FARGO electronics HDP820, HDP820-LC, HDP825 Service Manual

Download

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

• HDP820 (Dual-Sided Card Printer/Encoders)

• HDP820-LC (Dual-Sided Card Printer/Encoders)

• HDP825 (Dual-Sided Card Printer/Encoders)

• HDP825-LC (Dual-Sided Card Printer/Encoders)

Part Number: L000307

RESTRICTED USE ONLY FARGO Electronic, Inc.

HDP 800 Series Card Printer/Encoders Service Manual (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

HDP 800 Series Card Printer/Encoders Service Manual (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

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY FARGO Electronic, Inc.

Reviewing the HDP800 Series Printers Overview table

HDP800 Series Input

Hoppers

HDP820 (Dual-Sided Card Printer/Encoders)

HDP820-LC (DualSided Card Printer/Encoders)

HDP825 (Dual-Sided Card Printer/Encoders)

HDP825-LC (DualSided Card Printer/Encoders)

1 250 CR-80,

2 200 CR-80 Optional Optional

2 200 CR-80 Optional Included

Card Capacity

Accepted Card Size

CR-90 &

CR-100

CR-90 &

CR-100

Encoding Modules

Optional Optional

Optional Included

Lamination Module

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

iii

RESTRICTED USE ONLY FARGO Electronic, Inc.

How to use the manual

The HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0) 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 HDP 800 Series Card Printer/Encoders within concise, correlative tables.

You can use the Table of Contents to quickly locate an error message, 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 HDP 800 Series card Printer, relating to a specification, a procedural step, a window or screen, a component, a term, a qualifier or a related feature to this Printer.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY FARGO Electronic, Inc.

Safety Messages (review carefully)

Symbol Critical Instructions for Safety purposes

Danger: 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.

Caution: 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.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY FARGO Electronic, Inc.

123

323334

35363738

454

HDP 800 Series Card Printer/Encoders Overview

Reviewing the HDP 800 Series Block Diagram

Motors Sensors Parts

1 Card Input 13 Card Low 32 Card Input Roller 2 Card Feed Stepper 14 Card Detection 33 Cleaning Cartridge

3 Flipper Stepper 15 Flipper Table Card 34 Flipper Table Roller 4 Lamination Stepper 16 Encoding TOF 35 Flipper Table 5 Print Stepper 17 Flipper Home 36 Encoding Module 6 Lamination Headlift 18 Card TOF 37 Encoding Feed Roller 7 Film Supply 19 Lower Film 38 Card Feed Roller 8 Film Take Up 20 Film Take Up Encoder 39 Card Feed Roller 9 Ribbon Supply 21 Thermocouple 40 Platen Roller 10 Ribbon Take Up 22 Film Supply Encoder 41 Flattener Roller 11 Print Headlift 23 Upper Film 42 Card Feed Roller 12 Stacker Lift 24 Ribbon Sensor Array 43 Flattener Cooling Fan

25 Ribbon Encoder 44 Lamination Roller 26 Print Headlift 45 Transfer Platen Roller 27 Thermistor 46 Printhead 28 Stacker Lift 47 Printhead Cooling Fan 29 Stacker Full 48 Film Cooling Fan 30 Cover Interlock 49 Card Input Hopper 31 Release Lever 50 Card Output Stacker

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY FARGO Electronic, Inc.

LCD Display

Softkey Buttons

Card Input Hopper

Front Access Door

Reviewing HDP 800 Series Card Printer - Sequence of Operations

The following sequence describes a dual sided full color print job with magnetic encoding. This Printer also has an optional Card Stacker installed. (Note: The HDP825/825-LC Printers have two (2) Card Input Hoppers that load 100 cards in each Hopper.)

Step

Process

1 The File information is received from the PC.

2 The Heater warms up and/or maintains the heat on the hot Roller using the

Thermocouple to help maintain the desired temp.

3 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.)

4 The Film Ribbon Drive turns ON until the Film is positioned with the Film alignment

Sensor. All stop. (Note: The Film Ribbon Encoder is active during this step.)

5 The Headlift Motor engages, moving the Printhead down until Headlift Sensor is

activated. All stop.

Continued on the next page

Print Station

Printhead

Card Output

Hopper

Film Tension

Knobs

LED Light

Scroll Buttons

Access Card Slot

Transfer Station

Release Lever

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

Card Thickness Adjustment Knob

Card Cleaning Assembly

vii

RESTRICTED USE ONLY FARGO Electronic, Inc.

Reviewing HDP 800 Series Card Printer - Sequence of Operations (cont.)

Step Process

5 The Fan turns ON as required to keep head cool.

6 The Ribbon Drives, Film Ribbon Drive and Stepper turn ON and the Printhead

burns the image data until the image data is depleted. All stop. (Note: The Ribbon Encoders are active during this step.)

7 The Headlift Motor engages, moving the Printhead up until the Headlift Sensor is

activated. All stop.

8 The Ribbon Drives and Film Ribbon Drive advance until the Print Ribbon Encoder

sees acceleration at release. (Note: The Ribbon Encoders are active during this step.)

9 The Ribbon Drives move until the Print Ribbon Position Sensor finds the next

panel. All Motors stop. (Note: The Ribbon Encoder is active during this step.)

10 The Film ribbon drive turns ON until the images portion of the Film is positioned

before the Printhead, using the Film Alignment Sensor. All stop. (Note: The Ribbon Encoder is active during this step.)

11 The Headlift Motor engages, moving printhead down until the Headlift Sensor is

activated. All stop.

12 Ribbon Drive, Film Ribbon Drive and Stepper all turn ON and the Printhead burns

image data until the image data is depleted. All stop. (Note: The Ribbon Encoders are active during this step.)

13 The Headlift Motor engages, moving the Printhead up until the Headlift Sensor is

activated. All stop.

14 The Ribbon Drive and Film Ribbon Drive engage until print ribbon encoder sees

acceleration at release. (Note: The Ribbon Encoders are active during this step.)

15 Repeat Steps 9 to 14 for the appropriate number of color/heat seal panels.

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

viii

RESTRICTED USE ONLY FARGO Electronic, Inc.

o create a slack region between the Printer and Laminator sections. All stop.

Reviewing HDP 800 Series Card Printer - Sequence of Operations (continued)

Step Process

16 The Ribbon Drives turn ON to advance the printed portion of the Film to a position

near the heated lam Roller using the Lamination Film Alignment Sensor.

The Ribbon Drive stays ON for a certain number of additional clicks after turns OFF t (Note: Ribbon encoders and dancer zero position switch are active during this step.)

17 The Ribbon Drive is used with the Lamination Film Alignment Sensor to locate the

printed Film more precisely under the hot Roller. All stop.

18 This is simultaneous to Steps 1 to 17 and then Steps 19 to 24 will occur.

19 The DC Motor and Stepper Motor turn ON and run until a card is seen by the card

Sensor, which will cause the Card Input Motor to stop.

The Stepper will continue to run a certain number of steps to position the card on the Flipper Table. All stop. Card Low Sensor will check for cards in Input Hopper.

20 Stepper will turn ON, causing the Flipper to turn to the magnetic angular position.

The Flag Sensor and counted steps are used to determine the angular position. All stop.

21 Stepper will engage to drive the card past the Mag Card Sensor and the Mag

Head.

22 Stepper engages to drive the card to a centered position on the Flipper Table

using the Mag Card Sensor and a step count. All stop.

23 Stepper will turn ON, causing the Flipper to turn to the default (flat) position. The

Flat Sensor and counted steps are used to determine the angular position. All stop.

24 Steppers engage to move the card OFF the Flipper and to a position near the hot

Roller, using Card Feed Sensors and a step count. All stop.

25 Stepper engages to move the card to a position directly under the hot Roller. The

Top of Form Sensor determines card edge and number of steps to position card. All stop.

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY FARGO Electronic, Inc.

Reviewing HDP 800 Series Card Printer - Sequence of Operations (continued)

Step Process

26 If the heater is not at the required temperature yet, the job will pause.

27 The Headlift Motor turns ON to lower the hot Roller and will stop when the Headlift

Sensor is activated. All off.

28 The Stepper and Ribbon Drive engage to laminate the printed Film onto the card.

They will turn off after a given number of steps based on the position given by the card Sensor. All stop. (Note: The Ribbon Encoder is active during this step.)

29 The Headlift Motor turns on to raise the hot Roller, stopping when the Headlift

Sensor is activated.

30 The Ribbon Drive and Stepper turn ON for a given number of clicks based on

ribbon encoder, until the ribbon is released.

31 The Stepper turns ON to move the card through the flattening section and into the

output hopper (based on steps from a known position). All stop.

32 The Heater and Thermocouple are maintained at a set temperature at all times

when the Printer is ON. The cooling fan is ON when the Printer is ON.

33 The Stacker Lift Motor engages until the Stacker Lift Sensor is activated.

34 The Stacker Full Sensor checks for presence of cards.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY FARGO Electronic, Inc.

Reviewing the HDP 800 Series Card Printer/Encoders - Boot up Sequence

Step Process

1 The Card feed stepper turns ON (to check for a card on the Flipper table).

2 The Lam Headlift turns until the head up position is returned from the Headlift

Sensor).

3 The Film transfer take-up Motor turns ON to take up any slack in the dancer (and

runs until the Dancer Down Sensor is activated).

4 The Print Headlift turns until head up position is returned from Headlift Sensor.

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

to magenta, then backs up to yellow (the Ribbon Sensor detects marks on the ribbon).

6 The Transfer Ribbon advances forward two panels from supply (advances until

the Print Film Sensor senses 2 marks on the Film).

7 The Transfer Ribbon advances forward one panel onto take up (advances until

the Transfer Film Sensor senses 1 mark on the Film)

8 The Transfer Ribbon advances forward one panel from supply (advances until

the Print Film Sensor senses 1 mark on the Film).

9 The Transfer Ribbon advances forward one panel onto take up (advances until

the transfer Film Sensor senses 1 mark on the Film).

10 The Transfer Ribbon reverses for one panel from take up (reverses until transfer

the Film Sensor senses 1 mark on the Film).

11 The Transfer Ribbon reverses for one panel onto supply (reverses until the Print

Film Sensor senses 1 mark on the Film).

