the card, the
sentinel’s binary word also includes a parity bit.)

Longitudinal Redundancy Check (LRC)

This is a final parity check for the entire data string. Unlike the parity bit
mentioned in the preceding section, the LRC is a complete binary word itself,
with the same number of bits as the specific data characters.

Each bit in the LRC binary word (except its own parity bit) represents a single
parity check for all of the preceding bits in the same position. This can best be
explained by examining the binary data in the tabular form shown below. Each
character’s parity bit makes the horizontal sum
makes the vertical sum

of all the individual bits an even number. (The LRC’s
own parity bit sets the parity for the LRC word in the same manner as it would
for any other character.)

of bits an odd number. The LRC

Name

Start Sentinel 1 0 0 0 1 0 1

Sample Data 1 0 1 0 1 1 1

Sample Data 0 1 0 0 0 1 1

Field Separator 0 1 1 1 1 1 0

Sample Data 1 1 1 0 0 1 1

Sample Data 1 1 1 1 0 1 0

End Sentinel 0 0 1 1 1 1 1

Pre-LRC Sum

LRC

Post-LRC Sum

Parity

Binary Char Code

Bit

5

4

3

2

2

2

2

0 0 1 1 0 0 1

4 6 4 4 6 6

3 4 6 5

1

2

2

Bit

Sum

0

2

3 %

5 7

3 C

5 ^

5 S

5 Z

5 ?

3

Char

CP60 and CP60 Plus Service Manual 2-21

Magnetic Stripe Primary Data Standards

The magnetic stripe on a card can store binary data in any form you wish;
however, to maintain consistency, national and international standards are
followed. A primary data standard is one that specifies how information is
stored on a card. A secondary standard is one that specifies the content of the
information stored on a card.

ISO/IEC 7811 (Parts 2 and 6)

This is the primary standard for recording that most other formats and standards
are based on. This standard dictates how information is written to a card, but
does not describe the content of the information. It covers 2-track and 3-track
magnetic stripe cards, where 1, 2, or 3 tracks may be used.

In the past, this 3-track recording standard was referred to as IAT, which is an
acronym for IATA, ABA, and TTS. This acronym should not be used to describe
a 3-track card, because it describes the “content” not the “technique.” It is more
accurate to describe these tracks as ISO-1, 2, or 3.

Full Name Abbreviated

ISO/IEC 7811 part 2 or 6
Track 1
ISO/IEC 7811 part 2 or 6
Track 2
ISO/IEC 7811 part 2 or 6
Track 3

 Note that this standard permits the use of a single-track recording, but doing

so does not make the recording a JIS Type-II card. That is a completely
different standard, and is discussed below.

AAMVA DL/ID-2000

This is the standard used for U.S. driver’s licenses. It follows the ISO standard
except for some changes in data type and record length. Technically, this is not a
primary standard, but since it modifies some aspects of the primary ISO/IEC
standard, it is treated as though it were a primary standard.

Former

Name

ISO-1 IATA

ISO-2 ABA

ISO-3 TTS

Designation

Saflok and Ving

These are proprietary formats that the printer is capable of encoding, however
the specifics of these formats cannot be published.

2-22 Theory of Operation

Multiple Record Format (SDS)

This is a special format that is used most often by the casino industry. The main
purpose for the change in format is to introduce redundancy into the data to
protect against misreads at the card readers. Because the cards are not intended
to be universal from one provider to another, there is no specific standard
format. Each card issuer can have their own variations on the basic format. Some
of the aspects that may be encountered within this format are shown in the table
below.

Parameter Comments

Number of Records

Number of Start Sentinels

Number of Nulls

Each track is permitted to repeat the primary data
record as many times as the issuer chooses. Each
duplicate record contains its own start and end
sentinels and error checking characters.

Each data record is permitted to repeat the start
and end sentinel any number of times. This is to
ensure that the beginning and end of the record
has been detected.

Between duplicate data records, there can exist
empty, non-recorded space. This separates the
records to ensure that two adjacent records are
not misread as one record.

JIS X 6302 (Type I and Type II Cards)

JIS X 6302 is the Japanese standard for magnetic striped cards and identifies two
distinct card formats.

Type I: A JIS Type I card is a 3-track card. As of the 1998/1999 revision of this standard,

the Type I card standard conforms to the ISO/IEC standard for 3-track cards.
For this reason, Type I cards will not be discussed separately from ISO/IEC
cards. However, note that some card issuers may still be producing cards under
the 1979/1988 version of JIS X 6302. This manual does not cover that standard,
but the system will nonetheless support the format.

Type II: A JIS Type II card is a single-track card, and does not have an ISO/IEC

equivalent. In the past, this type of card has frequently been referred to as
J-Stripe, J-Track, NTT, or simply JIS Type II. (JIS Type II is now preferred.)

CP60 and CP60 Plus Service Manual 2-23

Magnetic Media Locations

The physical location and size of the magnetic stripe on a card follows the
specifications outlined in the two drawings below. The first graphic is for a two
or three track card (ISO/IEC and JIS Type I). (Note that under the ISO and JIS
standards, even if only one of the three tracks is used, the minimum track size
follows this specification.)

2-24 Theory of Operation

Data Track Locations

The positions where data can be recorded on a 3-track stripe are described in the
graphic below. This applies to all three of the aforementioned standards, but
does not apply to a JIS Type II card.

CP60 and CP60 Plus Service Manual 2-25

Summary of Specifications

The preceding sections described where magnetic data can reside on a card. This
section describes the general format of that magnetic data. The following table
summarizes the data specifications for the primary standards.

Parameter

ISO/IEC 7811

JIS Type I

JIS Type II

Track 1 Track 2 Track 3 Single Track

Bit Density 210 75 210 210
Total Length 79 40 107 72
Record

Length

Data Type

Start
Sentinel

End Sentinel ? ? ? DEL
Field

Separator
Word Parity ODD EVEN
LRC Parity EVEN EVEN

76 37 104 69

7-bit
A/N

% ; ; DEL

^ = =

5-bit N 5-bit N

7-bit A/N

N = Numeric character set
A/N = Alphanumeric character set

2-26 Theory of Operation

Character Encoding

@ 0 1

7-bit Alphanumeric Character Set as Defined by ISO/IEC 7811

Note Char Parity

25 24 23 22 2

Space 1 0 0 0 0 0 0
H ! 0 0 0 0 0 0 1
H " 0 0 0 0 0 1 0

R # 1 0 0 0 0 1 1

$ 0 0 0 0 1 0 0

S % 1 0 0 0 1 0 1
H & 1 0 0 0 1 1 0
H ' 0 0 0 0 1 1 1

( 0 0 0 1 0 0 0

) 1 0 0 1 0 0 1
H * 1 0 0 1 0 1 0
H + 0 0 0 1 0 1 1
H , 1 0 0 1 1 0 0

- 0 0 0 1 1 0 1

. 0 0 0 1 1 1 0

/ 1 0 0 1 1 1 1

0 0 0 1 0 0 0 0

1 1 0 1 0 0 0 1

2 1 0 1 0 0 1 0

3 0 0 1 0 0 1 1

4 1 0 1 0 1 0 0

5 0 0 1 0 1 0 1

6 0 0 1 0 1 1 0

7 1 0 1 0 1 1 1

8 1 0 1 1 0 0 0

9 0 0 1 1 0 0 1
H : 0 0 1 1 0 1 0
H ; 1 0 1 1 0 1 1
H < 0 0 1 1 1 0 0
H = 1 0 1 1 1 0 1
H > 1 0 1 1 1 1 0

E ? 0 0 1 1 1 1 1

Code Description

Binary

1

0

2

Note Char Parity

2

H

A 1 1 0 0 0 0 1
B 1 1 0 0 0 1 0
C 0 1 0 0 0 1 1
D 1 1 0 0 1 0 0
E 0 1 0 0 1 0 1
F 0 1 0 0 1 1 0
G 1 1 0 0 1 1 1
H 1 1 0 1 0 0 0
I 0 1 0 1 0 0 1
J 0 1 0 1 0 1 0
K 1 1 0 1 0 1 1
L 0 1 0 1 1 0 0
M 1 1 0 1 1 0 1
N 1 1 0 1 1 1 0
O 0 1 0 1 1 1 1
P 1 1 1 0 0 0 0
Q 0 1 1 0 0 0 1
R 0 1 1 0 0 1 0
S 1 1 1 0 0 1 1
T 0 1 1 0 1 0 0
U 1 1 1 0 1 0 1
V 1 1 1 0 1 1 0
W 0 1 1 0 1 1 1
X 0 1 1 1 0 0 0
Y 1 1 1 1 0 0 1

Z 1 1 1 1 0 1 0
R [ 0 1 1 1 0 1 1
R \ 1 1 1 1 1 0 0
R ] 0 1 1 1 1 0 1
F ^ 0 1 1 1 1 1 0

H _ 1 1 1 1 1 1 1

Binary

5

24 23 22 2

0 0 0 0 0

1

0

2

H

These 14 characters ! " & ' * + , : ; < = > @ _ are reserved for hardware control and
cannot be part of the data content. (These may or may not be used by different
device manufacturers.)

R Additional reserved characters.
S,E,F Reserved characters for Start Sentinel, End Sentinel, and Field Separator

CP60 and CP60 Plus Service Manual 2-27

5-bit Numeric Character Set as Defined by ISO/IEC 7811

0 0 0 0

0 0 0 1

0 0 1 0

0 0 1 1

0 1 0 0

0 1 0 1

0 1 1 0

0 1 1 1

1 0 0 0

1 0 0 1

1 1 0 1 0

0 1 0 1 1

1 1 1 0 0

0 1 1 0 1

0 1 1 1 0

1 1 1 1 1

Note Char Parity

3

2

Binary

2

2

2

1

0

2
0 1
1 0
2 0
3 1
4 0
5 1
6 1
7 0
8 0
9 1

H :

S ;

H <

F =

H >

E ?

Code Description
H These characters are used to control the hardware and cannot be part of the data

content. (These may or may not be used by different device manufacturers.)

S,E,F Reserved characters for Start Sentinel, End Sentinel, and Field Separator

2-28 Theory of Operation

Smart Card Technology

The information presented in the following section is not required for servicing
the CP60 and CP60 Plus printers but is presented to augment the customer
engineer’s training and knowledge base.

The underlying concept of smart cards is fairly simple: A chip is embedded
inside a plastic card—the chip may be microprocessor based, or a simple
memory device. The capabilities of a smart card, however, are a little more
complex. They can be as simple as a means of identification, or as complex as a
financial database.

