FARGO electronic DTC500 User Manual

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

 DTC510 (Single-Sided Card Printer/Encoders)  DTC515 (Single-Sided Card Printer/Encoders)  DTC515-LC (Single-Sided Card Printer/Encoders)  DTC520 (Dual-Sided Card Printer/Encoders)  DTC525 (Dual-Sided Card Printer/Encoders)  DTC525-LC (Dual-Sided Card Printer/Encoders)

Part Number: L000699

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DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0), property of FARGO Electronics, Incorporated

Copyright  2002, 2003, 2004, 2005, 2006 by FARGO Electronics, Incorporated. All rights reserved. Printed in the United States of America. Exclusive permission is granted to authorized resellers of FARGO products to reproduce and distribute this copyrighted document to authorized FARGO customers, who have signed a “no disclosure agreement” regarding the restricted, proprietary use of said document.

The revision number for this document will be updated to reflect changes, corrections, updates and enhancements to this document.

Revision Control

Date Document Title

Number

Revision 5.0 1 January 2004 DTC500 Card Printer/Encoders User Guide

(Rev. 5.0)

These reference documents were thoroughly reviewed to provide FARGO with professional and international standards, requirements, guidelines and models for our technical, training and user documentation. At all times, the Copyright Protection Notice for each document was adhered to within our FARGO documentation process. This reference to other documents does not imply that FARGO is an ISO-certified company at this time.

 ANSI/ISO/ASQ Q9001-2000 American National Standard, (sub-title) Quality Management

Systems - Requirements (published by the American Society of Quality, Quality Press, P.O. Box 3005, Milwaukee, Wisconsin 53201-3005)

 The ASQ ISO 9000:2000 Handbook (editors, Charles A. Cianfrani, Joseph J. Tsiakals

and John E. West; Second Edition; published by the American Society of Quality, Quality Press, 600 N. Plankinton Avenue, Milwaukee, Wisconsin 53203)

 Juran's Quality Handbook (editors, Joseph M. Juran and A. Blanton Godfrey; Fifth

Edition, McGraw-Hill)

Any questions regarding changes, corrections, updates or enhancements to this document should be forwarded to:

FARGO Electronics, Incorporated Support Services 6533 Flying Cloud Drive Eden Prairie, MN 55344 (USA) (952) 941-9470 (800) 459-5636 FAX: (952) 941-7836

www.fargo.com

E-mail: sales@fargo.com

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Reviewing the DTC500 Series Printers Overview table

DTC500 Series Input

Hoppers

DTC510 (Single-Sided Card Printer/Encoders)

DTC515 (Single-Sided Card Printer/Encoders)

DTC515-LC (SingleSided Card Printer/Encoders)

DTC520 (Dual-Sided Card Printer/Encoders)

DTC525 (Dual-Sided Card Printer/Encoders)

DTC525-LC (DualSided Card Printer/Encoders)

1 100 N/A Optional N/A

2 200 Included Optional Optional

2 200 Included Optional Included

2 100 N/A Optional N/A

2 200 Included Optional Optional

2 200 Included Optional Included

Card Capacity

Security Encoding

Modules

Lamination Module

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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How to use the manual

The DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0) is, in fact, the troubleshooting and field service manual for the entire DTC500 card printer. The manual is designed to provide Installers and Technicians with quick, efficient lookup of related procedures, components and terms. The manual can be used effectively either in soft or hard copy, depending on the preference of the Installer or Technician.

Manual Description

Sequence of Operations, Glossary of Terms and Technical/Functional Specifications (hyper-linked)

Table of Contents (hyperlinked)

Troubleshooting, Replacement, Removal, Diagnostic and Navigation Procedures (in hyper-linked Sections)

Cross-Referencing (hyperlinked)

Comprehensive Index (hyper-linked)

You can go directly to the Sequence of Operations, Glossary of Terms, Technical Specifications and Functional Specifications to learn how to use the processes, procedures, functions and windows for the DTC500 Card Printer/Encoders within concise, correlative tables.

You can use the Table of Contents to quickly locate, for example a procedure, the index or an appendix.

You can go directly to Specifications, General Troubleshooting, Printer Adjustments, Parts Replacement, Printer Packing, Board Level Diagnostics, LCD On-Line Menu Navigation and Firmware Updates to find troubleshooting, removal and replacement procedures. The section titles are always labeled according to their function for consistent usage.

You can use the cross-referencing links to quickly locate an error message or a procedure.

You can use the Comprehensive Index to quickly locate information on the DTC500 Card Printer/Encoders, relating to a specification, a procedural step, a window or screen, a component, a term, a qualifier or a related feature to this printer.

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Safety Messages (review carefully)

Symbol Critical Instructions for Safety purposes

Danger:

Caution:

Failure to follow these installation guidelines can result in death or serious injury.

Information that raises potential safety issues is indicated by a warning symbol (as shown to the below).

 To prevent personal injury, refer to the following safety messages

before performing an operation preceded by this symbol.

 To prevent personal injury, always remove the power cord prior to

performing repair procedures, unless otherwise specified.

 To prevent personal injury, make sure only qualified personnel

perform these procedures.

This device is electrostatically sensitive. It may be damaged if exposed to static electricity discharges.

Information that raises potential electrostatic safety issues is indicated by a warning symbol (as shown to the below).

 To prevent equipment or media damage, refer to the following

safety messages before performing an operation preceded by this symbol.

 To prevent equipment or media damage, observe all established

Electrostatic Discharge (ESD) procedures while handling cables in or near the Circuit Board and Printhead Assemblies.

 To prevent equipment or media damage, always wear an

appropriate personal grounding device (e.g., a high quality wrist strap grounded to avoid potential damage).

 To prevent equipment or media damage, always remove the

Ribbon and Cards from the printer before making any repairs, unless otherwise specified.