12 The Transfer Ribbon reverses for one panel from take up (reverses until the

Transfer Film Sensor senses 1 mark up on the Film).

13 The Transfer Ribbon reverses for one panel onto supply (reverses until the Print

Film Sensor senses 1 mark on the Film).

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY FARGO Electronic, Inc.

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 Top Cover

Cancel

Button

Resume

(pause) Button

Card Output

Hopper

Lamination

LED Light

Rejection Card Hopper

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

xii

RESTRICTED USE ONLY FARGO Electronic, Inc.

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 the 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.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

xiii

RESTRICTED USE ONLY FARGO Electronic, Inc.

Reviewing Lamination Module Boot up Sequence

Step Process

1 The Lamination Headlift turns until the 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.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

xiv

RESTRICTED USE ONLY Fargo Electronics, Inc.

Table of Contents

Section 1: Specifications _________________________________________________ 10

Reviewing the HDP800 Series Printers Overview table ________________________ 10 Regulatory Compliances ________________________________________________ 11 Agency Listings _______________________________________________________ 11 Technical Specifications ________________________________________________ 12 Functional Specifications________________________________________________ 16

Printer Components: Access Card Slot to Parallel Interface Port_______________ 17 Printer Components: LCD and Softkey Control Pad ________________________ 25 Printer Components: Centronics-Type Parallel Interface _____________________ 31 Printer Components: Print Ribbons _____________________________________ 32 Printer Components: Blank Cards_______________________________________ 33 Printer Components: Card Input Hopper (HDP820/820-LC) __________________ 34 Printer Components: Card Input Hopper (HDP825/825-LC) __________________ 35 Printer Components: Card Output Hopper ________________________________ 36 Printer Components: Lamination Roller __________________________________ 37

Reviewing the Card Lamination Module____________________________________ 38

Reviewing the Lamination Top Cover and Station __________________________ 39 Reviewing the Securing Latches and Lamination LED Light __________________ 40 Reviewing the Cancel button ___________________________________________ 41 Reviewing the Resume (pause) button____________________________________ 42 Reviewing the Rejection Card Hopper and Card Output Hopper _______________ 43 Reviewing the Module and Printer interaction _____________________________ 44 Reviewing the Module and LCD Display interaction ________________________ 45 Reviewing the Module’s Programmed Default Temperature __________________ 46 Reviewing the Laminator Temperature Adjustment _________________________ 47

Reviewing the Overlaminates ____________________________________________ 48

Reviewing the Thermal Transfer Film and PolyGuard Overlaminates ___________ 48 Reviewing the CR-90 or CR-100 Patch Size _______________________________ 49 Reviewing the Overlaminate Design _____________________________________ 49

Section 2: General Troubleshooting _______________________________________ 50

LCD/SmartGuard Messages______________________________________________ 50

Reviewing LCD Messages_____________________________________________ 50 Reviewing SmartGuard™ Error and Status Messages _______________________ 58

Communications Errors _________________________________________________ 60

Resolving the Communication Errors ____________________________________ 60

Firmware Errors _______________________________________________________ 63

Resolving the Upgrade Failed error ______________________________________ 63

Card Feeding Errors ____________________________________________________ 65

Resolving the Card Feeding problem (HDP820/820-LC) _____________________ 65 Resolving the Card Feeding Errors (HDP825/825-LC)_______________________ 68 Resolving the stalled Cards on or at the Feed Rollers ________________________ 71 Resolving the jammed Cards on the Flipper Table __________________________ 71 Resolving the Flipper Alignment Error Message____________________________ 72 Resolving the Cards being fed improperly off the Flipper Table _______________ 73

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving the Card Jam Error Message___________________________________ 74 Resolving the Card Jam: Lam Error Message______________________________ 75

Magnetic Encoding Errors _______________________________________________ 76

Resolving the No ENC Response Error Message ___________________________ 76 Resolving the No Magnetic Encoder Error Message_________________________ 76 Resolving the Failed Magnetic Encode Error Message _______________________ 77 Removing the Card jam in the Printer’s Magnetic Encoding Area ______________ 78 Resolving the Printer being unable to read Encoded Magnetic track Data problem _ 79 Resolving the magnetic stripe Data being printed on a Card problem ___________ 80

E-card Encoding Errors _________________________________________________ 81

Resolving the Job Mismatch error _______________________________________ 81 Removing the Card jam in the Printer’s Smart Card Encoding Area ____________ 82 Resolving the No Prox Encoder Error Message ____________________________ 83 Resolving the No Smart Encoder Error Message ___________________________ 83 Resolving the Failed Smart Encode Error Message__________________________ 84

Printing Process Errors__________________________________________________ 85

Resolving the Ribbon Alignment Error Message ___________________________ 85 Resolving the Print Ribbon Jam_________________________________________ 86 Resolving the Print Ribbon Error Message ________________________________ 86 Resolving the Print Ribbon Out Error Message_____________________________ 87 Resolving the Wrong Print Ribbon Error Message __________________________ 87 Resolving the Unknown Ribbon Type Error Message _______________________ 88 Resolving the Headlift Error Message ____________________________________ 88 Resolving the Printer pausing between Panels problem ______________________ 89 Resolving the Printhead Temp Error Message______________________________ 90 Resolving the Printer Open Error Message ________________________________ 90

Transfer Process Errors _________________________________________________ 91

Resolving the Upper and Lower Film errors _______________________________ 91 Resolving the Film Sensor errors________________________________________ 93 Resolving the Transfer Cooling error ____________________________________ 97 Resolving the Card Jam Error Message___________________________________ 98 Resolving the Temperature Timeout Error Message _________________________ 99 Resolving the Transfer Lift Error Message ________________________________ 99 Resolving the Output Stacker errors ____________________________________ 100

Card Lamination Errors ________________________________________________ 101

Resolving the Overlaminate Jam _______________________________________ 101 Resolving the Card Lamination Placement errors __________________________ 103 Resolving the Lam Error/Out Error Message _____________________________ 104 Resolving the Lamination (not adhering to the card surface) problem __________ 106

Diagnosing the Image Problems _________________________________________ 108

Resolving the Pixel failure problems ____________________________________ 108 Resolving the Card surface debris problems ______________________________ 110 Resolving the incorrect Image Darkness problems _________________________ 113 Resolving the Ribbon wrinkle problems _________________________________ 115 Resolving the excessive Resin Printing problems __________________________ 117 Resolving the incomplete Resin Printing problems_________________________ 118

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving the HDP Film wrinkle problems_______________________________ 119 Resolving the incomplete Transfer problems _____________________________ 121 Resolving an incomplete transfer on the leading edge problem _______________ 122 Resolving an incomplete transfer on the trailing edge problem _______________ 122 Resolving the Image Placement problems ________________________________ 123 Resolving the poor Image Quality problems ______________________________ 127 Resolving the Image washout on Film problems___________________________ 128 Resolving the Registration problems ____________________________________ 129 Resolving the Card Skewed Image problems _____________________________ 131

Printing a Test Image __________________________________________________ 132

Reviewing the Gray/Align YMC/K Self-Test _____________________________ 132 Reviewing the Color/Resin YMCK Self-Test _____________________________ 133 Reviewing the Color Bars YMC Self-Test _______________________________ 133 Reviewing the Card Count Self-Test ____________________________________ 134 Reviewing the Magnetic Test option ____________________________________ 134 Reviewing the Lamination Color/Resin YMCK+L Self-Test _________________ 135

Section 3: Card Lamination Module______________________________________ 136

Safety Messages (review carefully) _______________________________________ 136

Opening the Card Lamination Module __________________________________ 137 Loading the Overlaminate ____________________________________________ 140

Adjusting the Card Lamination Module ___________________________________ 143

Adjusting the Card Flattener __________________________________________ 143 Adjusting the Card Guide Rail_________________________________________ 145 Adjusting the Internal Card Guide ______________________________________ 149 Attaching the Card Lamination Module _________________________________ 152

Section 4: Printer Adjustments __________________________________________ 164

Safety Messages (review carefully) _______________________________________ 164 Adjusting the Card Size ________________________________________________ 165

Adjusting the Card Input Guide ________________________________________ 166 Adjusting the Card Stacker Output Guide ________________________________ 170 Adjusting the Internal Card Guide ______________________________________ 173

Adjusting the Card Thickness Knob ____________________________________ 176 Fine-Tuning the Card Separator Adjustment Assembly (D840995) ______________ 177 Printing on Alternate Card stocks ________________________________________ 178

Selecting the Right Cards and optimize the HDP Print Process _______________ 178

Selecting the Appropriate HDP Printer Driver settings ______________________ 179

Conducting the Tape Adhesion Test ____________________________________ 181 Printer Driver Options _________________________________________________ 184

Installing Printer Driver Updates _______________________________________ 184 Setting Up the Printer Driver ____________________________________________ 186

Setting up Windows 98SE/Windows Millennium __________________________ 186

Setting up Windows NT/Windows 2000/Windows XP______________________ 186 Using the Device Options tab ___________________________________________ 187

Adjusting the Ribbon Type ___________________________________________ 188

Adjusting the Film Type _____________________________________________ 189

Adjusting for the color matching _______________________________________ 190

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Adjusting for the Resin Dither _________________________________________ 191

Using the Print Both Sides option ______________________________________ 192

Using the Split 1 Set of Ribbon Panels option_____________________________ 193

Using the Print Back Side First option___________________________________ 194

Using the Print on Back Side Only option________________________________ 195

Using the Rotate Front 180 Degrees or Rotate Back 180 Degrees options _______ 196

Using the Print in Single Card Mode option ______________________________ 197

Using the Link Card to Print Job option _________________________________ 198

Using the Disable Printing option ______________________________________ 199 Using the Image color tab ______________________________________________ 200 Using the Image Transfer tab____________________________________________ 204

Adjusting the Image Position controls ___________________________________ 205

Adjusting the Transfer Dwell Time and Temperature _______________________ 207

Adjusting the Flattener Temperature ____________________________________ 208 Using the K Panel Resin tab_____________________________________________ 209