 Although it is not a mandated parameter (and some overlap may exist), all

smart cards have a unique identifier which identifies the card type, the
manufacturer, and the specific card. Most card manufacturers present this
unique identifier as part of the “answer to reset” which is discussed below.
Even if the card protocol permits it, this identifier should not be altered.

There are two basic types of smart cards;

Smart Cards

Contact smart cards connect to the external interface via a set of eight electrical
contact points. Non-contact smart cards interact with the external interface
through a principle called inductive coupling. There are many variations on the
basics of smart cards, including proprietary designs. The discussion below will
be limited to discussing smart card architecture as defined under ISO/IEC 7816
(1-10) and ISO/IEC 14443 (1-4).

(or a combination of both types, as shown in the graphic below).

Contact Smart Cards and Non-Contact

About This Graphic

The photograph above is an actual transparent card with magnetic stripe, a
contact-type processor, a 125 kHz non-contact type processor, and a 13.56 MHz
non-contact type processor. This graphic (without annotations) was provided by

CP60 and CP60 Plus Service Manual 2-29

HID Corporation and is shown here for educational purposes. The printed image
on the card is an artist’s rendering.

Contact Smart Cards

A contact smart card needs to connect to an external interface to provide the
processor with power and set up serial communication. The eight terminal
contacts are described in the table below. (Note that two contacts are reserved for
future use.)

There are two classes of contact smart cards: Type-A cards operate at 5 volts, and
Type-B cards operate at 3 volts.

Smart Card Contacts

No. Name Purpose No. Name

C1 VCC Supply voltage (3 or 5 V) C5 GND Ground

C2 RST Resets the processor C6 VPP Variable voltage for programming

C3 CLK Provides the timing (clock) signal C7 I/O Data line

C4 N/A Reserved for future use C8 N/A Reserved for future use

Purpose

Initiating Communication

When the card is inserted into a reader, it needs to be initialized and
communication protocols defined. Note that steps 1 through

6 all occur while the

card is forced to remain in a reset state (no activity).

1. The card reader senses that the card is in position under the contacts. In most

cases, this is a mechanical switch that detects the presence of a card (any type
of card).

2. The Reset line (C2) is held low. (The active-low reset forces the card to remain

in the reset state until released.)

3. Power is applied to the Vcc and Gnd contacts.

• A Type-A reader will apply 5 volts to the card. (Type-B cards must accept

the overvoltage, but are not allowed to respond.)

• A Type-B reader will apply 3 volts to the card.

• A Type-A/B reader will first apply 3 volts to the card. If no response is

received, it removes power, waits, and reapplies power at 5 volts.

4. The I/O line is held in the Receive mode (high impedance).

5. If the card is a Type-A card, the programming voltage (Vpp) is placed in the

pause value, which is equal to Vcc.

2-30 Theory of Operation

6. The clock signal is activated.

7. The reader releases the Reset by bringing it to a high voltage.

8. The card then issues its Answer To Reset (ATR). The ATR is a hexadecimal

string up to 32 characters and contains:

• The format of the communication

• Permissible baud rates

• Parameters of the circuitry in the card

• Required programming voltage on Vpp

• The make and model of the card

• Other information the manufacturer chooses

9. With communication parameters known, the interface can begin to

communicate with the card.

10. Serial communication across the I/O line commences.

11. If necessary, the voltage on Vpp is altered, and information can be written to

the card.

CP60 and CP60 Plus Service Manual 2-31

Non-Contact Smart Cards

Types of Cards

Whenever a new technology is developed by multiple manufactures, there tends
to be multiple protocols for the device. For example, during the 1980’s there were
as many personal computer types as there were manufacturers. In time, the
number of computer types dwindled as designs were standardized. The same is
true with smart card technology, except there still exists many off-standard card
types.

The primary information in this section is geared toward the ISO/IEC 14443
Type-A and Type-B cards. However, recognition should be given to a few other
formats that are still widely used.

The photograph on page
and the standardized 13.56 MHz antenna. This card is used to help facilitate the
transfer from the 125 kHz system to the common 13.56 MHz system. The lower
frequency format is not supported by any of the ISO/IEC standards. These low
frequency cards are frequently referred to as Wiegand cards, and generally only
provide a unique ID when energized.

The FeliCa card format was developed by the Sony Corp. and is similar to the
standard Type-A card, except it uses 212 kb/s data rate instead of the
standardized 106 kb/s data rate. There are also some variations on the
modulation protocol.

The Mifare card is fairly common because it is based on an open standard used
by many manufacturers. According to the Phillips Corporation this format is
fully compliant with the ISO/IEC 14443-A standard.

Communication

Communication with non-contact smart cards is slightly more complicated
because there is no physical connection between the interface and the card. The
card reader sends out a radio frequency broadcast, which not only provides
power to the card, but also establishes communication. This is called inductive
coupling, and is similar to the function of a transformer.

2-29 shows a combicard with both a 125kHz antenna

Inductive coupling works the same way as a transformer does, except that the
two coils are farther apart (called loosely coupled). The operating field of the
card reader has a frequency of 13.56 MHz. This is called the carrier frequency.

2-32 Theory of Operation

Signal Modulation

The concept of signal modulation arises from the relationship between frequency
and required antenna size. Namely, the antenna needs to be on the same order as
the wavelength of the signal. The lower the frequency--the longer the
wavelength--the larger the antenna required to transmit or receive the signal.

An audio signal for example, would require an antenna of approximately
300 Km in length. This wouldn’t fit very well in the trunk of your car for
listening to your favorite music, and a boom box would be totally out of the
question.

Instead, the lower frequency (the data signal) is combined with a higher
frequency (the carrier). The higher frequency is more easily transmitted and
received. Combining two signals together is called modulation.

There are many different types of signal modulation, but they all boil down to
three basic parameters—altering the amplitude, frequency and/or phase of the
carrier signal.

You are probably familiar with the terms Amplitude Modulation and Frequency
Modulation because these are used by most consumer radios. We know them as
AM and FM radios. Because of their nature, digital signals can utilize many
variations on these basic modulation schemes.

The following diagrams show a couple of the basic modulation schemes as well
as the variants used by digital signals. The AM and FM modulation diagrams are
shown with analog data signals, but phase-shift modulation is easiest to show
with a digital signal.

CP60 and CP60 Plus Service Manual 2-33

Signal Modulation Summary Diagram

Amplitude Modulation:

The magnitude (height) of the
carrier signal is varied according
to the height of the data signal.
This is what is used in AM radio.

Note: The blue data signal is
shown here for clarity. It is not
actually present in the actual
modulated signal.

Frequency Modulation:

The frequency of the carrier
signal is varied according to the
height of the data signal. This is
what is used in FM radio.

Note: The modulated frequency
remains close to the carrier
frequency, but the drawing is
exaggerated for clarity.

Amplitude Shift Keying:

This is a digital variant on the
AM modulation. It comes in two
common forms: 100% and 10%.

Note: 10% modulation
(ASK10%) means the carrier is
modulated by only 10%. 100%
modulation means that the
carrier signal is fully modulated.
Both of these variants are shown
to the right.

Load Modulation:
The card switches the resistance
of its antenna, which alters the
current in the transmitter.
Note: This is a complex topic
and will be discussed in greater
detail later.

Phase Modulation:
A data transition is signified by

a shift in the signal’s phase. In
this case, the phase is shifted 180
degrees by inverting the signal.

2-34 Theory of Operation

Reader to Card Communication

The reader communicates with the card by sending an amplitude modulated
signal at 13.56 MHz. The modulation variant depends on the class of card. A
Type-A card uses 100% Amplitude Shift Keying (ASK100%). A Type-B card uses
ASK10% modulation. These two variants are shown in the graphics above.

The benefit of ASK100 is that it is more immune to noise and errors because there
is a strong difference in amplitude at bit transitions. The drawback to this is that
the card doesn’t receive power during the low cycle of the modulation. The card
doesn’t turn off during these times, but the effect is that less overall (average)
power is being transmitted to the card.

ASK10 provides more power to the card because the modulated signal remains
within 10% of the maximum amplitude. The tradeoff is that the difference
between high and low amplitudes is minimal. This can lead to slightly more data
transmission errors.

CP60 and CP60 Plus Service Manual 2-35

Card to Reader Communication

The communication method back to the reader is elegantly simple, but a little
more complicated to understand. It is a passive communication because the card
doesn’t really send a signal back to the reader—it modifies the signal emanating
from the reader. This is called Load Modulation, and is based on a loosely coupled
transformer (two coils separated by distance and without an iron core).

A normal transformer is frequently thought of as a method for changing one
voltage to another, such as a computer power supply that takes 120 volts and
reduces it to 12 volts. While the voltage decreases across the transformer shown
below, the current increases proportionally. The value of the current in the
secondary winding is dependant on the load being powered. Consequently, the
current in the primary winding is inversely proportional to the load on the
secondary winding. As a result, if the load is varying with time, the circuitry on
the primary side of the transformer can detect the change in current draw.

When the card engages and disengages (switches) resistance in its own antenna,
the reader detects this change by examining the current draw within its antenna.

Type-A Card Modulation

The type of return modulation from the card to the reader differs with the two
classes of cards (Type-A and Type-B). Type-A cards use a simple On-Off-Keying
modulation (OOK). This is the binary equivalent of amplitude modulation. The
card switches the resistance seen by the card reader at a frequency of 1/16

th

the
frequency of the carrier signal. This means that during a modulation period, the
carrier signal is attenuated every eight cycles. The data stream is even slower
than this (1/128

th

of the carrier frequency) so each data bit will have several

transitions from modulation to non-modulation of the carrier.

2-36 Theory of Operation

Type-B Card Modulation

A Type-B card uses a combination of amplitude modulation and phase
modulation, called Binary Phase Shift Keying (BPSK). This method sends a
constant subcarrier frequency of 847 kHz using amplitude modulation, but shifts
the phase of the subcarrier by 180 degrees (inverted) at each data transition. In
other words, the carrier is always modulated with the subcarrier, but during data
transitions, the subcarrier signal is altered (inverted). The subcarrier is permitted
to invert only at its own transition points (which is why the frequencies are even
multiples of each other).

CP60 and CP60 Plus Service Manual 2-37



2-38 Theory of Operation

Chapter 3: Routine Maintenance

This chapter provides routine maintenance procedures for the CP60
and CP60 Plus card printers.

Required Tools and Supplies______________________________________________________
Routine Maintenance Procedure _________________________________________________ 3-3

Clean the Interior of the Printer ________________________________________________________3-3
Mechanical Inspection________________________________________________________________3-5
Run the Cleaning Card _______________________________________________________________3-8
Visual Inspection for Card Quality______________________________________________________3-8

3-2

CP60 and CP60 Plus Service Manual 3-1

Required Tools and Supplies

The following tools and supplies are needed for routine maintenance procedures.