 To prevent equipment or media damage, take jewelry off of

fingers and hands, as well as thoroughly clean hands to remove oil and debris before working on the printer.

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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12345

212223

DTC500 Card Printer/Encoders Overview

Reviewing the DTC500 Block Diagram

2526

Motors Sensors Parts

1 Hopper Lift 13 Card Detection 24 Card Input Roller 2 Hopper Transport 14 Flipper Table Card 25 Cleaning Cartridge

3 Encoding/Flipper Feed 15 Encoding TOF 26 Flipper Table Roller 4 Flipper Stepper 16 Flipper Home 27 Flipper Table 5 Ribbon Supply 17 Print TOF 28 Encoding Module 6 Ribbon Take-up 18 Ribbon Sensor Array 29 Encoding Feed Roller 7 Headlift 19 Ribbon Encoder 30 Card Feed Roller 8 Card Feed Stepper 20 Print Headlift 31 Platen Roller 21 Thermistor 32 Printhead 22 Cover Interlock 33 Printhead Cooling Fan 23 Release Lever 34 Card Input Hopper 24 RFID 25 Hopper Lift 26 Hopper Transport 27 Card Feed

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Reviewing DTC 525 Sequence of Operations

The following sequence describes a DTC525 doing a dual sided full color print job with magnetic encoding.

Step Process

1 The File information is received from the PC. 2 The Flipper Stepper activates and rotates the Flipper Table until the Flipper Home

Sensor is activated.

3 The Flipper Stepper rotates the Flipper Table back a specific number of steps

(based on the Flipper Offset setting) to return the Flipper Table to a level position. 4 The Card Detection Sensor detects the presence of a Card in the exception feed. 5 The Hopper Lift Motor activates and lowers the Card Hopper until the Hopper Lift

Sensor detects a change in state. 6 The Card Detection Sensor detects the presence of a Card.

If no card is seen, the following takes place:

a. The Hopper Lift Motor activates and raises the Card Hopper until the Hopper

Lift Sensor detects a change in state.

b. The Hopper Transport Motor activates and moves to the other Hopper until

the Hopper Position Sensor detects a change in state.

c. The Hopper Lift Motor activates and lowers the card Hopper until the Hopper

Lift Sensor is activated.

d. The Card Detection Sensor detects the presence of a Card. 7 The Card Feed Stepper activates and feeds a card through the Cleaning Roller

and onto the Flipper Table. 8 The Flipper Stepper rotates the Flipper Table a certain number of steps (based on

the Encoder Angle setting) to position the card for Encoding. 9 The Encoder/Flipper Feed Motor activates until the Card passes the Encoding

TOF Sensor.

10 The Encoding Feed Motor feeds the Card back to the Flipper Table while the

Magnetic Encoding Head transfers data onto the Magnetic Stripe.

Continued on the next page

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Reviewing DTC 525 Sequence of Operations (continued)

Step Process

11 Repeat Steps 9 to 10 for each Encoding and Verification pass. 12 The Card is centered on the Flipper Table based on input from the Flipper Table

Card Sensor.

13 The Flipper Stepper rotates the Flipper Table a specific number of steps (based on

the Flipper Offset setting) to the Home the Flipper Table.

14 The Card Feed Motor feeds the Card to the Print TOF Sensor. 15 The Ribbon Drives turn ON and move until the correct panel is found by the Print

Ribbon Sensor Array (5 reflective). All Stop. (Note: The Print Ribbon Encoder is

active during this step.)

16 The Headlift Motor engages and moves the printhead down until the Headlift

Sensor is activated. All Stop.

17 The Fan turns ON (as required) and blows cool air over the Printhead.

(Note: The Printhead Thermistor determinates the Printhead Temperature.)

18 Ribbon Drive and Card feed Motors activate and the printhead burns image data

until the image data is depleted. All Stop. (Note: The Ribbon Encoder is active

during this step.)

19 The Headlift Motor engages, moving the printhead up until the Headlift Sensor is

activated. All Stop.

20 The Card Feed Motor feeds the Card back to the Print TOF Sensor. 21 Repeat steps 14 to 20 for the appropriate Number of Color/Overlay Panels. 22 The Card Feed Motor transports the Card back to the Flipper Table. 23 The Flipper Stepper rotates in order to invert the Card. 24 The Card Feed Motor activates and moves the card to the Print TOF Sensor. All

Stop.

25 The Flipper Stepper rotates to return the Flipper Table to a level position. 26 Repeat Steps 14 to 20 for the appropriate Number of Color/Overlay Panels. 27 The Card Feed Motor activates to feed the Card out of the Printer.

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Reviewing DTC 520 Sequence of Operations

The following sequence describes a DTC525 doing a dual sided full color print job with magnetic encoding.

Step Process

1 The File information is received from the PC. 2 The Flipper Stepper activates and rotates the Flipper Table until the Flipper Home

Sensor detects a change in state. 3 The Flipper Stepper rotates the Flipper Table back a specific number of steps

(based on the Flipper Offset setting) to return the Flipper Table to a level position. 4 The Card Detection Sensor detects for the presence of a Card in the exception

feed. 5 The Hopper Lift Motor activates and lowers the Card Hopper until the Hopper Lift

Sensor detects a change in state. 6 The Card Detection Sensor detects the presence of a Card. 7 The Card Feed Stepper activates and feeds a card through the Cleaning Roller

and onto the Flipper Table. 8 The Flipper Stepper rotates the Flipper Table a specific number of steps (based on

the Encoder Angle setting) to position the card for Encoding. 9 The Encoder/Flipper Feed Motor activates until the Card passes the Encoding

TOF Sensor.

10 The Encoding Feed Motor feeds the Card back to the Flipper Table while the

Magnetic Encoding Head transfers data onto the Magnetic Stripe.

11 Repeat Steps 9 to 10 for each Encoding and Verification pass. 12 The Card is centered on the Flipper Table based on input from the Flipper Table

Card Sensor.