Selecting the Full Card with the K Panel Resin tab_________________________ 210

Selecting the Defined Area(s) with the K Panel Resin tab ___________________ 211

Selecting the Undefined Area(s) with the K Panel Resin tab _________________ 212

Defining the Area to activate the Card Grid ______________________________ 213

Measuring the Total Card area_________________________________________ 214

Measuring the Area to be positioned on the Card __________________________ 215

Selecting the Print YMC under the K and Print K Only options_______________ 216 Using the Magnetic Encoding tab ________________________________________ 218

Using the Encoding Mode option ______________________________________ 219

Encoding the Mode/Coercivity/Magnetic Track Selection ___________________ 221

Reviewing the Magnetic Track Options _________________________________ 222

Reviewing the Enable MLE Support checkbox____________________________ 223

Reviewing the Verification options _____________________________________ 224

Reviewing the Shift Data Left _________________________________________ 225

Reviewing the ISO Track Locations ____________________________________ 226

Sending the Track Information ________________________________________ 227

Reviewing the Sample String__________________________________________ 228

Reviewing the ASCII Code and Character Table __________________________ 229 Using the Card tab ____________________________________________________ 230

Selecting the Card Size from CR-80, CR-90 or CR-100 _____________________ 231

Selecting the Custom Card Size________________________________________ 233

Selecting the Card Type______________________________________________ 234

Reviewing the Orientation ____________________________________________ 236

Specifying the Copies _______________________________________________ 236

Clicking on the About button__________________________________________ 237 Using the Lamination tab (only with Card Lamination Module) ________________ 238

Selecting the Lamination Position ______________________________________ 239

Selecting the Lamination Side _________________________________________ 240

Selecting the Lamination Type ________________________________________ 241

Adjusting the Transfer Dwell Time and Transfer Temperature________________ 242

Selecting the Sensors button and Defaults button __________________________ 242

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Selecting the Sensors button and Defaults button __________________________ 243

Section 5: Cleaning ____________________________________________________ 244

Using the Required Supplies __________________________________________ 244 Safety Messages (review carefully) _______________________________________ 245

Cleaning inside the Printer____________________________________________ 246

Cleaning outside the Printer___________________________________________ 246

Cleaning the Printhead _______________________________________________ 247

Cleaning the Cleaning Rollers _________________________________________ 248

Cleaning the Card Feed Rollers ________________________________________ 252

Cleaning the Platen Rollers ___________________________________________ 256

Section 6: Parts Replacement____________________________________________ 258

Safety Messages (review carefully) _______________________________________ 259 Reviewing the Printer Components _______________________________________ 260

Reviewing the Input Hopper Components________________________________ 260

Reviewing the Print Module Components ________________________________ 263

Reviewing the Transfer Station Components _____________________________ 265

Reviewing the Base Module Components ________________________________ 266

Reviewing the Base Module Components ________________________________ 267

HDP Main Board Cable Connections Reference___________________________ 269

HDP Lamination Board Cable Connections Reference______________________ 270

HDP Lamination Module Board Cable Connections Reference _______________ 272 Cover Removal Procedures _____________________________________________ 273

Removing the Print Station cover (840361) ______________________________ 273

Removing the Front Transfer Cover (840362)_____________________________ 274

Removing the Mid Pulley Cover (D840166)______________________________ 275

Removing the Base Module cover (840363) ______________________________ 276

Removing the Card Input Hopper cover (840167) _________________________ 277

Removing the Card Output Hopper cover (840167) ________________________ 277

Removing the Back cover ____________________________________________ 278 Control Panel Assembly Components _____________________________________ 279

Replacing the Control Panel Assembly Components _______________________ 279 Printhead Assembly Components ________________________________________ 281

Replacing the Printhead (D840854)_____________________________________ 281

Replacing the Fan Assembly (D840986) _________________________________ 282

Replacing the Head Force Spring - 2 (840272) ____________________________ 283

Replacing the Ribbon Deflector (D840638) ______________________________ 284 Print Station Components replacement ____________________________________ 285

Replacing the Headlift Drive O-Rings (140212) ___________________________ 285

Replacing the Ribbon Drive O-Ring behind the Encoder Wheel (810492) ______ 286

Replacing the Ribbon Sensor Board Assembly (140407) ____________________ 287

Replacing the Encoder Wheel (810492) _________________________________ 288

Replacing the Ribbon Sensor Array Assembly (840108) ____________________ 289

Replacing the Ribbon Supply Motor Assembly (D840980) __________________ 290

Replacing the Ribbon Take-Up Motor Assembly (D840980) _________________ 291

Replacing the Headlift Motor Assembly (D840980)________________________ 292

Replacing the Ribbon Supply Encoder Sensor Assembly (D840982)___________ 293

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Replacing the HDP 800 Series Ribbon Hub ______________________________ 294

Replacing the HDP 800 Series Ribbon Take up Roller Hubs _________________ 313

Replacing the HDP 800 Series Film Supply Hub __________________________ 315

Replacing the Headlift Sensor Assembly (D840983) _______________________ 322 Transfer Station Components Replacements ________________________________ 323

Replacing the Film Drive O-Rings (140212)______________________________ 323

Replacing the Film Drive Encoder Wheel - 2 (810492) _____________________ 324

Replacing the Stepper Motor Assembly (840123)__________________________ 325

Replacing the Supply Encoder Sensor Assembly (840135) __________________ 326

Replacing the Lamination Take-Up Encoder Sensor Assembly (840136) _______ 327

Replacing the Lower Film Sensor Assembly (840199) ______________________ 328

Replacing the Upper Film Sensor Assembly (D841023)_____________________ 329

Replacing the Print Platen Roller (D840811) _____________________________ 330

Replacing the Transfer Peel Off Bar Assembly (D840698) __________________ 331

Replacing the Transfer Station Assembly (D841083) _______________________ 332

Replacing the Lamination Assembly (D841085)___________________________ 334

Replacing the Transfer Lift Sensor (A000126) ____________________________ 336

Replacing the Transfer Lift Motor (D840173)_____________________________ 337 Base Module Components Replacements __________________________________ 338

Replacing the Drive Belt – Platen Roller to Card Feed Roller (220071)_________ 338

Replacing the Drive Belt – Card Feed Roller to Card Feed Roller (220082) _____ 339

Replacing the Stepper Motor Assembly (D841045) ________________________ 340

Replacing the Pinch Roller Spring Plate-Front Input Side (D840865) __________ 341

Replacing the Pinch Roller Spring Plate-Front Output Side (D840865) _________ 342

Replacing the Pinch Roller Spring Plate-Back Input Side (D840865) __________ 343

Replacing the Pinch Roller Spring Plate-Back Output Side (D840865) _________ 344

Replacing the Drive Pulley - Back - 2 (D850190)__________________________ 345

Replacing the Gear - Card Transport - 2 (760330) _________________________ 346

Replacing the Compound Gear (D841032) _______________________________ 347

Replacing the Base Module (D841082)__________________________________ 348 Card Input Hopper Components Replacements______________________________ 350

Replacing the Input Hopper (D841087)__________________________________ 350

Replacing the Separator Adjustment Assembly (D840995) __________________ 351

Replacing the Flipper Table Sensor Board Assembly (140407) _______________ 352

Replacing the Card Low Sensor Board Assembly (140407) __________________ 353

Replacing the Cleaning Roller Drive Idler Gear - 2 (760401)_________________ 354

Replacing the Card Feed Gear - 3 (810271) on the Flipper Table Encoder Feed Motor

(E000062)_________________________________________________________ 355

Replacing the Card Feed Shaft Gear on the Cleaning Roller Assembly (810271) _ 356

Replacing the Feed/Encoding Motor Assembly (E000062) __________________ 357

Replacing the Cleaning Roller Assembly (840102)_________________________ 358

Replacing the Flipper Table Position Motor (840124) ______________________ 359

Replacing the Card Feed Motor Assembly (D841105) ______________________ 360

Replacing the Flipper Table Card Sensor Assembly (D840625)_______________ 361

Replacing the Card Feed Sensor (D840624) ______________________________ 362

Replacing the Magnetic Encoder Head (840104) __________________________ 363

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Replacing the Encoder Card Sensor (140407)_____________________________ 364 Power Assembly Components Replacements _______________________________ 365

Replacing the Power Switch (120011)___________________________________ 365

Replacing the Power Cord Receptacle (130067) ___________________________ 366

Replacing the Main Print Board (A000271) ______________________________ 367

Replacing the Lamination Board (140402) _______________________________ 368

Replacing the Power Supply (150240) __________________________________ 369 Output Stacker Components Replacements_________________________________ 370

Replacing the Output Stacker (D841079) ________________________________ 370

Replacing the Stacker Full Sensor (140407) ______________________________ 371

Replacing the Stacker Lift Motor (840130)_______________________________ 372 Card Lamination Module Component Replacements _________________________ 373

Replacing the Lamination Module Board Cover (D870151)__________________ 373

Replacing the Lamination Module Main Cover (D870159) __________________ 374

Replacing the Lamination Module Main Board (A000250) __________________ 375

Replacing the Lamination Module Arm Assembly (D870153)________________ 376

Replacing the Lamination Module Card Flipper Table Assembly (D870091) ____ 377

Replacing the Card Position Sensor Assembly (D870186) ___________________ 379

Replacing the Lamination Module Flipper Position Sensor (D870188) _________ 380

Replacing the Lamination Module Overlaminate Encoder Sensor (D870189) ____ 381

Replacing the Lamination Module Ribbon ID Sensor (820593) _______________ 382

Replacing the Lamination Module Overlaminate Sensor (D870241) ___________ 383

Replacing the Lamination Module Hopper Sensor Assembly (D870228) _______ 384

Replacing the Lamination Module Platen Motor (D870218) _________________ 386

Replacing the Lamination Module Flipper Table Motor (D870217) ___________ 388

Replacing the HDP820-LC/HDP825-LC Lamination Lid Hinge Bracket _______ 390

Adjusting the HDP820-LC/HDP825-LC Lamination Heat Shield Adjustment ___ 408 HDP820/HDP820-LC Magnetic and Smart Card Module Replacement___________ 414

Replacing the Magnetic/Smart Card Module______________________________ 418

Section 7: Packing the HDP800 Series Card Printer_________________________ 437 Section 8: Board Level Diagnostics _______________________________________ 438