Description Part Number

Compressed air (canned) TUL001-018
General purpose, non-abrasive cleaner Any
Lint-free cloth TUL001-020
Isopropanol cleaning pen 557492-001
Isopropanol cleaning card 552141-001
Cleaning sleeve 549288-002
Molykote DX grease 807421-001

 Cleaners used on the printer’s exterior should not contain any abrasives, oils,

fragrances, antibacterial agents, solvents, or isopropanol. Do not use soft­scrubbing cleansers, products with petroleum, or products with mineral,
pine, or lemon oil.

CAUTION: Use only canned compressed air on this printer. Do not use

facility air as it will have trace amounts of oil and moisture that will
accumulate on surfaces and possibly damage electronic components.

3-2 Routine Maintenance

Routine Maintenance Procedure

The entire routine maintenance procedure should be completed each time the
printer is serviced. This will help to extend the life of the printer.

 Refer to chapter 6 of this manual for removal and replacement procedures.

CAUTION: Do not spray or pour cleaner directly on or into any electrical

device.

Clean the Interior of the Printer

1. Unplug the printer.

2. Remove the printer enclosures.

3. Remove the chassis from the base enclosure.

4. Using canned compressed air:

• Blow out any debris near the sensors

• Blow out any dust from the control board and other surfaces of the base.

• Blow out any dust and debris from the underside of the chassis. Make

sure to include the cam sensor.

5. If the grease on the platen roller shaft has accumulated dirt and debris, wipe

off the grease with a dry cloth, and re-grease the surfaces with Molykote DX
grease.

CP60 and CP60 Plus Service Manual 3-3

6. Use a cloth dampened with water to clean the sensor reflector on the

printhead cartridge.

7. Using an isopropanol cleaning pen, clean the thermal printhead by rubbing

the isopropanol tip over the printing portion of the printhead.

Sp35707s

3-4 Routine Maintenance

Mechanical Inspection

Inspect the following components and replace as needed.

1. Check the fixed cleaning rollers to make sure they are not nicked or gouged.

Replace them if they are dry.

2. Check all other rollers for wear or damage.

3. Check springs to verify they are in position and not damaged.

4. Inspect the transport system:

• Inspect the timing belt for wear and missing teeth.

• Inspect the three or four idler pulleys and make sure they are securely

seated.

• Inspect the drive pulleys for wear and broken teeth.

• Inspect the platen roller gear and pulley for wear and broken teeth.

5. Inspect the ribbon drive gear for wear and broken teeth. Make sure it is

securely seated on the motor shaft.

CP60 and CP60 Plus Service Manual 3-5

6. Inspect the ribbon cartridge.

• Inspect the spindle gear for wear and missing teeth.

• If the cassette has a plastic encoder wheel, inspect it for scratches and

missing lines.

• Check the spindles for proper movement, and that the clutches are

providing a slight drag.

7. Inspect the print cam gear and motor gear on the underside of the printer for

wear and broken teeth.

8. Inspect the cam lobes for wear or grooves.

3-6 Routine Maintenance

9. Reassemble the printer.

10. Wipe the exterior of the printer with a cloth dampened with a non-abrasive,

general purpose cleaning solution. Let the printer dry before connecting
power.

CP60 and CP60 Plus Service Manual 3-7

Run the Cleaning Card

1. Connect the printer to the computer and turn on the power.

2. Remove the cleaning roller, print ribbon, and any cards from the input

hopper.

3. Open the Printer Toolbox Dialog, and click on Clean Printer.

4. If additional cleaning is required, wipe the rollers with the isopropanol

cleaning pen or 99% isopropanol.

• The transport rollers can be rotated by turning the manual advance knob.

• The pick roller can be rotated by reaching in through the output hopper.

• Access the lower cleaning roller by removing the cleaner rocker assembly.

• Access the front drive roller by removing the front roller rocker arm.

• Access the magnetic stripe encoder roller by removing the magnetic

encoder roller rocker assembly.

5. Put a new cleaning sleeve on the cleaning spindle, and replace the roller.

Visual Inspection for Card Quality

1. Print an internal test card by pressing and holding the Ready button on the

printer and connecting power.

2. Continue holding the Ready button until a 3-tone signal is heard.

3. Release the Ready button. The printer begins printing the test card.

4. Inspect the test card for obvious flaws in quality. If you find problems, refer

to chapter 4, Troubleshooting.



3-8 Routine Maintenance

Chapter 4: Troubleshooting

This chapter provides information for troubleshooting problems with
the CP60 and CP60 Plus card printers.

General Notes___________________________________________________________________ 4-2
General Troubleshooting Procedures _____________________________________________ 4-2

Non-Clearing Repetitive Messages_____________________________________________________4-2
Troubleshooting Sensors_______________________________________________________________4-3
Troubleshooting Motors _______________________________________________________________4-4

Testing General DC Motors ________________________________________________________4-4
Testing the Ribbon and Pick Motors_________________________________________________4-5
Testing the Cam Motor ____________________________________________________________4-5
Testing the Printhead Fan__________________________________________________________4-6
Testing Transport and Duplex Motors________________________________________________4-6

Troubleshooting Other Devic es ________________________________________________________4-6

Testing the Smart Card Solenoid____________________________________________________4-6
Testing the Duplex Clutch__________________________________________________________4-7
Diagnosing the Duplex Interface Board_____________________________________________4-8
Diagnosing the Ribbon RFID Antenna_______________________________________________4-8

Performance Problems___________________________________________________________ 4-9

Printer Initialization Errors_______________________________________________________________4-9
Card Jams at Card Input_____________________________________________________________4-10
Card Stalls at Output Stacker_________________________________________________________4-10
Card Jams in Printing Area ___________________________________________________________4-11
Ribbon Break Errors __________________________________________________________________4-12

Error Codes ____________________________________________________________________ 4-13

Error Code Prefixes___________________________________________________________________4-13
General Notes_______________________________________________________________________4-13
Driver API (AP)_______________________________________________________________________4-14
Printer Driver Errors (DR)_______________________________________________________________4-14
Input Errors (IS)_______________________________________________________________________4-17
Duplex Module Errors (DM) ___________________________________________________________4-17
System Errors (SY) ____________________________________________________________________4-18
Magnetic Stripe Errors (MS) ___________________________________________________________4-19
Print Errors (PR)_______________________________________________________________________4-24
Smart Card Errors (SC)________________________________________________________________4-26

CP60 and CP60 Plus Service Manual 4-1

General Notes

 The CP Series Info Central help file contains a great deal of information for

troubleshooting the system--such as print quality and software
communication problems.

• To open Info Central, click on the icon installed to the desktop when the

SmartDriver was installed on the computer.

• If Info Central was not installed, insert the SmartDriver CD, click on User

Information and then CP Series Info Central and e-Guide to install it.

General Troubleshooting Procedures

CAUTION: This section is intended only for a fully trained technician.

Performing these procedures in an inappropriate manner will damage the
printer. Even a trained technician should use care in applying these
procedures to avoid permanent damage to the printer.

The following procedures are intended to be a rough guideline for isolating the
cause of a failure. These scenarios do not cover every aspect of the devices, but
should provide enough information to isolate the root cause of a failure.

Many of these procedures assume a familiarity with the printer’s diagnostic
software. For brevity, details about the diagnostic software are not discussed
unless required. For further information about Diagnostics, refer to chapter 5 of
this manual.

CAUTION: Unless instructed otherwise, always unplug the printer before

connecting or disconnecting any electrical device from any circuit board.

Non-Clearing Repetitive Messages

If the printer encounters an error that will not allow it to begin production,
clearing the error message may result in the printer continuing to test for the
same error condition. This will result in a repetitive error message which
prevents the customer engineer from performing diagnostic routines to
troubleshoot the error.

Some examples of this type of situation may include a failed duplex motor, cam
motor, card input sensor, duplex sensor, etc.

When the error message is displayed and the printer beeps, do not clear the error
message from the computer's screen. Instead, hold the Ready Button in until the
Ready Light turns red and the printer beeps once more (about 10 seconds). The
printer will clear its errors, but will not reinitialize. The printer ignores the error
until a task is performed to reveal the error again. During the course of your
investigation, you may need to repeat this procedure.

4-2 Troubleshooting

Troubleshooting Sensors

This procedure is used to determine if a sensor has failed or if the main control
board is not seeing the sensor properly. The first step in troubleshooting a sensor
is to determine if the sensor is toggling from an active state to an inactive state as
a physical condition changes.

1. Verify that the sensor is fully plugged in to the control board. In some cases,

an unplugged sensor will be displayed as “active” in the Diagnostics
window.

2. Using Diagnostics, observe the sensor status indicator as the sensor is

blocked and unblocked.

• To test the ribbon index sensor, remove the ribbon cartridge, and open

and close the swingarm. (Also verify that the reflector is in position on
the printhead).

• To test the magnetic stripe registration sensor, slide a card between the

sensor and the reflector on the rocker arm.

• Because the ribbon motion sensor has two channels, the only way to

verify that both channels are functioning is with a volt meter. Use the test
points in the figure below to test the sensor.

3. Unplug the printer and swap the sensor with another sensor:

 You cannot swap the ribbon motion sensor with any other sensor. It is not

compatible with any other sensor.

• Because this is a test of the sensor, the original sensor does not need to be

removed. Simply unplug the original sensor from the control board and
plug in a replacement sensor.

• If a spare sensor is not available, you can use an adjacent sensor from

within the printer. (Except for the ribbon motion sensor, all sensors are
electrically compatible.)

• The sensor does not need to be the same type. For example, a

transmissive sensor can be used in place of a reflective sensor. (The
transmissive sensor is easier to block and unblock.)

4. If the replacement sensor functions, then the original sensor is defective.

Verify this by reconnecting the original sensor.

5. If the replacement sensor is non-functional and other sensors in the printer

are observed to be functional, then the main control board is defective. (If
none of the sensors are functional, you may have a communication problem
between the printer and Diagnostics.)

CP60 and CP60 Plus Service Manual 4-3

Troubleshooting Motors

The best way to determine if a motor has failed versus a main control board
failure, is to swap the motor with a similar motor. If a motor has failed, then a
replacement motor should function. Conversely, if the motor’s driver has failed,
then a replacement motor will not function either.

CAUTION: This is intended to be a limited test using Diagnostics to verify if

a motor turns or not. Do not attempt to operate the printer with motors
swapped out. Limit your test to short periods of time.