Continued on the next page

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Reviewing DTC 520 Sequence of Operations (continued)

13 Flipper Stepper rotates the Flipper Table a certain number of steps (based on the

Flipper Offset setting) to return the Flipper Table to a level position.

14 The Card Feed Motor feeds the Card to the Print TOF Sensor. 15 The Ribbon Drives turn ON and move until the correct panel is detected by the

Print Ribbon Sensor Array (5 reflective). All Stop. (Note: The Print Ribbon

Encoder is active during this step.)

16 The Headlift Motor engages and moves the Printhead down until the Headlift

Sensor detects a change in state. All Stop.

17 The Fan turns ON (as required) and blows cool air on the Printhead.

(Note: The Printhead Thermistor determines the Printhead Temperature.)

18 Ribbon Drive and Card feed Motors activate and the printhead burns image data

until the image data is depleted. All Stop. (Note: The Ribbon Encoder is active

during this step.)

19 The Headlift Motor engages, moving the printhead up until the Headlift Sensor is

activated. All Stop.

20 The Card Feed Motor feeds the Card back to the Print TOF Sensor. 21 Repeat Steps 14 to 20 for the appropriate Number of Color/Overlay Panels. 22 The Card Feed Motor transports the Card back to the Flipper Table. 23 The Flipper Stepper rotates to invert the Card. 24 The Card Feed Motor activates and moves the Card to the Print TOF Sensor. All

Stop.

25 The Flipper Stepper rotates to return the Flipper Table to a level position. 26 Repeat steps 14 to 20 for the appropriate Number of Color/Overlay Panels. 27 The Card Feed Motor activates to feed the Card out of the Printer.

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Reviewing DTC 515 Sequence of Operations

The following sequence describes a DTC515 doing a full color print job with magnetic encoding.

Step Process

1 The File information is received from the PC. 2 The Flipper Stepper activates and rotates the Flipper Table until the Flipper Home

Sensor detects a change in state. 3 The Flipper Stepper rotates the Flipper Table back a specific number of steps

(based on the Flipper Offset setting) to return the Flipper Table to a level position. 4 The Card Detection Sensor detects for the presence of a Card in the exception

feed. 5 The Hopper Lift Motor activates and lowers the Card Hopper until the Hopper Lift

Sensor detects a change in state. 6 Card detection sensor detects for the presence of a card.

If no card is seen, the following takes place:

a. The Hopper Lift Motor activates and raises the card Hopper until the Hopper

Lift Sensor detects a change in state.

b. The Hopper Transport motor activates and move to the other Hopper until the

Hopper Position Sensor detects a change in state.

c. The Hopper Lift Motor activates and lowers the Card Hopper until the Hopper

Lift Sensor detects a change in state.

d. The Card Detection Sensor detects for the presence of a Card. 7 The Card Feed Stepper activates and feeds a Card through the Cleaning Roller

and onto the Flipper Table. 8 The Flipper Stepper rotates the Flipper Table a specific number of steps (based on

the Encoder Angle setting) to position the Card for Encoding. 9 The Encoder/Flipper Feed Motor activates until the Card passes the Encoding

TOF Sensor.

10 The Encoding Feed Motor feeds the Card back to the Flipper Table while the

Magnetic Encoding Head transfers the data onto the Magnetic Stripe.

Continued on the next page

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Reviewing DTC 515 Sequence of Operations (continued)

Step Process

11 Repeat Steps 9 to 10 for each Encoding and Verification pass. 12 The Card is centered on the Flipper Table based on input from the Flipper Table

Card Sensor.

13 The Flipper Stepper rotates the Flipper Table a certain number of steps (based on

the Flipper Offset setting) to return the Flipper Table to a level position.

14 The Card Feed Motor feeds card to the Print TOF Sensor. 15 The Ribbon Drives turn ON and move until the correct panel is found by the Print

Ribbon Sensor Array (5 reflective). All Stop. (Note: The Print Ribbon Encoder is

active during this step.)

16 The Headlift Motor engages and moves the Printhead down until the Headlift

Sensor is activated. All Stop.

17 The Fan turns ON (as required) and blows cool air on the Printhead.

(Note: The Printhead Thermistor determines the Printhead Temperature.)

18 The Ribbon Drive and Card Feed Motors activate and the Printhead burns the

image data until the image data is depleted. All Stop. (Note: The Ribbon Encoder

is active during this step.)

19 The Headlift Motor engages and moves the Printhead up until the Headlift Sensor

detects a change in state. All Stop.

20 The Card Feed Motor feeds the Card back to the Print TOF Sensor. 21 Repeat Steps 14 to 20 for the appropriate Number of Color/Overlay Panels. 22 The Card Feed Motor activates to feed the Card out of the Printer.

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Reviewing DTC 510 Sequence of Operations

The following sequence describes a DTC510 doing a full color print job with magnetic encoding.

Step Process

1 The File information is received from the PC. 2 The Flipper Stepper activates and rotates the Flipper Table until the Flipper Home

Sensor detects a change in state. 3 The Flipper Stepper rotates the Flipper Table back a specific number of steps

(Based on the Flipper Offset setting) to return the Flipper Table to a level position. 4 The Card Detection Sensor detects the presence of a Card in the exception feed. 5 The Hopper Lift Motor activates and lowers the Card Hopper until the Hopper Lift

Sensor detects a change in state. 6 The Card Detection Sensor detects for the presence of a card. 7 The Card Feed Stepper activates and feeds a Card through the Cleaning Roller

and onto the Flipper Table. 8 The Flipper Stepper rotates the Flipper Table a specific number of steps (based on

the Encoder Angle setting) to position the card for Encoding. 9 The Encoder/Flipper Feed Motor activates until the card passes the Encoding TOF

Sensor.