Board Errors_________________________________________________________ 438

Resolving the EE Memory Error _______________________________________ 438

Resolving the EE Checksum Error _____________________________________ 438

Resolving the DRAM Memory Error ___________________________________ 439

Resolving the RAM Memory Error _____________________________________ 439

Resolving the FPGA Error____________________________________________ 439 Sensor Testing _______________________________________________________ 440

Reviewing the Sensor Location and Voltages _____________________________ 441

Reviewing the Sensor Layout on Ribbon Sensor array ______________________ 442

Reviewing the Sensor Location and Voltages for the Lamination Module_______ 443

Section 9: LCD On-Line Menu Navigation ________________________________ 444

Entering the LCD Menu and selecting an Option ____________________________ 444

Selecting from the HDP800 Series Menu Option Structure Tree ______________ 446 Reviewing the Printer Setup ____________________________________________ 447

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Preparing to Adjust the Print Offset, Transfer TOF and Transfer EOF__________ 449

Aligning the Print Offset _____________________________________________ 450

Setting the Transfer TOF _____________________________________________ 452

Setting the Transfer EOF _____________________________________________ 454

Setting the Transfer EOF _____________________________________________ 455

Adjusting the Transfer Tension ________________________________________ 456

Adjusting the Film Drive _____________________________________________ 457

Adjusting the Ribbon Tension _________________________________________ 457

Adjusting the Ribbon Drive ___________________________________________ 458

Adjusting the Transfer Temperature ____________________________________ 458

Setting the Flattener Temperature ______________________________________ 459

Setting the Printhead Resistance _______________________________________ 459

Adjusting the Image Darkness _________________________________________ 460

Changing the Encoder Settings ________________________________________ 461

Setting the Magnetic TOF ____________________________________________ 462

Setting the Magnetic TOF ____________________________________________ 463

Adjusting the Flipper Offset___________________________________________ 464

Adjusting the Lamination Flipper Offset _________________________________ 464

Adjusting the LAM TOF and EOF _____________________________________ 465

Adjusting the Lamination Sensor Calibration _____________________________ 466

Adjusting the Lamination Temperature Setting____________________________ 466

Show the Error Count _______________________________________________ 466

Using the Show Card Count option _____________________________________ 467

System Upgrade (Firmware Upgrade) ___________________________________ 467

Section 10: Firmware Updates___________________________________________ 468

Firmware Updater Application Program ___________________________________ 468 Downloading Firmware Updates _________________________________________ 470 Updating the Printer's Firmware _________________________________________ 471

Updating the Main Firmware__________________________________________ 471

Updating the LCD Firmware __________________________________________ 474 Firmware Upgrades (as of 10/07/03) ______________________________________ 476

Section 11: Fargo Technical Support _____________________________________ 478

Contacting Fargo Technical Support ______________________________________ 478 Reading the Serial Numbers on a Fargo printer______________________________ 479

Finding out when a Fargo Card Printer was manufactured ___________________ 479

Reviewing Example No. 1: Serial Number 80453289 ______________________ 479

Reviewing Example No. 2: Serial Number A1280224______________________ 479

Section 12: Reviewing Spare Parts Lists___________________________________ 480

Reviewing Spare Parts List for HDP 800 Series Card Printer_________________ 480

Reviewing Spare Parts List for Card Lamination Module____________________ 494

Glossary of Terms _____________________________________________________ 502 Index ________________________________________________________________ 522 Appendix A: Engineering Drawings ______________________________________ 535

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Appendix B: Technical Updates _________________________________________ 535 Appendix C: Miscellaneous _____________________________________________ 535

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

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 HDP 800 Series Card Printer/Encoders.

Reviewing the HDP800 Series Printers Overview table

HDP800 Series Input

Hoppers

HDP820 (Dual-Sided Card Printer/Encoders)

HDP820-LC (DualSided Card Printer/Encoders)

HDP825 (Dual-Sided Card Printer/Encoders)

HDP825-LC (DualSided Card Printer/Encoders)

1 250 CR-80,

2 200 CR-80 Optional Optional

2 200 CR-80 Optional Included

Card Capacity

Accepted Card Size

CR-90 &

CR-100

CR-90 &

CR-100

Encoding Modules

Optional Optional

Optional Included

Lamination Module

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

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

Agency Listings

Term Description

Emissions Standards

CE, FCC, CRC c1374, BSMI, ITS (EN 55022 Class B:1995, FCC Class B, EN 82082-1:1997).

Safety Standards

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

UL 1950, CSA C2.2 No.950-95 and TüV-GS (EN 60950 A1-A4, A11).

RESTRICTED USE ONLY Fargo Electronics, Inc.

Technical Specifications

Term Description

Accepted Standard Card Sizes

Accepted Card Thickness

Accepted Electronic Card types

HDP820/820-LC:

• CR-80: 3.375 in. x 2.125 in. (85.6mm x 54mm) (corresponds to

ID1)

• CR-90: 3.63 in. x 2.37 in. (92mm x 60mm)

• CR-100: 3.88 in. x 2.63 in. (98.5mm x 67mm); laminate with CR-

90 or CR-100 size PolyGuard only if laminating with HDP800 Series-LC

HDP825/825-LC:

• CR-80: 3.375” L x 2.125” W/85.6mm L x 54mm W

.030 in. (30 mil) to .070 in. (70 mil) (.762mm to 1.778mm). (30 mil maximum for CR-100 size cards)

(.030" to .040"/.762mm to 1.02mm if laminating with HDP800 SeriesLC; thicker cards are allowed to pass through the Lamination Module if you choose to print-only)

HID Proximity Cards, MIFARE Contactless Smart Cards and Contact Smart Cards

Accepted Card Compositions

Colors Up to 16.7 million colors and 256 shades per Pixel.

Card Capacity

Dimensions

ABS, PVC, PET and PETG

HDP820/HDP820-LC: 250 cards (.030"/.762mm); auto or manual feed

HDP825/HDP825-LC: 200 cards (.030"/.762mm) auto or manual feed

• HDP820/825: 15” H x 26.1” W x 14"D/381mm H x 663mm W x

356mmD

• HDP820-LC/825-LC: 15” H x 34.75” W x 14"D/381mm H x

883mm W x 356mmD

• LC Module: 14.2” H x 13” W x 10”D/362mm H x 330mm W x

254mmD

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Technical Specifications (continued)

Term Description

Display User-friendly, SmartScreen LCD Control Panel; LED display on

Card Lamination Module.

Encoding Options

Fargo Certified Supplies

HDP Film Options

• 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)

• Contact Smart Card Encoder (ISO 7816), Parts 1-4; T=0 & T=1

• Contactless Smart Card Encoder (MIFARE

)

• Prox Card Encoder (HID read-only) (Note: Corporate Express

1000 Cards can be used with special order Weigand/ASCII Converter)

Fargo Card Printer/Encoders require highly specialized media to function properly. To maximize printed card quality and durability, 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.

• Clear, 1,250 prints

• Standard Holographic

• Custom Holographic, special order

HDP Film Storage

77ºF (25ºC) or lower for no longer than 1.5 years.

Temperature

Humidity 20% to 80% Non-Condensing.

Input Hopper Card Capacity

Interface

HDP820/HDP820-LC: 250 cards (.030"/.762mm) HDP825/HDP825-LC: 200 cards (.030"/.762mm)

• Centronics parallel, IEEE-1284 Compliant

• Optional USB to Parallel Adaptor

• Interfacing information for E-card Options

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

Continued on the next page

RESTRICTED USE ONLY Fargo Electronics, Inc.

Technical Specifications (continued)

Term Description

Maximum Accepted

(HDP825/825-LC only) 2.125 in. to 2.63 in. (54mm to 67mm).

Card Width Range

Maximum Accepted

3.375 in. to 3.88 in. (85.6mm to 98.5mm).

Card Length Range

Memory 8 MB RAM; expandable to 32 MB RAM.

Operating

65ºF to 80ºF (18ºC to 27ºC).

Temperature

Options The options are the 32MB RAM Upgrade Kit, Printer Cleaning Kit,

External Print Server (Windows only; required for stand-alone networking of printer/encoders), Card Lamination Module and USBto-Parallel Interface Cable (Windows 98/Me/2000/XP only).

Output Hopper Card Capacity

Overlaminate Options (HDP800 Series-LC only)

100 cards (.030"/.762mm); 250 cards with optional Card Output Stacker

All overlaminates are available in either clear, holographic globe design or custom holographic design. They can also be optimized for use with smart cards and Magnetic Stripes. PolyGuard available in CR-80, CR-90 and CR-100 patch sizes. Here are the options:

• Thermal Transfer Overlaminate, .25 mil thick, 500 prints

• PolyGuard Overlaminate, .6 mil thick, 250 prints

• PolyGuard Overlaminate, 1.0 mil thick, 125 prints

Print Area Over-the-edge on all accepted standard card sizes (YMCKH ribbon

required for over-the-edge printing on CR-100 cards).

Print Method HDP Dye-Sublimation/Resin Thermal Transfer

Printing Method HDP™ Dye-Sublimation/Resin Thermal Transfer.

Printing Resolution Up to 16.7 million colors and 256 shades per Pixel.

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Technical Specifications (continued)

Term Description

Print Ribbon Options

• Full color, YMC, 700 prints

• Full color with resin black, YMCK, 250 or 500 prints

• Full color with two resin black Panels, YMCKK, 400 prints

• Full color with resin black and heat seal Panel for difficult to print

surfaces, YMCKH, 400 prints; extra wide for over-the-edge printing on CR-100 cards

All HDP ribbons utilize Fargo's exclusive RibbonTraq™ system for maximum print quality, performance, reliability and ease of use.

Print Speed-Batch Mode

• 35 seconds per card/112 cards per hour (YMC with transfer)

• 38 seconds per card/94 cards per hour (YMCK with transfer)

• 66 seconds per card/54 cards per hour (YMCKK with transfer)

• 40 seconds per card/90 cards per hour (YMCK/Lamination)*

• 72 seconds per card/50 cards per hour (YMCKK/Lamination)*

Resolution 300 dpi (11.8 dots/mm)

Software Drivers Windows 95/ 98/ ME/ NT/ 2000/XP.

Supply Voltage 100 to 240 VAC, 3.75A.

Supply Frequency 50 Hz/60 Hz.