Testing General DC Motors

• The ribbon, pick, and cam motors are all driven from the same motor driver

chip (integrated circuit). If all three motors have failed, the main control
board is faulty and needs to be replaced.

• If a motor is drawing too much power from the motor driver IC, an LED will

be illuminated to indicate an over-current condition.

• Once the LED has been turned on, it can be reset only by unplugging the

printer.

• If operating a specific motor (but not the other two) results in this LED

being turned on, the likely cause is that the motor has failed.

• If the LED turns on regardless which motor is operating, then it is more

likely that the main control board is faulty.

4-4 Troubleshooting

Testing the Ribbon and Pick Motors

Because the ribbon and pick motors are identical, swapping the two motors can
isolate whether the motor is faulty or the control board is faulty.

1. Remove the wires from both motors.

2. Take the two wires from the operable motor and connect them to the motor

to be tested. (The pick motor is shown below for reference.)

3. Using Diagnostics, operate the motor. (Note that the motor you select in

Diagnostics is the opposite of the one you are actually testing. If in doubt,
operate both motors from Diagnostics.)

Testing the Cam Motor

Use care with this procedure. Even though the motors are different, their
controlling circuitry is similar. The connectors are not compatible, but can be
interchanged for testing purposes only.

1. Unplug the DC motor harness (ribbon and pick motors).

2. Connect the cam motor to one side of the DC motor connector as shown

below. (Note that you will receive a repetitive error (see page
printer is powered up.)

• Connect the cam motor to either pick or ribbon motor positions. Note that

the motor connector does not fit properly in the socket, but it fits enough
for testing purposes.

3. Using the motor tests diagnostics, operate the ribbon or pick motor and see if

the cam motor rotates.

4-2) when the

CP60 and CP60 Plus Service Manual 4-5

Testing the Printhead Fan

To test the printhead fan, it can be connected to the cam motor’s connection.
These two motors are not compatible, but the driver circuitry for the cam motor
will operate the fan.

CAUTION: You cannot connect the cam motor into the fan’s connector. The

circuitry of the control board will be damaged.

Testing Transport and Duplex Motors

The two stepper motors cannot be tested using the methods presented above.
The only reliable way of verifying if the motor is non-functional is to replace the
motor with another identical motor.

Troubleshooting Other Devices

Testing the Smart Card Solenoid

The driving circuitry for the smart card solenoid is located on the smart card
daughter board. A power transistor on the daughter board amplifies the signal
going to the solenoid. If the solenoid is not receiving a signal, the daughter board
is the likely cause. To verify that the solenoid itself is functioning, plug it into the
cam motor’s connector.

CAUTION: Do not attempt to connect the solenoid into the printhead fan’s

connector, as this may damage the fan’s driving circuitry.

4-6 Troubleshooting

Testing the Duplex Clutch

CAUTION: Connecting or disconnecting the duplex interface cable from the

main control board with the printer powered may result in immediate
damage to the main control board. Never make modifications to the interface
board with the printer powered.

The driving circuitry for the duplex clutch is located on the duplex interface
board. If the duplex clutch is not receiving a signal, the most likely cause is the
interface board or the cable leading to the main control board.

From an electrical standpoint, the duplex clutch is similar to a solenoid. When
the clutch is energized, it will lock the center shaft of the duplex flipper with the
main drive gear of the duplex transport. Testing the clutch will require some
physical involvement with the printer (manually rotating the flipper).

1. Manually rotate the duplex flipper to determine which direction the flipper is

supposed to operate.

 The flipper should rotate in only one direction. If it can be rotated in both

directions, the spring is damaged and needs to be replaced.

2. With the printer powered off, remove the duplex clutch cable from the

interface board and connect it to the cam motor connector. (Note that you
will receive a repetitive error (see page

3. In Diagnostics, set the motor test duration to 3 seconds, and activate the cam

motor circuit.

A. While the Diagnostics program energizes the cam motor circuit, manually

rotate the duplex flipper in the same direction determined in the step
above.

• When the clutch is relaxed, the main duplex gear will not rotate.

• When the clutch is energized, the main duplex gear will rotate as you

rotate the flipper.

B. After Diagnostics releases the cam motor circuit, you should notice that

the main duplex gear rotates freely from the rotation of the flipper.

• If you did not observe the main duplex gear rotating as you rotated

the flipper, then it is likely that the clutch is faulty.

• If the duplex gear did rotate, then the most likely cause is a faulty

interface board. The secondary cause is a faulty duplex clutch.

4-2) when the printer is powered up.)

CP60 and CP60 Plus Service Manual 4-7

Diagnosing the Duplex Interface Board

CAUTION: Connecting or disconnecting the duplex interface cable from the

main control board with the printer powered may result in immediate
damage to the main control board. Never make modifications to the interface
board with the printer powered.

Whenever a problem arises that is related to the duplex module, the first thing to
check is the cable between the duplex interface board and the main control
board.

All of the duplex sensors pass directly through the duplex interface board
without intervention, so if a sensor is non-functional, the most likely cause is the
cable between the interface board and the main control board.

The interface board contains driver circuitry for the duplex clutch and the duplex
motor. If either of these devices aren’t working yet the device itself is not the
cause, the interface board is likely at fault.

Diagnosing the Ribbon RFID Antenna

The circuit board for the RFID antenna is very simple and not prone to failure. If
a failure exists in identifying a ribbon, the most likely cause is with the ribbon
cartridge's ID tag. This is best tested by replacing the supply spool with a new
spool.

If the printer cannot read any ID tag, first check the cable leading to the main
control board. If the cable is connected properly, then the main control board is
likely at fault.

4-8 Troubleshooting

Performance Problems

Printer Initialization Errors

Symptom Comments

The printer initializes but reports a
card stuck in the transport, and
the transport runs more than
expected.

The printer initializes but reports a
card stuck in the duplex.

The printer initializes but reports a
broken print ribbon.

The printer initializes and the
ribbon is advanced, but the
printer reports that the index
mark could not be found.

Frequent time-out errors occur at
the beginning of printing.

The printer continually reports a
card jam at the smart card
module, but no card is present.

• Check the operation of the card input sensor using the
sensor screen in Printer Diagnostics. If the sensor is always
blocked, it is either disconnected or not fully sea ted
(obscured by part of the chassis).

• Check the operation of the magnetic stripe registration
sensor using the sensor screen in Printer Diagnostics. If the
sensor is always active (non-reflecting):

• The sensor may be disconnected.

• The sensor may not be seated (doesn't reflect off of

rocker).

• The rocker assembly may be stuck in an elevated
position.

• The reflective pad on the rocker may be missing.

• The sensor has failed.

• Check the operation of the duplex entry sensor using the

sensor screen in Printer Diagnostics. If the sensor is always
blocked, it is either disconnected or not fully sea ted
(obscured by part of the chassis).

• Verify that a cartridge is installed.

• Check the encoder wheel for damage.

• Make sure the ribbon motion sensor is connected and

functioning.

Remove the ribbon and close the cover. Check the sensor
setting in Diagnostics. If the sensor is not active:

• Make sure the reflective tape is present on the printhead.

• Make sure the sensor is plugged in.

• Replace the sensor.

If there are other USB devices on th e same computer, they
may interfere with timely communication with the printer.
Specifically look for the following:

• Is the card creation program saving its file or database to
a USB device?

• USB mass storage devices, where some program
application is set to auto-save to the device.

• A program application that is using or referencing a USB
device on a regular basis.

The smart card contact contains a small mechanical switch.
The switch contacts may be stuck.

CP60 and CP60 Plus Service Manual 4-9

Card Jams at Card Input

Symptom Comments

A card is not picked from the
input hopper.

The card is picked but stalls at
the cleaning rollers.

A card is picked and appears to
be properly positioned, but the
error is still reported.

• Cl ean th e prin ter.

• Use graphic quality cards.

• Fan cards properly.

• Inspect the pick roller for buildup or debris.

• Inspect the card gate to make sure it is securely fastened.

• Inspect the card stock for burrs and excessive static

buildup.

• Inspect the pick roller and motor function.

• Cl ean th e prin ter.

• Inspect the cleaning rollers for excessive debris.

• T ransport not workin g.

• Insp ec t the cleani ng rocker assembly springs to make sure

they are tensioning the rocker assembly.

• Check for double card pick.

• Cl ean the card input sensor.

• Check the position of the card input sensor and make sure

it is firmly seated.

• Check the operation of the card input sensor using the
sensor screen in Printer Diagnostics.

• If the sensor is always blocked, it is either disconnected, or
not fully seated (obscured by part of the chassis).

• If the sensor never blocks, either the cable has a short
circuit, or the sensor is not seated at all (outside of the card
track).

Card Stalls at Output Stacker

Symptom Comments

Completed cards frequently fail
to drop into the card output
stacker.

4-10 Troubleshooting

• Cl ean th e prin ter.

• This situation is more likely to occur with thinner cards or

cards printed on one side only.

• Reduce static in the area of the printer by increasing the
relative humidity.

• Use thicker cards.

• Empty output tray often.

• Make sure the static brushes are installed.

Card Jams in Printing Area

Symptom Comments

Card stops prior to reaching the
platen roller.

Card stops under the printhead. • Two cards were picked and one is in the back of the

Card stops past the printhead. • Inspect the rear rocker arm assembly and springs for

• Cl ean th e prin ter.

• Increase the card registration distance.

• Check the front rocker assembly springs for damage.

• Check the front card guide and spring for damage.

• Check the position of the sensors and make sure they are

firmly inserted into the printer.

transport.

• If using a monochrome ribbon, make sure an CP Series print
ribbon is installed. Other ribbons are not designed for the
increase in printhead heat.

• Inspect the card for improper print ribbon panel
placement. Printing with the wrong panel can cause the
ribbon to adhere to the card.

• Decrease the printing brightness setting.

• Inspect the card guide and rocker assembly springs for

placement and damage.

placement and damage.

• Insp ec t the magn etic str i pe rocker arm and springs for
placement and damage.

• Make sure the magnetic stripe head is firmly seated.

• Inspect the rear card guide and spring for damage.

CP60 and CP60 Plus Service Manual 4-11

Ribbon Break Errors

Symptom Comments

Ribbon did not break, but the
error is reported.

The ribbon frequently breaks. • Check the Card Registration Offset.

• Cl ean the printhead. It may be preventing the ribbon from
advancing.

• Check the ribbon encoder wheel. Verify that it is
positioned in the sensor and is not damaged.

• Check the ribbon motion sensor cable to make sure it is
connected.

• Ch eck th e sensor to make sure i t is functional and correctly
aligned.