10 The Encoding Feed Motor feeds card back to the flipper table while the Magnetic

Encoding Head transfers data onto the Magnetic Stripe.

11 Repeat Steps 9 to 10 for each encoding/verification pass. 12 The Card is centered on the Flipper Table based on input from the Flipper Table

Card Sensor.

Continued on the next page

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Reviewing DTC 510 Sequence of Operations (continued)

Step Process

13 The Flipper Stepper rotates the Flipper Table a specific number of steps (based on

the Flipper Offset setting) to return the Flipper Table to a level position.

14 The Card Feed Motor feeds card to the Print TOF Sensor. 15 The Ribbon Drives turn ON and move until the correct panel is found by the Print

Ribbon Sensor Array (5 reflective). All Stop. (Note: The Print Ribbon Encoder is

active during this step.)

16 The Headlift Motor engages and moves the Printhead down until the Headlift

Sensor is activated. All Stop.

17 The Fan turns ON (as required) and blows cool air over the Printhead.

(Note: The Printhead Thermistor determines the Printhead Temperature.)

18 The Ribbon Drive and Card Feed Motors activate and the Printhead burns the

image data until the image data is depleted. All Stop. (Note: The Ribbon

Encoder is active during this step.)

19 The Headlift Motor engages and moves the Printhead up until the Headlift Sensor

is activated. All Stop.

20 The Card Feed Motor feeds card back to the Print TOF Sensor. 21 Repeat steps 14 to 20 for the appropriate Number of Color/Overlay Panels. 22 The Card Feed Motor activates to feed the Card out of the Printer.

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Reviewing DTC500 Boot up Sequence

Step Process

1 The Printer checks the installed memory in the Printer. 2 The Printers Firmware is initialized. 3 The Headlift Motor activates and cycles the Printhead one full rotation. 4 The Encoding Feed Motor activates and the Magnetic TOF Sensor checks for

the presence of a Card.

4 The Hopper Transport Motor activates until the Hopper Position Sensor detects

a change in state.

5 The Print Ribbon moves forward until it finds the panel, pauses, advances to

magenta, then backs up to yellow (where the Ribbon Sensor detects marks in the ribbon.

6 The Hopper Lift Motor activates and raises the Hopper until the Hopper Lift

Sensor detects a change in state.

7 The Card Feed Motor activates to clear any Cards from the Card path.

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Lamination

Lamination Station

Reviewing the Lamination Module Sequence of Operations

The LAM sequence of operations begins after printing has occurred with the Card Printer.

Step Process

1 The card is fed onto the Lamination Module Flipper Table. 2 The card is fed to the Card Position Sensor. 3 The Lamination Ribbon Motor begins cycling until the Upper Lamination Sensor

detects the mark. 4 The Card Feed Motor activates to center the card on the Platen Roller. 5 The Lamination Roller Lift Motor cycles until the Lamination Roller Lift Sensor

detects state change.

Continued on the next page

Securing

Latches

Lamination

LED Light

Cancel

Button

Resume

(pause) Button

Card Output

Hopper

Top Cover

Rejection Card Hopper

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Reviewing the Lamination Module Sequence of Operations (continued)

Step Process

6 The Card Feed Motor and the Lamination Ribbon Motor activate for the length of

the card. 7 The Lamination Roller Lift Motor cycles until Lamination Roller Lift Sensor detects

state change. 8 The card is fed back to the Flipper Table. 9 The Flipper Table Clutch engages.

10 The Flipper Table Motor activates until the Card is inverted based on the Flipper

offset setting.

11 The Flipper Table Clutch disengages. 12 The card is fed off the Flipper Table. 13 The Flipper Table Clutch engages. 14 The Flipper Table Motor activates until the Flipper Table is homed. 15 The Flipper Table Clutch disengages. 16 Repeat Steps 2 through 7. 17 The card is fed out of the Printer.

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Reviewing Lamination Module Boot up Sequence

Step Process

1 The Lamination Headlift turns until head up position is returned from Headlift

Sensor.

2 The Lamination Ribbon motor activates to determine the presence of a roll of

lamination. 3 The Lamination Flipper table homes itself. 4 The Card sensor checks for the presence of a card and ejects it if found.

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Table of Contents

Reviewing the DTC500 Series Printers Overview table ________________________________________3 How to use the manual _________________________________________________________________4 Safety Messages (review carefully)________________________________________________________5

DTC500 Card Printer/Encoders Overview__________________________________________ 6

Reviewing the DTC500 Block Diagram__________________________________________________6 Reviewing DTC 525 Sequence of Operations _____________________________________________7 Reviewing DTC 520 Sequence of Operations _____________________________________________9 Reviewing DTC 515 Sequence of Operations ____________________________________________11 Reviewing DTC 510 Sequence of Operations ____________________________________________13 Reviewing DTC500 Boot up Sequence _________________________________________________15 Reviewing the Lamination Module Sequence of Operations _________________________________16 Reviewing Lamination Module Boot up Sequence ________________________________________18

Section 1: Specifications________________________________________________________ 25

Reviewing the DTC500 Series Printers Overview table _______________________________________25 Regulatory Compliances _______________________________________________________________26 Agency Listings______________________________________________________________________27 Technical Specifications _______________________________________________________________27 Functional Specifications ______________________________________________________________32

Printer Components: LCD display to Parallel Interface Port_________________________________34 Printer Components: LCD and Softkey Control Pad_______________________________________38 Printer Components: Centronics-Type Parallel Interface ___________________________________43 Printer Components: Print Ribbons ____________________________________________________44 Printer Components: Embedded Fonts and Bar Codes _____________________________________44 Printer Components: Blank Cards _____________________________________________________45 Reviewing the upgraded 81754 PVC Cards ______________________________________________46 Printer Components: Card Input and Output Hoppers______________________________________48 Printer Components: Lamination Roller ________________________________________________49