System Requirements

IBM-PC or compatible. Windows 95/ 98/ ME/ NT/ 2000/XP. Pentium

™

class 133 MHz computer with 32 MB of RAM or higher, 200 MB free hard disk space or higher and ECP parallel port with DMA access.

Warranty

Printer: One year; optional Extended Warranty Program (U.S. only)

Printhead: Lifetime; unlimited pass

Weight

HDP820/825: 70 lbs. (31.8kg). HDP820-LC/825-LC: 87 lbs./39.5kg LC Module: 21 lbs./9.5 kg

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Functional Specifications

The Card Printer utilizes two different, yet closely related printing technologies to achieve its remarkable direct-to-card print quality for dye-sublimation and resin thermal transfer. The Card Printer will print from any IBM-PC® or compatible running Windows® 98Se/Me, Windows NT 4.0, Windows 2000 or Windows XP Pro.

The following describes how each of these technologies works:

Function Description

DyeSublimation

Dye-Sublimation is the print method the Card Printer uses to produce smooth, continuous-tone images that look photographic. (Note: This process uses a dye-based ribbon roll that is partitioned by a number of consecutive color Panels.)

• Process colors: The Panels are grouped in a repeating Series of

three process colors - yellow, magenta and cyan (YMC), along the entire length of the Print Ribbon.

• Panels: The Printer always prints the yellow Panel first, followed by

the magenta Panel and the cyan Panel.

• Printhead: As the Print Ribbon passes beneath the Printhead,

hundreds of thermal elements within the Printhead heat the dyes on the ribbon. (Note: When these dyes are heated, they vaporize and diffuse into the surface of the card. A separate pass is made for each of the three color Panels on the ribbon.)

• color Shades: By combining the colors of each Panel and by varying

the heat used to transfer these colors, it is possible to print up to 16.7 million different shades of color. (Note: This blends one color smoothly into the next, producing photo-quality images with absolutely no dot pattern.)

• Dye-Diffusion Thermal Transfer: It is the process of heating a dye

suspended in a cellulous substrate until the dye can flow, diffusing into the dye receptive surface of the card or InTM. This produces the image in the surface of the card.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

Continued on the next page

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: Access Card Slot to Parallel Interface Port

Component Description

Resin Thermal Transfer

Access Card Slot

Card Input Hopper

Card Output Hopper

Card Lamination Module

Resin Thermal Transfer is the print method the Printer uses to print sharp black text and crisp bar codes that can be read by both infrared and visible-light bar code scanners.

Like dye-sublimation, this process uses the same thermal Printhead to transfer color to a card from a resin-only Print Ribbon or the resin black (K) Panel of a full color Print Ribbon.

The difference, however, is that solid dots of resin-based ink are transferred and fused to the surface of the card. (Note: This produces very durable, saturated printing.)

If using the Printer's optional SmartGuard Security Feature, this is the slot in which a SmartGuard Access Card is inserted.

Load blank cards into this hopper.

Stores printed cards.

Works in conjunction with the Printer to apply a variety of different overlaminates to printed cards, providing increased card durability and security. The Module has its own LED indicator light and control buttons; so it can be operated separately from the Printer. (Note: When printing a batch of cards, the Printer can be encoding and printing one card while the Lamination Module laminates another card.) See Section 3: Card Lamination Module

on page 136.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

Continued on the next page

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: Access Card Slot to Parallel Interface Port (continued)

Component Description

Card Output Guide

If the Printer is equipped with an optional Card Output Stacker, adjust the stacker's Card Output Guide to the proper card size prior to printing, as shown below. (Note: This will ensure consistent card ejecting and stacking.)

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: Access Card Slot to Parallel Interface Port (continued)

Component Description

Film Tension Knobs

Allows you to manually tighten the HDP film after loading or whenever the Transfer Station is opened, as shown below.

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Softkey Buttons

Printer Components: Access Card Slot to Parallel Interface Port (continued)

Component Description

Front Access Door

LCD Display Displays the current status of the Printer.

LED Light Indicates the Printer ON, OFF, pause and error conditions.

Print Station Prints images onto the HDP film.

Printhead The component of the Print Station that actually does the printing. This

Softkey Buttons Current function is displayed above the button and will change

Opens to allow access to the inside of the Printer.

component is fragile and must not be bumped or touched with anything other than a cleaning pen.

depending upon the Printer's mode of operation.

Continued on the next page

Scroll Buttons

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Unlock Release Lever

Transfer Stations

Print Station

Printer Components: Access Card Slot to Parallel Interface Port (continued

Component Description

Scroll Buttons Used to scroll through menus and sub-menus and to adjust certain

menu options.

Transfer Station Transfers printed images and the HDP film to blank cards.

Transfer Station

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

to open Print and

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: Access Card Slot to Parallel Interface Port (continued)

Component Description

Card Thickness

Adjusts the Printer to feed varying card thicknesses. Adjustment Knob

Card Cleaning Assembly

Automatically cleans cards for higher print quality. (Note: Clean this

assembly after every 250 cards or as needed.)

Power Switch Turns the Printer power ON and OFF.

Power Port Connect to the included power cord.

Parallel

Connect to a Windows PC with a parallel cable. See below. Interface Port

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: Access Card Slot to Parallel Interface Port (continued)

Component Description

Release Lever Locks and unlocks the Print and Transfer Stations so they can be

opened and closed. (Note: This lever must be in its locked position in

order for the Printer to begin printing.)

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

LCD Display

Softkey Buttons

Card Input Hopper

Front Access Door

Printer Components: Access Card Slot to Parallel Interface Port (continued)

Refer to the previous table.

Print Station

Card Output

Hopper

Film Tension

Knobs

Transfer Station

Printhead

Release Lever

LED Light

Scroll Buttons

Access Card Slot

Card Thickness Adjustment Knob

Card Cleaning Assembly

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: LCD and Softkey Control Pad

The Printer provides a four line, eighty (80) character LCD Displays that can communicate helpful information about the Printer's operation.

• The top three lines of the LCD Display will always be used to communicate print status,

error messages and menu options.

• The bottom line of the LCD Display will always be used to communicate the current

function of the Printer's softkey buttons.

This section describes how the LCD Display and Softkey Control Pad work together.

Component Description

Softkey Buttons

The Printer has three softkey buttons that appear below the LCD Display. Their current function is indicated by the words appearing above them. This function will change according to the Printer's current mode of operation.

• Press the corresponding softkey button under the choice you want to

select. If no word appears above a particular button, this indicates it has no function in that particular mode of operation. The Printer also has another type of button on its control pad called scroll buttons. These buttons are located just to the right of the LCD Display.

• Use these buttons to scroll through help text, to navigate through the

Printer's menus and to adjust certain Printer settings.

LCD Display The Printer's LCD Display will change according to the Printer's current

mode of operation.

System Check Screens

When the Printer is first powered ON, the Printer's system check screens will briefly appear to display and test the amount of installed Printer memory, align the Print Ribbon and HDP film and lastly to display the READY screen and current Firmware version.

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: LCD and Softkey Control Pad (continued)

Component Description

Ready/Printer Open Screens

Once the Printer has finished its system check and with the Print and Transfer Stations closed, the Printer will display READY to indicate that the Printer is ready for operation. (Note: The Printer will stay in this mode until it receives a print job or it is turned OFF.)

• If the Release Lever is unlocked, the Release Lever Unlocked screen

will appear to remind you this item is open.

• If the Print and Transfer Stations are opened, the Printer Open

screen will appear. Press either the Forward or Back buttons to move the Printer's card path rollers in the indicated direction. Use the scroll buttons to select between moving the Print-Side Card Rollers or the Input-Side Card Rollers. This is helpful when cleaning the Printer or if clearing jammed media. In any of these screens, the Printer will always display the Menu option above the center softkey button. Press this button to access the Printer's menu options. (Note: The Menu option is available only in the Ready/Printer Open screens.)

• If the Printer is equipped with the Card Lamination Module and the

Lamination Station is opened, no LCD message will appear. Instead, the Lamination Module's LED will flash. (Note: To move the Lamination Module's rollers, push the Module's Cancel or Resume buttons.)

• If both the Print Station and Lamination Station are open, the LCD's

FORWARD and BACK softkey buttons will move ALL rollers. In any of these screens, the Printer will always display the MENU option above the center softkey button. Press this button to access the Printer's menu options. (Note: The MENU option is available only in the READY/PRINTER OPEN screens.)

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

Continued on the next page

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: LCD and Softkey Control Pad (continued)

Component Description

Print Status Screen

During operation, the LCD will indicate the current Print Status by showing you the area of the Printer that is active. It does this by displaying the following icons on the second line:

• FDR Indicates the Feeder Station is feeding a blank card into the

Printer.

• ENC Indicates the Encode Station is encoding a card (appears only if

you are using a Printer with an optional built-in Encoding Module).

• PRT Indicates the Print Station is printing onto the HDP film.

• TFR Indicates the Transfer Station is transferring an image to a blank

card.

• LAM indicates the Lamination Station is applying an overlaminate to a

card (appears only if using a Printer equipped with the optional Card Lamination Module. See Section 3: Card Lamination Module

on page

136.

Since the Printer is capable of performing several of these functions simultaneously, one or all of these icons may appear at once, depending on if you are printing just one card or a batch of cards.

The Print Status screen always displays Cancel in the lower left and Pause in the lower right.

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: LCD and Softkey Control Pad (continued)

Component Description

The Cancel button

The Pause button

Use this button to cancel print jobs and reset the Printer for the next print job.

• This Cancel function will cancel all print jobs in the Printer and will

completely reset the Printer. In this case, be sure to cancel the print jobs from the PC before pressing YES.

• Canceling all print jobs (in the middle of a batch print) will force the

Printer to waste or delete any images that may already have printed on the HDP film.

Caution: To avoid this, select the Print in Single Card Mode option from the Printer Driver before sending the next print job. If a card is left within the Printer after a print job is canceled, it will automatically be ejected.

Use this button to pause the Printer at any time during operation. Note the Printer will always finish its current task before pausing.

When the Printer is paused, the LED Light will flash and the Pause softkey button will change to Resume.

Press Resume to continue Printer operation.