• Check the ribbon motor and make sure it is functional.

• Check the ribbon motor gear and take-up spool gear for

damage or broken teeth.

• Check the ribbon cartridge clutch.

• Ch eck tha t the ribbon is attached to the take- up ribbon

core.

• Check to see that t he ribbon is not sticking to the card.

• Adjust the image trimming farther from the edge of the

card.

• Make sure an CP Series ribbon is installed.

• Make sure the printing intensity is not too dark. On an

edge-to-edge image when the leading edge of the image
uses 100% of a color (Y, M, or C), the ribbon may get
burned if the card is not fully under the printhead to absorb
the heat.

• Check for burrs on the edges of the cards.

• Make sure the cards being used are not already printed.

4-12 Troubleshooting

Error Codes

When an unexpected or undesired event occurs, the printer and/or software will
generate an error code to be displayed on the monitor. Many times the error code
is intended to be informational to instruct the operator to perform a required or
routine task. Other times the error code is the result of a non-routine event that
indicates a more serious problem with the system.

Error Code Prefixes

The error messages use the following prefixes to indicate the source of the
problem:

Driver API AP-008xx
Printer Driver Errors DR-009xx
Input Errors IS-012xx
Duplex Errors DM-007xx
System Errors SY-013xx
Magnetic Stripe Errors MS-014xx
Print Errors PR-017xx
Smart Card Errors SC-018xx

General Notes

This section does not instruct the user on how to handle routine errors. The
solutions presented are for repetitive errors. For example, a simple card jam can
occur periodically without a specific cause. However, a repetitive card jam
would indicate a problem with the printer.

 In the tables below, the name of the error handling procedure call is included

under the symptom of the error. This procedure name is never displayed, but
it is included here to provide additional information about the specific error.
For example, the procedure name called when a card is lost in the duplex is,
(2 ERR_FLP_CARD_LOST).

 There is a significant difference between a card being lost versus stuck (or

jammed). A lost card means it was not seen by a sensor. A jammed card
means the sensor never cleared. These two distinctions can be helpful when
determining the cause of an error. For example, if the printer is reporting a
jammed card but the card is not located under the sensor, then the first place
to begin troubleshooting is with the sensor (it is possibly unplugged).

CP60 and CP60 Plus Service Manual 4-13

Driver API (AP)

Error

Code

AP 00800
AP 00801
AP 00802

AP 00804
AP 00805
AP 00806

AP 00808 The application used a Datacard

AP 00809 Internal Datacard printer API error. Contact the print application developer.
AP 00810 The application used a Datacard

AP 00811 The application sent a value that is

AP 00812 The application sent a value that is

AP 00813 A printer error occurred while picking

AP 00814 A timeout error occurred while

AP 00815
through
AP 00825

Data includes too many characters
for the selected track format
(tracks 1,2,&3). Check the data
entered or the format selected.

Data includes a character not
allowed for the selected track format
(tracks 1,2,&3). Check the data
entered or the format selected.

printer function with a printer other
than the Datacard printer.

printer function out of the proper
sequence.

not consistent with current settings.

not supported by the Data card
printer API.

a card.

picking a card.

Custom magnetic stripe API
messages

Message text Comments

Verify the data is correct for the selected track,
and resubmit the card for printing.

Verify the data is correct for the selected track,
and resubmit the card for printing.

Select the CP60 or CP60 Plus printer.

Contact the print application developer.

Contact the print application developer.

Contact the print application developer.

Inspect the card pick system.

Check the communication cables.
Verify that another USB device is not interfering

with communication.

Printer Driver Errors (DR)

Error

Code

DR 00901 The printer is not responding. Check

the printer and USB cable
connections.

DR 00902 The printer is paused. Click OK to

continue printing.

4-14 Troubleshooting

Message text Comments

• Make sure the printer status light is showing
steady green.

• Ch eck th e ca bles.

• Make sure the computer’s USB port is

functioning.

• Check for a broken ribbon.

• Check the ready button; it may be defective.

Error

Code

Message text Comments

DR 00903 Error processing this card. Click Help

for steps to follow.

DR 00904 PC to printer communication error.

Check the data cable.

DR 00906 Printer driver error. Click Help for

more information.

DR 00907 The printer driver cannot access the

required PC resources. Click Help for
more information.

DR 00908 The printer driver cannot get enough

PC memory. Click Help for more
information.

DR 00909 Printer driver error. Click Help for

more information.

DR 00910 The printer firmware needs to be

updated. Click OK to update
firmware now.

DR 00912 The printer driver was not installed

successfully. Click Help for steps to
follow.

The driver has failed to create or access th e
temporary files containing the data for the card.

• Make sure the TEMP environment variable is set
correctly. User should have sufficient rights to
write to this folder.

• Make sure there is enough free disk space to
store the necessary card data.

Check for possible PC configuration failures such
as:

• Defective port.

• Defective main control board and its

connections.

• Wrong printer or communication parameters
are set.

Perform hard drive maintenance.

The print processor has an error opening or
reading the temporary files.

• Make sure the TEMP environment variable is set
correctly. User should have sufficient rights to
write to this folder.

• Delete the job and resend it from the
application.

• If the spooler crashes, restart Windows.

There is not enough memory to process and print
a card.

• Make sure that the computer resources are not
being used extensively by other applications.

• Cl ean up th e PC hard drive.

Run the Update utility to update the printer
firmware to make it compatible with the printer
driver. The update process takes several minutes.

• Cl ean up th e PC hard drive.

You may not have restarted Windows after you
installed the driver. Restart Windows and try
printing a card.

CP60 and CP60 Plus Service Manual 4-15

Error

Code

Message text Comments

DR 00914 The printer driver was not started

successfully. Close all applications
and restart the PC.

DR 00917 The current card is part of a two-

sided job. Click Help for steps to
follow.

DR 00918 Time out when processing this card.

Click Help for steps to follow.

DR 00919 The current printer was disconnected

or powered off. Card jobs might be
lost or duplicate cards might be
printed.

DR 00921 A printer has been identified. Please

wait while the driver reads the printer.

DR 00924 The driver does not support the

connected printer. Connect a
supported printer or install the driver
for this printer.

• Restart Windows, and then open the printing
application.

• Reinstall the driver:

a. Uninstall the print driver from the PC.
b. Restart Windows.
c. Run the Cleanup Utility.
d. Reinstall the driver.

• Perform hard drive maintenance for Windows;
the PC may not be able to load all the
components of the printer driver.

You have selected "Manual" for the Print on Both
Sides or Duplex Method setting for this card.

• The computer resources are being used by
other applications.

a. Close all applications you are not using. The

card creation application and the printer
driver are the only applications needed to
print cards.

b. Wait until the captured image is displayed

on the PC before printing the card to
prevent competition for PC resources.

• Interactive mode jobs, including smart card jobs
and read magnetic stripe jobs, are not
supported for networked printers. Do not send
interactive mode jobs to a network printer.

• The pri nter was disconnected from the PC after
a card was sent.

• The card might or m ight not print. The card
status and completion information will not be
available. The card might or might not be
removed from the Print Manager list.

• The printer was powered off after the card was
printed but before the printer returned card
completion or card status data to the driver.

• Pause the printer before powering it off.

4-16 Troubleshooting

Input Errors (IS)

Error

Code

IS-01206 A card was not picked successfully.

 ERR_IH_NO_CARD_PICKED

Symptom Comments

Duplex Module Errors (DM)

Error

Code

DM
00760

DM
00762

DM
00765

DM
00767

The duplex mechanism did not
reach the correct position.

 ERR_FLP_POSITION

The card is stuck in the duplex
module.

 ERR_FLP_CARD_JAM

The duplex module is not installed or
detected.

 ERR_FLP_NOT_INSTALLED

The card is lost in the duplex module.

 ERR_FLP_CARD_LOST

Symptom Comments

• Reload the card stock.

• Inspect the card gate in the input hopper

and verify that the spring is in place and
working correctly.

• Ch eck th e transpor t belt and pulleys f or
damage.

• Check the belt tensioner to make sure it is
putting t e n s ion on the transpor t timing belt.

• Check the rocker arm springs and make sure
they are placed correctly and not damaged.

• Test the card input sensor to see if it toggles.

• Test the pick motor functions.

• T e st the transport mo tor functions.

One or more sensor transitions was not
detected.

• Check the flipper for obstructions.

• Check if the clutch is functioning.

• Check if the sensor is functioning.

• Ch eck th e duplex mo tor.

The duplex entry sensor did not clear.

• Check the sensor.

• Check the duplex motor.

The driver attempted to send a duplex job to a
printer not equipped with a duplex module.
Check the duplex interface cable and circuit
board.

The duplex entry sensor was not blocked when
expected.

• Check the sensor.

• Check the duplex motor.

CP60 and CP60 Plus Service Manual 4-17

System Errors (SY)

Error

Code

Symptom Comments

SY-01305 The setting sent to the printer does not

match printer features.

 ERR_SYS_CONFIG_OPTIONS

SY-01306 The setting value you selected is not

valid.

 ERR_SYS_CONFIG_VALUE

SY-01310 EEPROM flash data error. Obtain a new

update file.

 ERR_SYS_FLASH_DATA

SY-01312 EEPROM flash size error.

 ERR_SYS_FLASH_SIZE

SY-01314 Warning! EEPROM flash write error. Do

not power off the printer. RETRY the
update file.

 ERR_SYS_FLASH_WRITE

SY-01317 Memory error

 ERR_SYS_MEM

SY-01325 The options or supplies installed do not

match settings or card data.

 ERR_SYS_SEQ_STR

SY-01327 The request sent to the printer is not

supported.

Check settings and printer options.

Check configuration setup in printer to make
sure it matches what is sent by the
application.

• Try to reinstall the printer firmware or
download an updated firmware update
utility. Make sure to use the correct
firmware update utility for the specific
printer.

• Main control board problem.

A logo loaded into flash memory is too large.

Main control board problem.
NOTE: Do not power off the printer. Try to

reinstall the printer firmware or download an
updated firmware update utility.

The printer could not save the data being
sent.

A color card job was sent to the printer but
the ribbon is monochrome. If the ribbon is
not monochrome:

• Check the RFID antenna

• Check the supplies ID by swapping with

another ribbon.

 ERR_SYS_UNIMPLEMENTED

SY 01331 Data transmission error.

 ERR_SYS_COMM

SY -1332 General printer fault.

 ERR_SYS_HW_FAILURE

Power cycle the printer.

Power cycle the printer.