Reviewing the Card Lamination Module __________________________________________________50

Determining the Ready Status of the Card Lamination Module_______________________________51 Reviewing the Lamination Top Cover and Station_________________________________________52 Reviewing the Securing Latches and Lamination LED light _________________________________53 Reviewing the Cancel button _________________________________________________________54 Reviewing the Resume (pause) button __________________________________________________55 Reviewing the Rejection Card Hopper and Card Output Hopper______________________________56 Reviewing the Module and Printer interaction____________________________________________57 Reviewing the Module and LCD display interaction _______________________________________58 Reviewing the Module’s Programmed Default Temperature_________________________________59 Reviewing the Laminator Temperature Adjustment________________________________________60

Reviewing the Overlaminates ___________________________________________________________61

Reviewing the Thermal Transfer Film and PolyGuard Overlaminates__________________________61 Reviewing the CR-90 or CR-100 Patch Size _____________________________________________62 Reviewing the Overlaminate Design ___________________________________________________62

Reviewing the Visual Security Solutions __________________________________________________63

VeriMarkTM Cards - 2-D holographic foil application _____________________________________63 Custom HoloMarkTM Cards _________________________________________________________63 Visual Security - Card Stock Part Numbers ______________________________________________63 Visual Security - Fargo Certified Overlaminates (Special Order in 50 quantity minimum)__________63 Visual Security Card Stock - Tolerances ________________________________________________64 VeriMarkTM - Application Specifications_______________________________________________64 HoloMarkTM and Custom HoloMarkTM - Application Specifications ________________________64

Section 2: General Troubleshooting ______________________________________________ 65

Reviewing the LCD display and LED light_________________________________________________65

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Troubleshooting the LCD Messages____________________________________________________65 Verifying the Encoding Settings for DTC500 Series Card Printer and Encoders__________________72 Verifying Encoder Settings for DTC 510/DTC 515 (Symptom A) ____________________________73 Verifying Encoder Settings for DTC 510/DTC 515 (Symptom B) ____________________________73 Verifying the Encoding Settings for the DTC 520/DTC 525 _________________________________77

Communications Errors________________________________________________________________81

Resolving the Communication Errors___________________________________________________81

Card Feeding Errors __________________________________________________________________86

Resolving the Card Feeding Errors_____________________________________________________86 Resolving the Card Jam on the Flipper Table_____________________________________________89 Resolving the Card Hopper Jam Error Message___________________________________________91 Resolving the Card Hopper Empty Error Message_________________________________________92

Encoding Errors______________________________________________________________________93

Resolving the No Magnetic Encoder Error Message _______________________________________93 Resolving the No ENC Response Error Message__________________________________________93 Resolving the Failed Magnetic Encode Error Message _____________________________________94 Resolving the No Prox Encoder Error Message ___________________________________________94 Resolving the No Smart Encoder Error Message __________________________________________95 Resolving the Failed Smart Encode Error Message ________________________________________95 Removing the Card Jam in the Printer’s Magnetic Encoding Area ____________________________96 Removing the Card Jam in the Printer’s Smart Card Encoding Area___________________________97 Resolving the Printer not reading Encoded Magnetic Track Data _____________________________98 Resolving the Magnetic Stripe Data being printed on a Card problem ________________________100

Printing Process Errors _______________________________________________________________101

Resolving the Ribbon Alignment Error Message_________________________________________101 Resolving the Print Ribbon Error Message _____________________________________________102 Resolving the Print Ribbon Out Error Message __________________________________________102 Resolving the Ribbon Jam/Broke Error Message_________________________________________102 Resolving the Wrong Print Ribbon Error Message _______________________________________103 Resolving the Unknown Ribbon Type Error Message _____________________________________104 Resolving the Headlift Error Message _________________________________________________105 Resolving the Printer pausing between panels error_______________________________________106 Resolving the Printhead Temp Error Message ___________________________________________107 Resolving the Flipper Alignment Error Message _________________________________________108

Firmware Errors ____________________________________________________________________109

Resolving the Update Firmware Now _________________________________________________109 Resolving an Upgrade Failed error____________________________________________________109 Resolving a Program Exception Error _________________________________________________112

Diagnosing the Image Problems ________________________________________________________113

Resolving the Pixel failure problems __________________________________________________113 Resolving the Card surface debris problems ____________________________________________116 Resolving the incorrect Image Darkness problems _______________________________________119 Resolving the Ribbon wrinkle problems _______________________________________________122 Resolving the excessive Resin Printing problems ________________________________________124 Resolving the incomplete Resin Printing problems _______________________________________126 Resolving the cut off or off-center Card Image problems __________________________________128 Resolving the poor Image Quality problems ____________________________________________129

Printing a Test Image ________________________________________________________________130

Reviewing the Gray/Align YMC/K Self-Test ___________________________________________130 Reviewing the Color/Resin YMCK Self-Test ___________________________________________131 Reviewing the Color Bars YMC Self-Test ______________________________________________131 Reviewing the Card Count Self-Test __________________________________________________132 Reviewing the Magnetic Test option __________________________________________________132

Section 3: Card Lamination Module ____________________________________________ 133

Safety Messages (review carefully)______________________________________________________133

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Loading the Overlaminate_____________________________________________________________134 Adjusting the Card Lamination Module __________________________________________________137

Adjusting the Card Flattener_________________________________________________________137 Adjusting the Card Guide Rail _______________________________________________________139 Adjusting the Internal Card Guide ____________________________________________________143 Attaching the Card Lamination Module ________________________________________________145

Section 4: Printer Adjustments_________________________________________________ 151

Safety Messages (review carefully)______________________________________________________151

Adjusting the Internal Card Guide ____________________________________________________152 Printer Driver options ________________________________________________________________154 Using the Device options tab___________________________________________________________154

Adjusting for the Ribbon Type_______________________________________________________155