The LED Light This light works in conjunction with the Printer's LCD Display to help

communicate the Printer's current status. It is especially effective when you are too far away from the Printer to read the LCD Display. The following explains how to interpret both LED Lights on the exterior of the Printer.

• Off: Indicates the Printer power is OFF.

• Solid GREEN: Indicates the Printer is powered ON and ready for

operation.

• Flashing GREEN: Indicates a Printer ERROR or ATTENTION

condition. Refer to the Printer's LCD Display for information.

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: LCD and Softkey Control Pad (continued)

Component Description

Error/Attention Screens

The Printer is capable of communicating two similar yet different types of message or prompt screens:

The first is called an ERROR screen. (Note: This screen appears if an error occurs and will completely stop Printer operation. In this case, the LCD will display ERROR on the first line and a brief description of the error on the second line. If multiple errors occur at the same time, the first line will display ERROR 1 of 2 or whatever the total number of errors may be. To see the other error(s), use the scroll keys.)

• Press the Help button if you would like a more detailed explanation of

the error message. This will bring up the help screen explaining the nature of the error and how to correct it. If necessary, use the scroll buttons to scroll down the paragraph of help text.

• Press Quit when you are done reading. Once the error is corrected,

resume operation or reset the Printer according to how you were instructed in the help screen.

The second type of prompt is called an Attention screen. (Note: This screen will not stop Printer operation and serves to communicate helpful reminders, such as if you are running low on print supplies and also communicates any other Printer conditions of which you should be aware. In this case, the LCD will display Attention on the first line and a brief description of the condition on the second line.)

• If multiple messages need to be communicated at the same time, the

first line will display Attention 1 of 2 or whatever the total number of messages may be.

• Like error messages, help text explaining the particular condition can

also be accessed by pressing the Help button.

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: LCD and Softkey Control Pad (continued)

Component Description

Access Card Slot

This is the slot in which a SmartGuard Access Card is inserted if you are using the Printer's SmartGuard Security Feature. (Note: This unique feature prevents the Printer from operating unless a custom access card is inserted.)

• To use the SmartGuard feature, refer to the instructions included with

it for information on how to enable and use this security feature.

• To avoid using the SmartGuard feature, do not insert an access card

to operate the Printer.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: Centronics-Type Parallel Interface

The Card Printer is equipped with a standard 8-bit centronics-type parallel interface port. (Note: This communication port is the means through which the Printer receives data from the computer. This section describes the pin assignments and signal specifications for this port.)

• The Centronics-type parallel interface is a widely used Printer interface due to its

standardization throughout the PC industry.

• The Printer's parallel interface connector is a standard 36-pin Amp type with two metal-

wire retaining clips and is ECP (Extended Capabilities Port) compatible. (Note: It mates with a standard, bi-directional PC to Printer parallel cable. For best results, keep the interface cable to under 6 feet in length.)

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: Print Ribbons

The Card Printer utilizes both dye-sublimation and/or resin thermal transfer methods to print images directly onto blank cards. Since the dye-sublimation and the resin thermal transfer print methods each provide their own unique benefits, Print Ribbons are available in dyesublimation-only and combination dye-sublimation/resin versions.

To make it easier to remember which Print Ribbons are which, a letter code has been developed to indicate the type of ribbon Panels found on each ribbon.

This letter code is as follows:

= Dye-Sublimation Yellow Panel

= Dye-Sublimation Magenta Panel

= Dye-Sublimation Cyan Panel

= Resin Black Panel

= Heat Seal Panel

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: Blank Cards

Caution: Never run cards with a contaminated, dull or uneven surface through the

Printer. Printing onto such cards will ultimately lead to poor print quality. Always store the card stock in its original packaging or in a clean, dust-free container. Do not print onto cards that have been dropped or soiled.

Type Description

Card Size The HDP825 and HDP825-LC Card Printers accept only standard CR-80

sized cards (3.375” L x 2.125” W/85.6mm L x 54mm W) with a thickness of 30 mil (.030"/.762mm) to 70 mil.

The HDP820 Card Printers accept CR-80 to CR-100 sized cards.

Card Design

Card Surface

UltraCard stock

The Printer will print onto any card with a clean, level and polished PVC surface.

Suitable cards must have a polished PVC surface free of fingerprints, dust or any other types of embedded contaminants.

Due to the importance of using high-quality blank cards, a factory-approved card stock called UltraCard™ is available and recommended for best results.

• UltraCard stock has a glossy PVC laminate on top and bottom and is

optically inspected to provide the cleanest, most scratch and debrisreduced cards possible.

• Two types of these cards are available: UltraCard and UltraCard III.

UltraCard stock has a PVC core and offers medium card durability. UltraCard III stock has a 40% polyester core and offers high durability.

Both types of UltraCards produce printed images with a glossy, photo-quality finish.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: Card Input Hopper (HDP820/820-LC)

Type Description

Card Input Hopper (HDP820/820LC printer)

The Card Input Hopper is where cards are initially loaded for printing. The Printer's hopper provides a large door that opens up wide to make card loading simple and closes securely to help protect the card stock. (Note: The Printer will hold a maximum of 250 cards (HDP820/820-LC) in its one (1) Card Input Hopper, based on a standard 30 mil. card thickness.) See the Technical Specification.

• Load 250 cards into the one (1) Card Input Hopper in the

HDP820/820-LC printers.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: Card Input Hopper (HDP825/825-LC)

Type Description

Card Input Hopper (HDP825/825LC printers)

The Card Input Hopper is where cards are initially loaded for printing. Your printer's hopper provides a large door that opens widely to make card loading simple and closes securely to help protect your card stock. The printer will hold a maximum of 200 cards (HDP825/825-LC has two Card Input Hoppers; load 100 cards per Hopper) (based on a standard 30 mil card thickness).

• Load 100 cards in each of the two (2) Card Input Hoppers in the

HDP825/825-LC printers.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: Card Output Hopper

Type Description

Card Output Hopper

All standard HDP Card Printers provide a 100-card capacity Card Output Hopper (based on a standard 30 mil card thickness). (Note: This hopper stores the cards after they are printed.)

• As an option, the Printer can also be configured with an automatic

Card Output Stacker. If the Printer is configured with this option, the Card Output Stacker will stack printed cards in a first-in, first-out order. (Note: This option is useful if you need to keep the printed cards in a specific order, such as when printing cards with a serialized number.)

• The Card Output Stacker also holds a maximum of 250, 30 mil cards.

When the Card Output Stacker reaches this maximum capacity, the Printer will pause operation and the LCD will alert you by displaying OUTPUT HOPPER FULL. (Note: To make sure the cards remain neatly stacked in the Card Output Hopper, always keep the hopper door closed during printing.)

Both the Card Input Hopper and the Card Output Stacker are initially configured to automatically feed and print standard CR-80 sized cards.

(Technician Note #1: The HDP820 Printer is also capable of printing onto CR-90 and CR-100 sized cards.)

(Technician Note #2: The Optional Output stacker is not compatible with the Card Lamination Module.)

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printer Components: Lamination Roller

Danger: The Printer’s Lamination Roller can reach temperatures exceeding 350

degree F (175 C). Use extreme caution when operating the Laminator. Never touch the Lamination Roller unless the Printer Power has been turned off for at least 20 to 30 minutes.

Type Description

Controls Both the Printer itself and the Printer’s software Driver control the built-in

laminator.

Temperature Adjustment

New Temperature Setting

To change the temperature of the laminator, adjust its temperature through the Lamination tab within the Printer Driver setup window.

Once adjusted, the new temperature settings will be sent down with the next print job along with the rest of the Printer Driver information.

Before printing begins, the laminator will automatically adjust itself to the new temperature setting. (Note: This new temperature setting will remain programmed within the Printer until it is once again changed within the Printer Driver or until the Printer is turned OFF.)

Whenever the Printer is turned OFF, the laminator will automatically reset itself and return to its default temperature the next time the Printer is turned ON.

• Flip the Power Switch to OFF.

• Disconnect the Printer's power cord.

(Technician Note: Both the Power Switch and the Printer’s power cord serve to reset the laminator to its default temperature. The temperature setting within the Printer Driver, however, will stay the same until it is changed.)

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing the Card Lamination Module

Danger: The Printer’s Lamination Roller can reach temperatures exceeding 350° F

(175° C). Use extreme caution when operating the Laminator. Never touch the Lamination Roller unless the Printer has been turned off for at least 20 to 30 minutes.

Select Printer models support the attachment of an optional Card Lamination Module. This Module can be ordered pre-installed on your Printer from the factory or can be ordered separately as a field upgradeable Module.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Lamination

Lamination Station

Reviewing the Lamination Top Cover and Station

Component Description Reference

Lamination Top Cover

Lamination Station

Opens to allow access to the Lamination Station, overlaminate and card path.

Transfers overlaminates onto cards via its heated Lamination roller. The Lamination Station must be closed in order for the Printer to begin laminating.

Securing

Latches

See the Opening the Card

Lamination Module

procedure in Section 3, page

137.

See the Loading the

Overlaminate procedure in

Section 3, page 140.

Top Cover

Lamination

LED Light

Cancel

Button

Resume

(pause) Button

Card Output

Hopper

Rejection Card Hopper

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing the Securing Latches and Lamination LED Light

Component Description Reference

Securing Latches

Lamination LED Light

Locks the Lamination Station securely in place when closed.

The Lamination LED Light works in conjunction with the Printer's LCD Display to help communicate the Printer's current status. The following explains how to interpret the LED Light.

• Off: Indicates the Printer and

Lamination Module power is OFF.

• Solid Green light: Indicates the Card

Lamination Module is ready for operation.

• Slow Flashing Green light: Indicates

the Lamination Module's (pause) button was pushed and that the Lamination Module is paused. This also occurs when the Lamination Station is open.

See the Using the

Lamination tab (only with the Card Lamination Module) in

Section 5, page 238.

See the the Reviewing LCD Messages in Section 2, page

50.

• Fast Flashing Green light: Indicates

the Lamination Module is in need of attention due to an error or an error condition. Refer to the Printer's LCD Display for information.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing the Cancel button

Component Description Reference

Cancel

Button

The Cancel button serves to cancel the current Lamination job and reset the Card Lamination Module for the next Lamination job.