4-18 Troubleshooting

Magnetic Stripe Errors (MS)

Error

Code

MS-01401
MS-01402
MS-01403

MS-01404
MS-01405
MS-01406

MS-01407
MS-01408
MS-01409

MS-01410
MS-01411
MS-01412

Symptom Comments

Data sen t does not match
requirements for track 1, 2, or 3.

 MS_T1_DATA_ERR
 MS_T2_DATA_ERR
 MS_T3_DATA_ERR

Parity error reading data on
track 1, 2, or 3.

 MS_T1_PAR_ERR
 MS_T2_PAR_ERR
 MS_T3_PAR_ERR

LRC error reading data on track
1, 2, or 3.

 MS_T1_LRC_ERR
 MS_T2_LRC_ERR
 MS_T3_LRC_ERR

Start Sentinel error reading data
on
track 1, 2, or 3.

 MS_T1_SS_ERR
 MS_T2_SS_ERR
 MS_T3_SS_ERR

• Check the data entered to see if application is
sending data to match correct track format.

• Check the application and the printer
configuration to see that they match and are set
correctly.

If this occurs frequently:

• Run a cleaning card.

• Check the magnetic stripe head.

• Check the magnetic stripe optical encoder.

• Check the magnetic stripe daughter board.

If this occurs frequently:

• Run a cleaning card.

• Try different card stock.

• Check the printer’s coercivity setting to make

sure it matches the cards being used.

• Run the Calibrate MS Head in Diagnostics.

• Check the magnetic stripe head.

• Check the magnetic stripe optical encoder.

• Check the magnetic stripe daughter board.

The longitudinal redundancy check failed. If this
occurs frequently:

• Run a cleaning card.

• Try different card stock.

• Check the printer’s coercivity setting to make

sure it matches the cards being used.

• Run the Calibrate MS Head in Diagnostics.

• Check the magnetic stripe head.

• Check the magnetic stripe optical encoder.

• Check the magnetic stripe daughter board.

An error was encountered at the beginning of the
data record. If this occurs frequently:

• Run a cleaning card.

• Try different card stock.

• Check the printer’s coercivity setting to make

sure it matches the cards being used.

• Run the Calibrate MS Head in Diagnostics.

• Check the magnetic stripe head.

• Check the magnetic stripe optical encoder.

• Check the magnetic stripe daughter board.

CP60 and CP60 Plus Service Manual 4-19

Error

Code

Symptom Comments

MS-01413
MS-01414
MS-01415

End Sentinel error reading data
on
track 1, 2, or 3.

 MS_T1_ES_ERR
 MS_T2_ES_ERR
 MS_T3_ES_ERR

MS-01417 A card jam occurred when

attempting to write magnetic
stripe data on the card.

 MS_MOVE1_ERR

MS-01418 The card was lost before writing

magnetic stripe data.

 MS_MOVE2_ERR

An error was encountered at the end of the data
record. If this occurs frequently:

• Run a cleaning card.

• Try different card stock.

• Check the printer’s coercivity setting to make

sure it matches the cards being used.

• Run the Calibrate MS Head in Diagnostics.

• Verify that the data does not extend past the

end of the card.

• Check the magnetic stripe head.

• Check the magnetic stripe optical encoder.

• Check the magnetic stripe daughter board.

The magnetic stripe sensor was never cleared. If
the card is still over the sensor, check the following:

• Make sure the magnetic stripe rocker is applying
pressure to the card and the encoder roller is free
to turn.

• Inspect the card track for obstructions.

• Check card stock for powder, dirt, or oil on cards,

and then run a cleaning cycle.

• Ch eck th e transpor t belt and pulleys f or
operation.

If the card is not over the sensor, check the
following:

• Make sure the sensor reflector is in position on the
magnetic stripe rocker.

• Check the magnetic stripe sensor using the
sensor Diagnostics.

The card was never detected by the magnetic
stripe sensor. If the card is located between the
input sensor and the magnetic stripe sensor, check
the following:

• Inspect the card track for obstructions.

• Inspect the transport belt and pulleys for

operation.

• Inspect all of the rocker assemblies to ensure they
are applying pressure to the card and that the
rollers rotate freely.

If the card is at the sensor or past the sensor, check
the sensor functions:

• Block the magnetic stripe sensor and look for a
sensor transition in Diagnostics.

• To confirm if the main control board is faulty:
a. Turn off the printer.

4-20 Troubleshooting

Error

Code

Symptom Comments

b. Unplug the reflective sensor and connect a

functional transmissive sensor in its place.

c. Turn the power on and block the sensor.
d. If no sensor transitions are observed in

Diagnostics, the control board needs to be
replaced.

MS-01419 A card was lost outside of the

magnetic stripe area when
attempting to read data
encoded on the card.

 MS_MOVE3_ERR

MS-01420 A card was stuck when

attempting to read magnetic
stripe data encoded on the
card.

 MS_MOVE4_ERR

MS-01421 A card was lost when

attempting to read or write
magnetic stripe data on card.

 MS_MOVE5_ERR

MS-01424 Unable to read any data from

the card.

 MS_MINDATA_ERR

The card was not returned from the rear of the
printer, or the card has been read, but did not
reach the input sensor. (The read cycle is not
complete until the card is passed off to the input
sensor.)

• Check the card input and magnetic stripe
sensors for operation.

• Ch eck th e transport system for obstructions and
proper operation.

• Check the smart card and front rockers for
proper operation.

The magnetic stripe sensor never cleared after the
read operation. If the read-back direction is
"forward," then it may also be possible that the
card input sensor never cleared.

• Check the operation of the card input and
magnetic stripe sensors.

• Check the front and magnetic stripe rockers for
proper spring pressure and roller movement.

• Ch eck th e transpor t for proper operation or
obstructions.

The card was never detected by either the
magnetic stripe or card input sensors.

• Check the card input and magnetic stripe
sensors for operation.

• Ch eck th e transport system for obstructions and
proper operation.

• Inspect all of the rocker assemblies to ensure they
are applying pressure to the card and that the
rollers rotate freely.

This error can occur during normal encoding, but it
can also occur if the magnetic stripe head
calibration process fails to complete.

• Make sure cards are loaded correctly and that
they are magnetic stripe cards.

• Check data format. Printer and driver should
match.

• Verify that the coercivity setting matches the
card stock.

• Cl ean the magne tic stripe head.

CP60 and CP60 Plus Service Manual 4-21

Error

Code

Symptom Comments

MS-01425 Unexpected magnetic stripe

coercivity value.

 MS_CURRENT_ERR

• Check the magnetic stripe mechanical
assembly. Possible failed components are the
magnetic stripe head, the cable assembly, the
magnetic stripe encoder cable assembly, the
magnetic stripe control board, and the main
control board.

The coercivity value stored in the printer is out of
range. This should not happen, and indicates a
possible problem with the main control board
EPROM.

1. Using Diagnostics, change the printer's

coercivity setting.

2. Save the changes to power-on defaults. (If the

EPROM is defective, this will generate an error.)

3. Retry the magnetic stripe operation.

MS-01426 Magnetic stripe module settings

EEPROM read or write error.

 MS_EEPROM_ERR

MS-01427 Configuration information

passed through by the printer
driver was not accepted by the
magnetic stripe module.

 MS_CONFIG_ERR

MS-01428 Status request passed through

by the printer driver was not
accepted by the magnetic
stripe module.

 MS_STATUS_ERR

MS-0142 9 Data sent to a track does not

match the requirements for that
track.

 MS_ILLICIT_DATA_ERR

MS-01430 Control information passed

through by the printer driver was
not accepted by the magnetic
stripe module.

 MS_PASSTHROUGH_ERR

• Try the operation again.

• Reboot the computer and printer.

• If the error continues, replace the main control

board.

• Check the magnetic stripe configuration settings
using Diagnostics.

• For a custom applica tio n, incorrect values may
have been sent.

• Illegal command. Try again.

• Verify application is sending the correct data.

• Verify printer driver is loaded and configured

correctly.

• Check data cable connection between PC and
printer.

• Occurs after multiple individual track errors such
as MS 01401, MS 01402, and MS 01403 whe n
“display all messages” is checked in Diagnostics.

• Verify the magnetic stripe settings in the card
production application are correct and resubmit
the card for printing.

• Illegal command. Try again.

• Verify application is sending the correct data.

• Verify printer driver is loaded and configured

correctly.

• Check data cable connection between PC and
printer.

4-22 Troubleshooting

Error

Code

Symptom Comments

MS-01431 Magnetic stripe module settings

EEPROM read error.

 MS_OPS_READ_ERR

MS-01432 Magnetic stripe module settings

EEPROM read error.

 MS_FAC_READ_ERR

MS-01433 Magnetic stripe module settings

EEPROM write error.

 MS_OPS_WRITE_ERR

MS-01434 Magnetic stripe module settings

EEPROM write error.

 MS_FAC_WRITE_ERR

MS-01435 The magnetic stripe module is

not installed or detected. Make
sure the card creation
application does not send
magnetic stripe data if no
module is installed.

• Try the operation again.

• Reboot the computer and printer.

• If the error continues, replace the main control

board.

• Check the magnetic stripe configuration settings
using Diagnostics.

• Try the operation again.

• Restart Windows and power cycle the printer.

If the error continues, replace the main control
board.

• Check the magnetic stripe configuration settings
using Diagnostics.

• Try the operation again.

• Power cycle the printer.

If the error continues, replace the main control
board.

• Check the magnetic stripe configuration settings
using Diagnostics.

• Try the operation again.

• Power cycle the printer.

If the error continues, replace the main control
board.

• The main or magnetic stripe control board may
be defective.

• Power cycle the printer.

If the error continues, replace the main or
magnetic stripe control board.

 ERR_MS_NOT_INSTALLED

CP60 and CP60 Plus Service Manual 4-23

Print Errors (PR)

Error

Code

PR­01703

PR­01705

PR­01706

PR­01710

PR­01715

Symptom Comments

The printhead cam is not in the
correct position to print.

 ERR_PRN_HEAD_POSITION

The card is lost in the printer.

 ERR_PRN_CARD_LOST

The card is stuck in the printer.

 ERR_PRN_CARD_JAM

Factory settings read problem.

 ERR_PRN_FACT_EEREAD

The cover was opened during
printing.

• Check the printhead cam sensor.

• Inspect the cam gear for damage.

• Test the cam motor.

The card was not seen by a sensor when it was
expected.

• If the card is located under a sensor, begin
troubleshooting the sensor.

• Use Diagnostics to verify the function of the
transport.

A sensor did not clear when expected.

• If the card is located under a sensor, the problem is
likely related to the transport system.

• If the card is not located under a sensor, make sure
the sensor is plugged in and operating.