Adjusting for the Color matching _____________________________________________________156

Adjusting for the Resin Dither _______________________________________________________157

Using the Print Both Sides option (DTC520/DTC525 only) ________________________________158

Using the Split 1 Set of Ribbon Panels option (DTC520/DTC525 only) _______________________159

Using the Print Back Side First option _________________________________________________160

Using the Print on Back Side Only option (DTC520/DTC525 only) __________________________161

Using the Rotate Front by 180 Degrees option___________________________________________162

Using the Rotate Back by 180 Degrees option (DTC520/DTC525 only)_______________________163

Using the Buffer Single Card option __________________________________________________164

Using the Link Card to Print Job option________________________________________________165

Using the Disable Printing option_____________________________________________________166 Using the Image Color tab_____________________________________________________________167 Using the K Panel Resin tab ___________________________________________________________171

Selecting the Full Card with the K Panel Resin tab _______________________________________172

Selecting the Defined Area(s) with the K Panel Resin tab __________________________________173

Selecting the Undefined Area(s) with the K Panel Resin tab ________________________________174

Defining the Area to activate the Card Grid _____________________________________________175

Measuring the Total Card area _______________________________________________________176

Defining the positioning of the area on the Card _________________________________________178

Selecting the Print YMC under the K and Print K Only options _____________________________180 Using the Magnetic Encoding tab _______________________________________________________182

Using the Encoding Mode option _____________________________________________________183

Encoding the Mode/Coercivity/Magnetic Track Selection__________________________________185

Using the Magnetic Track Selection option _____________________________________________187

Reviewing the Enable MLE Support checkbox __________________________________________188

Using the Magnetic Track options ____________________________________________________189

Using the Bit Density radio buttons ___________________________________________________190

Using the Character Size radio buttons_________________________________________________190

Using the ASCII Offset ____________________________________________________________191

Using the LRC Generation radio buttons _______________________________________________192

Using the Character Parity radio buttons _______________________________________________192

Using the Verification option ________________________________________________________193

Reviewing the Shift Data Left _______________________________________________________194

Reviewing the ISO Track Locations___________________________________________________195

Reviewing the Sample String ________________________________________________________195

Sending the Track Information_______________________________________________________196

Reviewing the ASCII Code and Character Table_________________________________________197 Using the Overlay/Print Area tab _______________________________________________________198

Using the Overlay/Print Area dropdown menu __________________________________________199

Using the Overlay/Print Area ________________________________________________________200

Using Security Options (Visual Security Solutions)_______________________________________206

Selecting Orientation - Landscape under Card tab ________________________________________207

Selecting the Visual Security Solutions dropdown menu (A to D) ___________________________208

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Selecting Orientation - Portfolio under Card tab _________________________________________209

Selecting the Visual Security Solutions dropdown menu (E to H)____________________________210

Selecting the VeriMark radio button __________________________________________________211

Selecting the HoloMark radio button __________________________________________________212

Reviewing the Custom VeriMark Card ________________________________________________213

Reviewing the Custom HoloMark Card ________________________________________________214

Using SmartShield Area dropdown menu ______________________________________________215 Using the Card tab___________________________________________________________________216

Selecting the Card Size_____________________________________________________________217

Using the Card Hopper Selection (DTC515/DTC525 only) option ___________________________219

Reviewing the Orientation __________________________________________________________222

Specifying the Copies______________________________________________________________222

Using the Test Print button__________________________________________________________223

Clicking on the About button ________________________________________________________224

Using the Image Position button______________________________________________________225 Using the Lamination tab (only with Card Lamination Module) _______________________________228

Selecting the Lamination Position ____________________________________________________229

Selecting the Lamination Side _______________________________________________________230

Selecting the Lamination Type_______________________________________________________231

Selecting the Lamination Type_______________________________________________________232

Adjusting the Transfer Dwell Time and Transfer Temperature ______________________________233

Selecting the Sensors button and Defaults button_________________________________________233

Calibrating the Card Lamination Module’s Lamination Sensor______________________________234

Section 5: Cleaning___________________________________________________________ 235

Safety Messages (review carefully)______________________________________________________235

Cleaning the Printhead (850102) _____________________________________________________236

Replacing the Card Cleaning Tape____________________________________________________237

Cleaning the Platen and Card Feed Rollers _____________________________________________239

Cleaning the Platen________________________________________________________________242

Cleaning the Printer's Exterior _______________________________________________________243

Cleaning the Printer's Interior________________________________________________________243

Section 6 Packing the DTC500 Card Printer______________________________________ 245 Section 7 Board Level Diagnostics_______________________________________________ 246

Board Errors _______________________________________________________________________246

Resolving the EE Memory Error _____________________________________________________246

Resolving the EE Checksum Error____________________________________________________246

Resolving the DRAM Memory Error__________________________________________________247

Resolving the RAM Memory Error ___________________________________________________247

Resolving the FPGA Error __________________________________________________________247 Sensor Testing______________________________________________________________________248

Reviewing the Sensor Location and Voltages ___________________________________________249

Reviewing the Sensor Layout on Ribbon Sensor array ____________________________________250

Section 8 LCD On-Line Menu Navigation________________________________________ 251

Entering the LCD Menu and selecting an Option ___________________________________________251

Using the Softkey and Scroll buttons __________________________________________________252 Accessing the Menu Option Structure Tree________________________________________________252

Selecting from the Menu Option Structure Tree__________________________________________253 Using the LCD Menu ________________________________________________________________254

Printing the Self-test_______________________________________________________________254

Reviewing the Gray/Align YMC (DTC510/515) and Gray/Align YMC/K (DTC520/525) Self-Test _255

Reviewing the Color/Resin YMCK Self-Test ___________________________________________255

Reviewing the Card Count YMC Self-Test _____________________________________________256

Reviewing the Standard Resin Self-Test _______________________________________________256