• If a card is left within the Lamination

Module after a print job is canceled, it will automatically be ejected into the Rejection Card Hopper. (Note: With the Lamination Module's Transfer Station open, this button can also be used to manually rotate the feed rollers forward. This is helpful when cleaning the rollers or if clearing jammed media.)

• If you are printing and

laminating simultaneously and you would like to cancel both the print and Lamination jobs, press the Printer's CANCEL softkey button. (Note: This will cancel all jobs in the Printer. Any card currently laminating will finish and eject. The Lamination Module's Cancel button cancels only the Lamination job.)

See the Using the

Lamination tab (only with the Card Lamination Module) in Section 5, page

238.

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing the Resume (pause) button

Component Description Reference

Resume

(pause) button

Press the Resume button to resume operation after an error condition is cleared.

• If an error occurs, the Lamination

Module's LED will flash and the Printer's LCD will report the specific error.

• If this happens, correct the error and

press the Lamination Module's Resume button to continue printing.

Press this button to pause the Lamination Module during normal operation. (Note: The Lamination Module will always finish its current task before pausing.)

• If this button is pressed while a card

is being laminated, the Lamination Module will pause only after the current card has finished laminating and the Lamination Module has reached a safe stopping point.)

See the Using the Lamination

tab (only with the Card Lamination Module) in Section

5, page 238.

• If the Printer is paused, the LED

Light will flash slowly and will return to solid when operation is resumed. (Note: With the Lamination Station open, the Pause button can also be used to manually rotate the feed rollers backward. This is helpful when cleaning the rollers or when clearing jammed media.)

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing the Rejection Card Hopper and Card Output Hopper

Component Description Reference

Rejection Card Hopper

Card Output Hopper

The Rejection Card Hopper helps to separate potentially bad cards from a stack of good cards, which eject into the Card Output Hopper.

The Printer will automatically eject cards into this hopper to indicate:

• There is a printing error, laminating

error or encoding error.

• There is a card is left in the Printer after

a print job is canceled or the Printer restarted.

Stores up to 100 printed cards (30 mil cards).

a. When the hopper has reached its

maximum capacity of cards, note that the operation pauses and an Output Hopper Full message appears on the Printer's LCD Display.

b. Remove the stack of cards from the

hopper.

See the Using the

Lamination tab (only with the Card Lamination Module) in Section 5, page

238.

See the Using the

Lamination tab (only with the Card Lamination Module) in Section 5, page

238.

c. Press the Lamination Module's Resume

button to continue. (Note: If printing onto oversized cards, the Card Output Hopper Door should be placed in the open position in order for these larger cards to eject properly.)

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing the Module and Printer interaction

Term Description Reference

Module and Printer interaction

The Card Lamination Module works in conjunction with the Printer to apply a variety of different overlaminates to printed cards, providing increased card durability and security.

The Lamination Module features its own LED indicator light and control buttons so it can conveniently be operated separately from the Printer. (Note: This means that when printing a batch of cards, for example, the Printer can be encoding and printing one card while the Lamination Module laminates another card for maximum efficiency.)

In fact, you can even open the Lamination Module to replace the overlaminate while the Printer is printing or encoding and vice versa.

See the Using the Lamination

tab (only with the Card Lamination Module) in Section

5, page 238.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing the Module and LCD Display interaction

Term Description Reference

Module and LCD Display interaction

For ease of operation, the Card Lamination Module works in tandem with the Printer's LCD Display to communicate status message such as when an error occurs or when it is time to replace the overlaminate material.

If a Lamination error does occur, the Lamination Module's LED will flash and an attention level message will appear on the Printer's LCD Display. (Note: Since it is an ATTENTION level message, it will not interrupt printing.)

a. Correct the error. b. Press OK to clear the LCD's

ATTENTION message.

c. Press the Lamination Module's

Resume button to resume operation or its Cancel button to cancel the current Lamination job and accept the next. (Note: If canceled, the canceled card will eject into the Rejection Card Hopper.)

See the Using the Lamination

tab (only with the Card Lamination Module) in Section

5, page 238.

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing the Module’s Programmed Default Temperature

Term Description Reference

Programmed Default Temperature

Upon initial power up, the Lamination Module is programmed to heat the Lamination roller up to its default temperature.

• Target Temperature: If a print job is

sent while the Lamination Module is heating up, the Printer's LCD Display will read Laminator Warming. This will alternate with LAM Temp: [current] [target] which shows the current temperature of the Lamination Roller and the target temperature it is trying to reach. (Note: This indicates that the Lamination roller is heating to its preset temperature.)

• Initial Heating Process: The initial

heating process will generally take about 3 to 4 minutes. (Note: The LCD Display will read Laminator Warming or Laminator Cooling whenever the Lamination Roller is heating up or cooling down to the prescribed temperature. When the Lamination Module has reached its target temperature, Lamination will begin.)

See the Using the Lamination

tab (only with the Card Lamination Module) in Section

5, page 238.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing the Laminator Temperature Adjustment

Term Description Reference

Laminator Temperature Adjustment

To change the temperature of the Laminator, adjust its temperature through the Lamination tab within the Printer Driver setup window.

• New Temperature Settings: Once

adjusted, the new temperature settings will be sent down with the next print job along with the rest of the Printer Driver information. Before printing begins, the laminator will automatically adjust itself to the new temperature setting. (Note: This new temperature setting will remain programmed within the Printer until it is once again changed within the Printer Driver or until the Printer is turned OFF.)

• Automatic Reset: Whenever the

Printer is turned OFF, the laminator will automatically reset itself and return to its default temperature the next time the Printer is turned ON. (Note: Pressing the Lamination Module's or Printer's Cancel button or switching the Printer power OFF and ON both serve to reset the Laminator to its default temperature.)

See the Using the Lamination

tab (only with the Card Lamination Module) in Section

5, page 238.

• Consistent Temperature: The

temperature setting within the Printer Driver stays the same until it is changed.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing the Overlaminates

IMPORTANT! Fargo Card Printers require highly specialized overlaminates to function

properly. To maximize Printer life, reliability, printed card quality and durability, you must use only Fargo Certified Supplies. For this reason, the Fargo warranty is void, where not prohibited by law, if you use non-Fargo Certified Supplies. To order additional materials, please contact the authorized reseller.

Reviewing the Thermal Transfer Film and PolyGuard Overlaminates

Term Description Cross Reference

Thermal Transfer Film and PolyGuard Overlaminates

The Card Lamination Module will accept either a Thermal Transfer Film overlaminate or a Polyester Patch Overlaminate called PolyGuard™.

• Thermal Transfer Film: The Thermal

Transfer Film overlaminate is a relatively thin material which covers a card Edgeto-Edge and provides a medium level of card durability and security.)

• PolyGuard Overlaminate: PolyGuard

is a much thicker material which does not cover Edge-to-Edge, but provides an extremely high level of card durability and security. (Note: PolyGuard is available in either a 1.0 or .6 mil thickness and should always be used for those applications requiring the highest degree of card durability and security.)

See the Loading the

Overlaminate procedure in

Section 3, page 140.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing the CR-90 or CR-100 Patch Size

Term Description Cross Reference

CR-90 or CR-100

PolyGuard Overlaminate is available in a standard CR-80 patch size as well as a CR90 and CR-100 patch size for laminating

See the Loading the

Overlaminate procedure in

Section 3, page 140. oversized CR-90 or CR-100 cards. (Note: Thermal Transfer Film overlaminate will accommodate CR-80 and CR-90 card sizes, but is not recommended for CR-100 cards.)

Reviewing the Overlaminate Design

Term Description Cross Reference

Design Both PolyGuard and the Thermal Transfer

Film overlaminates are available in either a clear or generic secure holographic-type design. (Note: Custom holographic-type overlaminates are also available with specific designs, patterns, logos and security features.)

Please contact the authorized reseller for more information about custom Overlaminates..

See the Loading the

Overlaminate procedure in

Section 3, page 140.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Section 2: General Troubleshooting

The purpose of this section is to provide the User with specific procedures relating to the LCD/SmartGuard Messages, Communication Errors, Card Feeding Errors, Encoding Errors, Printing Process Errors, Transfer Process Errors and Diagnosing the Image Problems for the HDP 820 Card Printer.

IMPORTANT! Fargo Card Printers require highly specialized print ribbons to function properly. To maximize Printer life, reliability, printed card quality and durability, you must use only Fargo Certified Supplies. For this reason, your Fargo warranty is void, where not prohibited by law, if you use non-Fargo Certified Supplies. To order additional materials, please contact your authorized reseller.

LCD/SmartGuard Messages

The LCD display shows the current status of the Printer. Refer to the cause and solution tables in this section for all possible LCD messages. (Note: These tables display the LCD messages in alphabetical order. If the LCD message is communicating an error or requires an action, these tables will also offer a solution to what should be done.)

Reviewing LCD Messages

Message Cause Solution

Add Cards Indicates there is not an adequate

supply of cards in the Card Input Hopper.

Aligning Film

Aligning Ribbon

Card Jam A card is jammed in the Transfer

Card Jam: Flipper

If this appears as a prompt, the HDP Film is self-aligning to the proper position for printing.

If this appears as a prompt, the print ribbon is self-aligning to the proper position for printing.

Station or card flipping area of the Printer.

A card is jammed in the card flipping area of the Printer.

Add cards to the input hopper and press Resume to continue printing.

If this appears as an error, see the the Resolving the Film Sensor

errors procedure in Section 2, page

93.

If this appears as an error, see the

Resolving the Ribbon Alignment Error Message procedure in Section

2, page 85.

See the Resolving the Card Jam

Error Message procedure in Section

2, page 74.

See the Resolving the jammed

Cards on the Flipper Table

procedure in Section 2, page 71.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

Continued on the next page

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing LCD Messages (continued)

Message Cause Solution

Card Jam: Mag

Card Jam: Smart

Card Jam: Transfer

A card is jammed in the magnetic encoding area of the Printer.

A card is jammed in the smart card encoding area of the Printer.

A card is jammed in the Transfer Station of the Printer.

Cards Low Indicates there is not an adequate

supply of cards in the Card Input Hopper.

Data Input The print data sent to the Printer is

corrupt or has been interrupted.