Check the main control board assembly. Possible
failed components are the printhead, the cable, and
the main control board.

If the cover was not opened, check the sensor for a
loose connection.

PR­01716

PR­01717

PR­01718

PR­01719

PR­01720

PR­01721

 ERR_PRN_HEAD_OPEN

The cover is open.

 ERR_PRN_HEAD_OPEN_WARNING

Printing is suspended while the
printhead returns to operating
temperature.

 ERR_PRN_HEAD_TEMP_WARN

The printhead temperature is
too high.

 ERR_PRN_HEAD_TEMPERATURE

The printhead is not installed or
detected.

 ERR_PRN_HEAD_TYPE

The print ribbon index mark was
not found.

 ERR_PRN_NO_RIBBON_INDEX

Operational settings read error.

 ERR_PRN_OP_EEREAD

This will be reported if the sensor is disconnected. Use
Diagnostics to see if the sensor toggles when
blocked.

• Check the printhead fan and its connections; it
may be defective.

• Check for blocked air flow.

• Check the printhead assembly.

• Check the printhead fan and its connections; it

may be defective.

• Check for blocked air flow.

• Check the printhead assembly.

• Check cable connections.

• Replac e the printhead.

• Check the ribbon index sensor for proper

operation.

• Check the main control board assembly. Possible
failed components are the printhead, the cable,
and the main control board.

4-24 Troubleshooting

Error

Code

Symptom Comments

PR­01722

PR­01723

PR­01724

PR­01726

PR­01730

Operational settings write error.

 ERR_PRN_OP_EEWRITE

General printer fault.

 ERR_PRN_PRINTER_FAULT

The print ribbon is broken.

 ERR_PRN_RIBBON_BREAK

Out of print ribbon. Replace the
print ribbon with the same type
and click OK when ready.

 ERR_PRN_RIBBON_OUT

Unable to read the printhead
temperature. Power off the
printer and check the
printhead cable.

• Check the main control board assembly. Possible
failed components are the printhead, the cable,
and the main control board.

• Cycle the printer power and try printing again.

• Check the main control board.

• If this occurs while running a firmware update, run

the firmware update again.

If the ribbon is not broken:

• Verify that the print ri bbon is not misroute d and
that the cartridge is properly inserted.

• Check the operation of the ribbon motion sensor.

• Check the ribbon motor using the motor

Diagnostics.

If the ribbon breaks frequently:

• Check the following offsets using Diagnostics:

• Card registration

• Image clipping

• YMC, K, & T power

• Check the swingarm assembly; it may not be

secure or is defective.

If the ribbon is not empty:

• Check the ribbon index sensor for proper
operation.

• Verify that the ribbon ID tag was not swapped with
another ribbon.

• Check the printhead assembly. Possible failed
components are the printhead, the cartridge, the
cable, and the main control board.

• Conn ec t cables to the TPH car tridge.

 ERR_PRN_TPH_TEMP

PR­01737

PR
01738

The print ribbon is running low.

 ERR_PRN_RIB_LOW

The printer cannot identify the
ribbon installed. Install another
ribbon or click OK to print one­color (K) cards.

• Make sure the supplies ID was not transferred from
one ribbon spool to another.

• Check antenna board.

• Check antenna cable.

• If the ribbon is a new type, the printer's firmware

may need to be updated to recognize it.

 ERR_PRN_RIBBON_TYPE

CP60 and CP60 Plus Service Manual 4-25

Smart Card Errors (SC)

Error

Code

SC­01804

Message text Comments

The smart card module is not
installed or detected. Make
sure the card creation
application does not request
smart card programming.

 ERR_IC_NOT_INSTALLED

• Verify that the smart c ard option is enabled using
Diagnostics.

• Check the smart card assembly. Possible failed
components are the sensor, the cable, and the
smart card control board.

• Power cy cle the printer.



4-26 Troubleshooting

Chapter 5: Adjustments

This chapter provides instructions for adjusting the CP60 and CP60
Plus card printers.

General Notes___________________________________________________________________ 5-3
Installing Printer Diagnostics______________________________________________________ 5-3
Using Printer Diagnostics _________________________________________________________ 5-5

Parts of the Diagnostics Window_______________________________________________________5-5
Menu Options ________________________________________________________________________5-6
Changing Printer Values_______________________________________________________________5-8

Viewing and Saving Values ________________________________________________________5-9
Working With Scripts______________________________________________________________5-10

Setting Printer Value Parameters______________________________________________________5-11

Printer ID_________________________________________________________________________5-11
Card Registration Offset __________________________________________________________5-11
Card Strip Offset _________________________________________________________________5-12
Ribbon Type _____________________________________________________________________5-12
Ribbon Offset ____________________________________________________________________5-12

Vertical Offset ___________________________________________________________________5-12
Transport Speed__________________________________________________________________5-13
YMC, K, T, & F Strobe Duty ________________________________________________________5-13
YMC, K, T, and F Power and Base Power ___________________________________________5-14
Duplex Infeed Offset _____________________________________________________________5-14
Duplex Home Offset______________________________________________________________5-15
Duplex Print Return Offset_________________________________________________________5-15
Duplex Handoff Offset____________________________________________________________5-15
Smart Card Registration Offset ____________________________________________________5-15
Image Clipping Leading and Trailing ______________________________________________5-16

Setting Printer Options________________________________________________________________5-17
Viewing Printer Status ________________________________________________________________5-18
Testing Motors _______________________________________________________________________5-19
Testing Motor Functions ______________________________________________________________5-20
Setting Up Step Tests for the Printer____________________________________________________5-21
Running a Magnetic Stripe Test Card__________________________________________________5-22
Configuring the Magnetic Stripe Module ______________________________________________5-23
Configuring Custom Track Formats ____________________________________________________5-25
Running Magnetic Stripe Diagnostics__________________________________________________5-26

CP60 and CP60 Plus Service Manual 5-1

Testing the Smart Card Option________________________________________________________5-27

Network Option Adjustments ____________________________________________________ 5-29
Software Adjustment Procedures ________________________________________________ 5-33

Saving and Restoring a Printer Configuration __________________________________________5-33
Start Sentinel Position_________________________________________________________________5-35
Card Registration Offset Adjustment __________________________________________________5-36
Ribbon Offset Adjustment ____________________________________________________________5-37
Updating the Printer Firmware ________________________________________________________5-38
Duplex Rotational Adjustment ________________________________________________________5-39

5-2 Adjustments

General Notes

This document is organized sequentially for the customer engineer who is
encountering an CP60 or CP60 Plus printer for the first time, and begins with
installing the diagnostic software, navigating and using the software, and
concludes with specific adjustment procedures for the printer.

• Temperature Terminology: To distinguish between an absolute temperature

and a relative temperature (change in temperature), this manual will adhere
to standard notation. Absolute temperatures are indicated by °C (degrees
Celsius), and a change in temperature is indicated by C° (Celsius degrees).
For example: The difference between 25 °C and 30 °C is 5 C°.

 Helpful Hint: There may be times when you wish to perform a task while

observing sensor changes in another diagnostic window. It is permissible to
open multiple instances of Diagnostics to view separate dialog boxes not
normally viewable with a single instance. To do this, double-click on the
Diagnostics icon, and then double-click on the icon again. Two instances of
the software will open.

Installing Printer Diagnostics

Procedure

Before you begin, confirm that the printer driver has been installed on the
computer. Diagnostics will not run without the print driver.

1. Insert the printer driver CD into your CD drive. The CD should run

automatically and display the following window. If the CD does not auto
start, run the setup.exe file from the CD. When running, click the Printer
Support button.

CP60 and CP60 Plus Service Manual 5-3

2. From the displayed window, click the Printer Diagnostics button.

3. From the displayed window, click Next to begin the installation.

4. You will see a prompt for changing the destination directory. It is

recommended that you not change this setting. Click Next.

5. You will then be asked to which program group the icon should be added.

Make no changes and click Next.

6. The program performs the installation and informs you when it is completed.

Click on Finish.

5-4 Adjustments

Using Printer Diagnostics

1. The first time you use the Printer Diagnostics you may be required to select

the printer model. Make sure the printer is connected and powered on, and
then click on the appropriate printer.

2. Next, select User Properties from the File menu to change the logon level.
A. Select Advanced User from the list and press OK.

 Selecting Basic User will disable some of the settings within

Diagnostics. No password will be required for this option.

B. At the prompt, enter the service technician password (926918).

 Do not share this password with the end-user of the printer. It permits

access to settings that should not be altered by untrained personnel.

Parts of the Diagnostics Window

The main Diagnostic window shows the near-real-time status of the printer’s
sensors (there may be a communication delay). The lower right corner shows the
current Logon Level (either Basic or Advanced). Menu options that are not
appropriate for the printer are grayed out.

CP60 and CP60 Plus Service Manual 5-5

Menu Options

The options on the menus are for the purposes outlined in the table below.

Option Purpose

File | Choose Printer

File | User Properties

File | Exit
File | Exit Without Reset

Printer | Test Card

Use this option to select the printer for which you plan to use
Diagnostics.

Use this option to set the access level for Diagnostics. The Basic

User setting has some critical settings disabled. The Advanced
User setting requires a password (926918) to enable all settings.

 Do not share this password with the end-user of the

printer! It provides access to parts of the system that
should not be available to untrained personnel.

By default, exiting the program will reset the printer to e n s u re
the printer is ready to produce cards. It is recommended that
you reset the printer when exiting Diagnostics, but if you do not
wish to, select Exit without reset.

Use this option to print the default test card for the printer. The
gray test card is available to the Advanced User only. The
rewrite card is available only when the printer is configured for
rewrite cards. In rewrite mode, the white and grey cards are not
available.

Printer | Values

Printer | Options

Printer | Status

Printer | Flash Update

5-6 Adjustments

This option is for changing the operation parameters of the
printer. See additional information in

This option is for setting printer options. See additional
information in

This option is for checking the status of the printer (such as the
error log or print ribbon information) as described in
Printer Status.

This option provides a method for manually updating the
printer’s firmware. This feature is used only with *.fls files, and
does not function with the flash update found in the driver
software.

Setting Printer Options.

Changing Printer Values.

Viewing

Option Purpose

Printer | Motor Tests

Printer | Motor Cycle Tests

Printer | Step Test

Magnetic Stripe | Test Card

Magnetic Stripe|Configuration

Magnetic Stripe| Diagnostics

Smart Card | Test Card

This option allows you to operate each of the motors in the
printer for a specified duration as described in

This option is for selecting a motor to test by having it complete
a full cycle of operation as described in

This option runs routines from the printer’s firmware. Each routine
can be run individually or as a series of successive routines as
described in

This option provides access to printing test cards for the
magnetic stripe module. Only Advanced Users can read cards.