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Using the Magnetic Test option (only with Magnetic Encoding Module) ______________________257

Setting up the Printer ______________________________________________________________257 Print TOF and Print EOF Alignment Procedures ___________________________________________258

Preparing to Adjust the Print TOF and Print EOF ________________________________________259

Setting the Print TOF ______________________________________________________________259

Setting the Print EOF ______________________________________________________________260

Adjusting the Ribbon Tension _______________________________________________________262

Setting the Printhead Resistance______________________________________________________263

Adjusting the Image Darkness _______________________________________________________264

Changing the Encoder Settings_______________________________________________________265

Adjusting the Magnetic TOF ________________________________________________________266

Changing the Hopper Settings _______________________________________________________268

Changing the BAUD Rate Settings ___________________________________________________269

Adjusting the Flipper Offset _________________________________________________________269

Viewing the Report Supplies ________________________________________________________270

Using the Show the Error Count Tool _________________________________________________270

Showing the Card Count____________________________________________________________271

Selecting the System Upgrade (Firmware Upgrade) ______________________________________271

Section 9 Firmware Updates ___________________________________________________ 272

Firmware Updater Application Program__________________________________________________272 Downloading Firmware Updates________________________________________________________274 Updating the Printer's Firmware ________________________________________________________275

Updating the Main Firmware ________________________________________________________275

Updating the LCD Firmware ________________________________________________________278

Section 10 DTC500 Enhancement Kit Instructions Overview________________________ 280

Reviewing the Parts (included with the Kit; 1 set per Card Printer)___________________________280

Reviewing the required Tools________________________________________________________281

Reviewing the required Media supplies ________________________________________________281 Updating the Process Strategy__________________________________________________________282

Determining the Card Printer qualifications for the Update_________________________________282

Unpacking the Card Printer _________________________________________________________283

Removing the Printer's main plastic casing _____________________________________________284

Inspecting the Drive Pulley _________________________________________________________285

Installing the Push-Clip onto the Drive Roller ___________________________________________287

Removing and installing the Card Feed Roller (D850415) _________________________________288

Installing the Sensor Holder _________________________________________________________290

Installing the new Card Input Hopper in the single Hopper units (DTC510/520) ________________293

Installing the new Card Input Hopper in the dual Hopper units (DTC515/525)__________________296

Applying the Close Door While Printing Label (L000188) _________________________________299

Applying the Ribbon Loading Label (L000108) _________________________________________300

Replacing the plastic Printer casing ___________________________________________________301

Powering up the Unit and confirming its Ready status_____________________________________302

Upgrading the Firmware to Version 1.5.1 ______________________________________________303

Confirming the Printer operations ____________________________________________________306

Removing the Media from the Printer _________________________________________________314

Repackaging the Printer ____________________________________________________________314

Section 11 Fargo Technical Support_____________________________________________ 316

Contacting Fargo Technical Support_____________________________________________________316 Reading the Serial Numbers on a Fargo printer ____________________________________________317

Finding out when a Fargo Card Printer was manufactured _________________________________317

Reviewing Example No. 1: Serial Number 80453289_____________________________________317

Reviewing Example No. 2: Serial Number A1280224 ____________________________________317

Section 12 Reviewing Spare Parts Lists __________________________________________ 318

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Reviewing the Spare Parts List for DTC 500 Series Card Printer ____________________________318

Reviewing the Spare Parts List for the DTC500 LAM_____________________________________318

Glossary of Terms ____________________________________________________________ 319 Index_______________________________________________________________________ 339

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Section 1: Specifications

The purpose of this section is to provide the User with specific information on the Regulatory Compliances, Agency Listings, Technical Specifications and Functional Specifications for the DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0).

Reviewing the DTC500 Series Printers Overview table

DTC500 Series Input

Hoppers

DTC510 (Single-Sided Card Printer/Encoders)

DTC515 (Single-Sided Card Printer/Encoders)

DTC515-LC (SingleSided Card Printer/Encoders)

DTC520 (Dual-Sided Card Printer/Encoders)

DTC525 (Dual-Sided Card Printer/Encoders)

DTC525-LC (DualSided Card Printer/Encoders)

1 100 N/A Optional N/A

2 200 Included Optional Optional

2 200 Included Optional Included

2 100 N/A Optional N/A

2 200 Included Optional Optional

2 200 Included Optional Included

Card Capacity

Security Encoding

Modules

Lamination Module

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Regulatory Compliances

Term Description

CSA The Printer manufacturer has been authorized by UL to represent the

Card Printer as CSA Certified under CSA Standard 22.2. File Number: E145118

FCC The Card Printer complies with the requirements in Part 15 of the FCC

rules for a Class B digital device. (Note: These requirements are designed to provide reasonable protection against harmful interference in a residential installation.)

If equipment operation in a residential area causes unacceptable interference to radio and TV reception, the operator is required to take whatever steps are necessary to correct the interference.

ITS-EMC The Card Printer has been tested and complies with EN55022 Class B:

1995 and EN82082-1: 1997 standards for EMI emissions. (Note: Based on the above testing, the Printer manufacturer certifies

that the Card Printer complies with all current EMC directives of the European Community and has placed the CE mark on the Card Printer.)

License Number: J99032510

TÜV-GS The Card Printer has been tested and complies with IEC950 and bears

the TÜV-GS mark. License Number: S9971826

UL The Card Printer is listed under UL 1950 INFORMATION

TECHNOLOGY EQUIPMENT. File Number: E145118, Volume 1, Section 15

DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Agency Listings

Term Description

Emissions Standards

Safety Standards

EMC: ITS (EN 55022 Class B:1995), FCC Class B, EN 50082-1:1997, BSMI, CRC c1374, CE and CCIB

UL 1950, CSA C2.2 (No.950-95) and TüV-GS (IEC-950), CE and CCIB.