This option for configuring the magnetic stripe module is
available only to the Advanced User. It is for configuring Start
Sentinels, etc. as described in

This option provides access to functions for troubleshooting the
magnetic stripe module.

The smart card test is a built-in routine to simulate smart card
personalization. A card is picked from the hopper, personalized,
and transported to the smart card module. See additional
information in

Setting Up Step Tests for the Printer.

Configuring the Magnetic Stripe.

Testing the Smart Card Op tion.

Testing M o tor Functions.

Testing Motors.

CP60 and CP60 Plus Service Manual 5-7

Changing Printer Values

Use the Printer Values dialog box to change the operational parameters of the
printer. For a description of each parameter and how to change it, refer to
Printer Value Parameters. For information on how to create a test script, refer to
Working With Scripts. For information on whether to save your changes or
discard them, refer to

Viewing and Saving Values.

Setting

Procedure

1. If you need to access the advanced settings, log in as an Advanced User.

2. Select the parameter to change from the list in the Change Values box.

3. Type your change in the New Value data box and click on Apply. (The new

value is temporarily stored in the printer’s RAM memory, but it is not
permanently stored in EPROM memory yet. If you turn off or reset the
printer, the value is removed from RAM and the original power-on default
value is loaded.)

4. Use the Test card option or a card creation program to print a test card to

test your changes. The printer will use your new values for the test.

5. If the changes are not acceptable, either reset the printer or turn it off.

6. If the changes are acceptable, click on the Save current values to Power-on

button to store the changes permanently. You will be prompted for a
password. Enter 42360.

5-8 Adjustments

Viewing and Saving Values

The buttons on the right of the Printer Values dialog box are used to choose what
values are listed in the current values window.

Current values

Displays the current parameter values.

View current values Select to display the values that are currently loaded in

the printer’s non-permanent memory.

View power-on values Select to dis p la y the values that are currently loaded in

the printer’s permanent, power-on memory.

Save current values to file Writes all parameters and values currently saved in

memory to a text file.

View factory values Select to display the values that were permanently

written into the printer at the factory.

CP60 and CP60 Plus Service Manual 5-9

Working With Scripts

The scripting area allows you to create, load, and run scripts for adjusting
printers. A configuration script is a group of settings that are saved to a text file.

 Make sure the configuration script does not contain a Printer ID listing or a

Ribbon Type listing. If these parameters are present in the script file, use a
text editor to delete them.

The script display window shows the contents of the current script, whether
loaded from a file using Load Script or created by modifying printer values.

To perform a single step and run the selected line of the script, click on Run Step.
The line will be run and the next line highlighted.

To test the entire script, click on Run Script.

To delete the highlighted line of a script, click on Delete value. (This option may
not be available for loaded scripts.)

After making printer value changes, click Save to a configuration script to
record the changes in a configuration script. The script can then be loaded into
another printer for batch processing a series of printers.

Click on Clear list if you want to clear the scripting window.

5-10 Adjustments

Setting Printer Value Parameters

The following sections describe how to modify the printer parameters. Please
note the following:

• Just because a parameter is listed and explained here does not mean it should

be altered. Those parameters that should not be altered are so noted in the
description. Do not modify these parameters without contacting technical
support first.

• Some of these offsets have procedures for setting the values. If a procedure is

associated with the parameter, it has a link to the procedure.

Printer ID

This value should not be modified unless the main control board is replaced.
Altering this value will cause a new instance of the printer driver to be installed,
and altering it incorrectly may cause significant problems for the printer and the
customer's PC. This is available only to the advanced user.

If the main control board is replaced, follow the
Configuration procedure on page

Card Registration Offset

This parameter determines how far the card travels after being detected by the
card input sensor for the leading edge of the card to arrive at the printhead. This
setting can also be changed in the printer driver under the Advanced Settings
button.

• Refer to the Card Registration Offset Adjustment procedure (p. 5-36).

• Make sure the image clipping settings are not interfering with this

adjustment.

Range
Increase Value The printed image moves away from the leading edge of

Decrease Value The printed image moves toward the leading edge of the

Symptom/Solution

Saving and Restoring a Printer

5-33.

0 to 15,000 (in thousandths of an inch)

the card.

card.
Print ribbon breaks at the start of a printed panel

• Increase the card registration offset because the
printhead is heating up the ribbon but the card is not yet
in position to absorb some of this heat.

CP60 and CP60 Plus Service Manual 5-11

Card Strip Offset

This parameter determines how far the card travels after printing a panel to
allow the ribbon to be stripped away from the card. This offset begins when the
last portion of the image has been printed. This parameter should not be altered.

Range
Increase Value The card travels more distance after printing a panel. (This

Decrease Value
Symptom/Solution

Ribbon Type

Ribbon type is a read-only parameter that cannot be changed. The display will
show the type of ribbon that has been detected by the printer. However, it is
more informative to query the printer using
provide the ribbon type number as well as the Datacard part number.

Ribbon Offset

This parameter tells the printer how far to advance the print ribbon after the
index mark is detected by the ribbon index sensor. This value is applied only to
the first panel following an index mark.

0 to 15,000 (in thousandths of an inch)

will slow down throughput slightly.)
The card travels less distance after printing a panel.
Print ribbon sticks to the trailing edge of the ca rd.

• Increase the card strip offset.

Viewing Printer Status. This will

 This parameter should not be modified from the factory default setting. If it

Range
Value Too Large Printing will begin on the proper color panel, but will extend

Value Too Small Printing will begin with the wrong (previous) color panel but

Vertical Offset

This parameter shifts the image within the printhead to keep it centered on the
card. The variable is called vertical because many other printers process cards
with a vertical orientation to the card path. The variable is the same across all of
these printers, but the orientation of the card path is horizontal in this printer.

does become necessary to change it, refer to the
page

5-37.

0 to 10,000 (in thousandths of an inch)

past the end of the panel and into the next color. This
results in coloration errors at the trailing edge of the card.

will conclude with the correct color. This results in coloration
errors at the leading edge of the card, and frequently
results in the index mark being printed.

Ribbon Offset Adjustment on

5-12 Adjustments

 This value is best modified in the printer driver interface under the Edge to

Edge tab.

Range
Increase Value The printed image moves toward the right on a portrait-

Decrease Value The printed image moves toward the left on a portrait-

Transport Speed

This parameter controls the speed of the transport motor during card transport
but not during printing.

 Altering this parameter can cause resonance in the printer and/or increase

audible noise of the printer. This parameter should not be changed without
contacting technical support.

Range

YMC, K, T, & F Strobe Duty

These parameters are used to maintain a consistent print intensity between full
columns and partial columns (YMC=Yellow, Magenta, Cyan; K=Black;
T=Topcoat; F=Fluorescent).

-15 to 15

oriented card.

oriented card.

150 to 3000

 These parameters should not be changed. However, if one parameter is

altered, all three should be altered accordingly.

Range
Increase Value
Decrease Value
Symptom/Solution

0 to 255
Columns with fewer pixels print darker.
Columns with fewer pixels print lighter.
The shaded area directly above and below the white

square on the service test card prints light.

• Increase the YMC strobe setting.

The shaded area directly above and below the white
square on the service test card prints dark.

• Decrease the YMC strobe setting.

K-panel horizontal lines drop out but vertical lines print
properly.

• Increase the K-strobe setting.

CP60 and CP60 Plus Service Manual 5-13

YMC, K, T, and F Power and Base Power

These settings control the print threshold of each of the print panels. K and T
power settings can be made in the print driver, but YMC and F power can be
modified only from Diagnostics.

Power and Base Power serve the same function. The Base power setting is used
to compensate for variations in the printer, and the Power setting is used to tune
the printing results to suit the needs of the user (YMC=Yellow, Magenta, Cyan;
K=Black; T=Topcoat; F=Fluorescent).

Range
Value Too Low Colors will be dull and washed out. K-panel printing may

Value Too High

Duplex Infeed Offset

This parameter controls how far a card will travel after it leaves the duplex entry
sensor. If this value is incorrectly set, the card may bind as the duplex rotates.

Range
Increase Value
Decrease Value

-100 to 100

have dropouts.
Frequent ribbon breaks and bar code growth.

1 to 80
The card travels further into the duplex.
The card travels less distance into the duplex.

5-14 Adjustments

Duplex Home Offset

This parameter controls where the duplex flipper stops when in the home
position.

 Refer to the Duplex Rotational Adjustment procedure (p. 5-39).

Range
Increase Value The index pointer moves toward the lower letters (see the

Decrease Value The index pointer moves toward the higher letters (see the

Duplex Print Return Offset

This parameter controls where the duplex flipper stops when in the print return
(flipped) position.

Range
Value

 Adjust the Duplex Home Offset, and then set this value to be 6 units larger.

Duplex Handoff Offset

This parameter controls where the duplex flipper stops when in the vertical
handoff position.

1 to 40

adjustment procedure).

adjustment procedure).

1 to 70
Home Offset plus 6

Range
Value

70 to 130
Home Offset plus 77

 Adjust the Duplex Home Offset, and then set this value to be 77 units larger.

Smart Card Registration Offset

This parameter controls the distance a contactless smart card travels to reach the
programming station. Because of the nature of the contactless programming
operation, this parameter need not be precise. This parameter should not be
changed and is available only to the Advanced User.

Range

0 to 6000

 The approximate position of the contactless smart card should be the same as

a contact smart card. If this position cannot be determined, set the offset so
the trailing edge of the card covers the location of the magnetic head but does
not cover the location of the magnetic head's pivot pin.

CP60 and CP60 Plus Service Manual 5-15

Image Clipping Leading and Trailing

These settings clip (truncate) the image so printing begins in the correct position.

Range

0 to 1000 (in thousandths of an inch)

Increase Value Increases the amount of unprinted space on the leading or

trailing edge of the card.

Decrease Value Decreases the amount of unprinted space on the leading

or trailing edge of the card.

Symptom/Solution

Undesirable white space on the leading edge of the card.

• Reduce the leading edge image clipping.

• Also check the

36) to make sure that is not the cause.

Undesirable white space on the trailing edge of the card.

• Reduce the trailing edge image clipping.

• Verify that the card design is not too short to extend to

the end of the card.

Frequent ribbon breaks at the leading or trailing edge of a
card.

• Increase the image clipping to prevent the printhead
from overheating the ribbon before printing should
begin.

Card Registration Offset Adjustment (p. 5-

5-16 Adjustments