Technical Specifications

Term Description

Accepted Standard Card Size

Accepted Card Thickness

Accepted Card Types

Accepted Card Compositions

CR-79 Adhesive Back: 3.303 in. x 2.051 in. (83.9mm x 52.1mm) (cannot be laminated with DTC515-LC or DTC525-LC)

CR-80: 3.375 in. x 2.125 in. (85.6mm x 54mm) (corresponds to ID1) .010 in. (10 mil) to .050 in. (50 mil) (.254mm to 1.27mm); unless

laminating. HID Proximity Cards, Mifare Contactless Smart Cards and Contact

Smart Cards PVC or polyester cards with polished PVC finish; monochrome resin

required for 100% polyester cards.

Barcodes Code 39, Code 128 B & C with and without check digit (available with

embedded font and bar code option): 2 of 5, UPC-A, EAN 13 and PDF-417 2D bar code and other symbologies (available via Windows driver).

Card Input Hopper Capacity

Card Output Hopper Capacity

 DTC510/520: Single-stack hopper, 100 cards (30 mil); auto or

manual feed

 DTC515/525: Dual-stack hopper, 200 cards (30 mil); auto or

manual feed

 DTC515-LC/525-LC: Dual Hopper; 200 cards (.030”); auto or

manual feed

100 cards (30 mil)

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DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Technical Specifications (continued)

Term Description

Card Cleaning Removable card cleaning cartridge with replaceable cleaning tape. Colors Up to 16.7 million colors and 256 shades per pixel. Dimensions DTC510/515/520/525: 10.75 in. H x 18.5 in. W x 11 in. D (273mm x

470mm x 279mmD). DTC515-LC/525-LC: 10.75 in. H x 30.5 in. W x 11 in. D (273mm x

775mm x 279mmD). LC Module: 10.25” H x 30” W x 11”D/260mm H x 762mm W x

279mmD

Display SmartScreen LCD Control Panel; LED display on Card Lamination

Module.

Fonts Resident Swiss Bold 8, 10, 12, 14, 16, 18 and 22 are available with

embedded font and bar code option.

TrueType fonts are available via the Windows driver. Humidity 20% to 80% Non-Condensing. Interface

 Centronics Parallel, IEEE 1284 compliant

 Optional EIA-232C serial interface (for embedded fonts and bar

codes option)

 Optional USB-to-Parallel Interface Cable (Windows

98/Me/2000/XP)

Memory 4 MB RAM Operating

65ºF to 80ºF (18ºC to 27ºC). Temperature

Print Area

CR-80 edge-to-edge: (3.37 in. x 2.12 in./85.5mm x 53.5mm)

CR-79: (3.3 in. x 2.051 in./83.8mm x 52.1mm)

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DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Technical Specifications (continued)

Term Description

Print Speed – Batch Mode

 DTC510/515: 7 seconds per card/514 cards per hour (K)*

 DTC510/515: 12 seconds per card/300 cards per hour (BO)*

 DTC510/515: 27 seconds per card/133 cards per hour

(YMCKO)*

 DTC520/525: 35 seconds per card/102 cards per hour

(YMCKOK)*

 DTC515-LC/525-LC: 30 seconds per card/133 cards per hour

(YMCK/lamination)*

 DTC525-LC: 36 seconds per card /102 cards per hour

(YMCKK/lamination)*

*Indicates the print Ribbon type and the number of Ribbon panels

printed where Y=Yellow, M=Magenta, C=Cyan, K=Resin Black,

B=Dye-Sublimation Black and O=Overlay.

 Print speeds do not include the time needed for the PC to process

the image.

 Process time is dependent on the size of the file, the CPU,

amount of RAM and the amount of available resources at the time of the print.

 Print speed indicates an approximate batch print speed and is

measured from the time a card feeds into the Printer to the time it ejects from the Printer. (Note: The single card print speeds will be slower than the batch print speeds listed above since batch print speed is enhanced by the Printer's multi-tasking capabilities

when printing multiple cards in succession.) Printing Method Dye-Sublimation/Resin Thermal Transfer. Overlaminate

Options (for LC)

Thermal Transfer Overlaminate, .25 mil thick PolyGuard Overlaminate, 1.0 mil and .6 mil thick All overlaminates available in clear, holographic globe design or

custom holographic design

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DTC500 Series Card Printer/Encoders User Guide (Rev. 5.0)

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Technical Specifications (continued)

Term Description

Options

Encoding Options

 Printer Cleaning Kit  External Print Server (Windows only; required for stand-alone

networking of printer/encoders)

 Card Lamination Module (DTC515 and DTC525 only)  Embedded Fonts and Bar Codes to print from AS/400, mainframe

and other systems

o Code 39, Code 128 B & C with and without check digit o 2 of 5 o UPC-A o EAN 13 o PDF-417 2D bar code and other symbologies available via

Windows driver

o Resident: Swiss Bold 8, 10, 12, 14, 16, 18 and 22

 ISO Magnetic Stripe Encoding Module, dual high- and low-

coercivity, Tracks 1, 2 and 3

 JIS II Magnetic Stripe Encoding Module  E-Card Docking Station (required for all e-card options or 3rd party

Smart card encoding)

Fargo Certified Supplies

Printing Resolution

 Contactless Smart Card Encoder (MIFARE)  Contact Smart Card Encoder reads from and writes to all

ISO7816-1/2/3/4 memory and microprocessor smart cards (T=0,

T=1) as well as synchronous cards

 Prox Card Encoder (HID read-only); I class Fargo Card Printer/Encoders require highly specialized media to

function properly. To maximize printed card quality, printhead life and printer/encoder reliability, use only Fargo Certified Supplies. Fargo warranties are void, where not prohibited by law, when non-Fargo Certified Supplies are used.

Up to 16.7 million colors and 256 shades per pixel. 300 dpi (11.8 dots/mm)

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