Data Timeout

Door/Lever Unlocked

The print data sent to the Printer is corrupt or has been interrupted.

You are trying to print with the Front Access Door open or the Release Lever in the unlocked position.

See the Removing the Card jam in

the Printer’s Magnetic Encoding Area in Section 2, page 82.

See the Removing the Card jam in

the Printer’s Magnetic Encoding Area in Section 2, page 82.

See the Resolving the Card Jam

Error Message procedure in

Section 2, page 74.

Add cards to the input hopper and press Resume to continue printing.

See Communication Errors in Section 2, page 60.

See Communication Errors

Section 2, page 60.

See the Resolving the Printer

Open Error Message procedure in

Section 2, page 90.

DRAM Memory

The Printer's memory Module is bad or not installed properly.

Error

EE Checksum

Permanent circuit Board memory is bad.

Error

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

See the Resolving the DRAM

Memory Error procedure in

Section 8, page 439.

See Resolving the EE Memory

Error procedure in Section 8, page

438.

Continued on the next page

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing LCD Messages (continued)

Message Cause Solution

EE Memory Error

Ejecting Used Card

Permanent circuit Board memory is bad.

The system Firmware has detected a card already in the Printer and is ejecting it.

Film (lower) Film (upper)

The HDP Film is not installed properly or has run out, jammed, broken or been damaged.

Film Out The HDP Film has run out. Install

new Film and press RESUME to continue.

Film Sensing The Printer was unable to sense the

HDP Film properly while printing.

See the Resolving the EE

Checksum Error procedure in

Section 7, page 438.

See Card Feeding Errors

Section 2, page 65.

If this appears as an error, see the the Resolving the Film Sensor

errors procedure in Section 2,

page 93.

If this appears as an error, see the the Resolving the Film Sensor

errors procedure in Section 2,

page 93.

If this appears as an error, see the the Resolving the Film Sensor

errors procedure in Section 2,

page 93.

Flipper

Unable to align flipper. See the Resolving the Flipper

Alignment

FPGA An unexpected hardware error has

occurred.

FPGA Load Fail

Indicates an unexpected hardware error has occurred.

Alignment Error Message

procedure in Section 2, page 72.

See the Resolving the FPGA Error procedure in Section 8, page 439.

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing LCD Messages (continued)

Message Cause Solution

Film Low The HDP Film will soon run out.

Install new film and press Resume to continue.

Flattener Time out

FPGA Timeout

The card flattener was unable to reach optimum temperature.

An unexpected hardware error has occurred.

Head Lift The Printer was unable to raise or

lower the Printhead.

Head Resistance Error

Head Voltage Error

Please enter a value for head resistance in the LCD Printer Setup menu.

A hardware fault has prevented setting the correct Printhead voltage.

If this appears as an error, see the the Resolving the Film Sensor

errors procedure in Section 2,

page 93.

See Resolving the Temperature

Timeout Error Message procedure

in Section 2, page 99.

See the Resolving the FPGA Error procedure in Section 8, page 439.

See the Resolving the Headlift

Error Message in Section 2, page

88.

See the Setting the Printhead

Resistance procedure in Section

9, page 459.

See the Resolving the Printhead

Temp Error Message procedure in

Section 2, page 90.

Heat Source Off

The Transfer Roller and Flattener were turned off to save energy while idle.

Initializing Indicates the Printer is beginning its

startup system check.

Job Mismatch

The Feed Module is out of sequence with the Transfer section.

Press OK to turn the Heat source back on.

See Printer Components: LCD

and Softkey Control Pad in

Section 1, page 25.

See Resolving a Job Mismatch

error in Section 2, page 81.

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing LCD Messages (continued)

Message Cause Solution

Mag Encode Failed

Multiple Cards Fed

No ENC Response

No MAG Encoder

No Prox Encoder

No SMART Encoder

The magnetic stripe was not encoded properly.

Two or more cards fed from the Card Hopper.

There is no response from the Encoder control Module.

You are trying to send encoding data, but the Printer is not configured with this Encoder type.

See the Resolving the Failed

Magnetic Encode Error Message

procedure in Section 2, page 77.

See the Resolving the Card

Feeding problem in Section 2,

page 65.

See the Resolving the No ENC

Response Error Message

procedure in Section 2, page 76.

See the Resolving the No

Magnetic Encoder Error Message procedure in Section

2, page 76.

See the Resolving the No Prox

Encoder Error Message

procedure in Section 2, page 83.

See the Resolving the Failed

Smart Encode Error Message

procedure in Section 2, page 84.

Output Hopper Full

The output stacker is full of cards; empty the output stacker to avoid a jam.

Remove cards from the Output Hopper and press OK to continue.

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing LCD Messages (continued)

Message Cause Solution

Pause... Indicates the Printer is paused. See Printer Components: LCD

and Softkey Control Pad in

Section 1, page 25.

Print Data The print data sent to the Printer is

corrupt or has been interrupted.

Print Ribbon The print ribbon is not installed properly

or has run out, jammed, broken or been damaged.

Print Ribbon

The print ribbon will soon run out. Pause the current print job and

Low

Print Ribbon

The print ribbon has run out. See Resolving the Print Ribbon

Out

Print Timeout

The Printer was unable to complete the print process.

Printer Open You are trying to print with the Print

and/or Transfer Station open.

Printhead Temp

The Printhead temperature regulator is not functioning properly.

See Communication Errors in Section 2, page 60.

See the Resolving the Print

Ribbon Error Message

procedure in Section 2, page 86.

replace the ribbon.

Out Error Message in Section 2,

page 87.

See Communication Errors in Section 2, page 60.

See the Resolving the Printer

Open Error Message procedure

in Section 2, page 90.

See the Resolving the Printhead

Temp Error Message procedure

in Section 2, page 90.

Program Exception

The system Firmware has detected an error while attempting to process the current print job.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

See Communication Errors Section 2, page 60.

Continued on the next page

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing LCD Messages (continued)

Message Cause Solution

Realigning Film

Smart Encode Failed

Starting Selftest

Temperature Timeout

Testing

Memory

Transfer Cooling

Indicates the Printer is aligning the HDP Film to the proper position for printing. Usually occurs after the Printer has finished a print job.

The card's smart chip was not encoded properly.

Indicates the self-test print is preparing to print.

The Transfer Roller is unable to reach the optimum temperature.

Indicates the Printer's memory is being tested.

The Printer's Transfer Roller is cooling to the proper temperature.

No action required.

See the Resolving the Failed

Smart Encode Error Message

procedure in Section 2, page 84.

See the Printing a Test Image procedure in Section 2, page

132.

See Resolving the Temperature

Timeout Error Message

procedure in Section 2, page 99.

See Printer Components: LCD

and Softkey Control Pad in

Section 1, page 25.

See the Resolving the Transfer

Cooling Error procedure in

Section 2, page 97.

Transfer Lift The Printer was unable to raise or

lower the transfer roller.

Transfer Timeout

The Printer was unable to complete image transfer.

See Resolving the Transfer Lift

Error Message procedure in

Section 2, page 99.

See Transfer Process Errors in Section 2, page 91.

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing LCD Messages (continued)

Message Cause Solution

Transfer Warming

Unable To Feed Card

Update Firmware Now

Unknown Ribbon Type

Upgrade Failed

Wrong Print Ribbon

The Transfer Roller is warming to the proper temperature.

The Printer is unable to feed a card from the Card Hopper.

The system Firmware MUST be updated.

The Printer does not recognize the print ribbon that is installed in the Printer.

The Printer was unable to complete a Firmware upgrade.

The print ribbon installed in the Printer does not match the ribbon type selected in the Printer Driver.

No action required.

See the Resolving the Card

Feeding problem procedure in

Section 2, page 65.

See the Updating the Printer’s

Firmware procedure in Section

8, page 471.

See the Resolving the Unknown

Ribbon Type Error Message

procedure in Section 2, page 88.

See the Updating the Printer's

Firmware procedure in Section

10, page 471.

See the Replacing the Wrong

Print Ribbon Error Message

procedure in Section 2, page 87.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing SmartGuard™ Error and Status Messages

Message Cause Solution

Access Card Deleted

Access Card Ready

Delete Card Data?

Insert Access Card

Insert New Card

Invalid Access Card

Invalid Password

The data on the SmartGuard Access Card was successfully deleted.

The SmartGuard data has successfully been encoded onto the SmartGuard Access Card.

To delete the SmartGuard Access Card data, press the Yes button.

You are trying to print without the SmartGuard Access Card inserted.

To duplicate the SmartGuard Access Card, remove the valid access card and insert a blank access card.

The SmartGuard Access Card is invalid or is inserted backwards or up side down.

You have entered an invalid SmartGuard password.

Press the OK button to continue.

To cancel the deletion process, press the NO button.

Insert a valid SmartGuard Access Card.

Press the Copy button to complete duplication or press Cancel to cancel duplication.

Insert a valid SmartGuard card or reinsert the card properly with the chip end down and facing you.

Re-enter the correct password using any of the standard keyBoard characters.

Reading Access Card

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

Indicates the Printer is reading the data from the SmartGuard Access Card.

Press the OK button to continue.

Continued on the next page

RESTRICTED USE ONLY Fargo Electronics, Inc.

Reviewing SmartGuard™ Error and Status Messages (Cause and Solution Table) (cont.)

Message Cause Solution

SmartGuard Disabled

SmartGuard Enabled

Writing Access Card

Indicates that the SmartGuard Security Feature has successfully been disabled.

Indicates that you no longer need to insert an access card to operate the Printer.

Indicates that all data has successfully been encoded onto the SmartGuard Access Card.

• The SmartGuard Security Feature

now protects the Printer.

• From now on, you must insert a

valid access card to operate the Printer.

Indicates the SmartGuard Access Card is being encoded.

Press the OK button to continue.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Communications Errors

Resolving the Communication Errors

Symptom(s): Incorrect output, communications error on PC or Printer, stalling, no response

from Printer, no job printed or paper out error.

Step Procedure

1 Confirm that the system meets the minimum requirements, as shown here:

• IBM-PC or compatible.

™

• Windows 98Se/ME/NT/2000/XP Pentium

32 MB of RAM or higher

• 200 MB free hard disk space or higher

• ECP parallel port with DMA access

2 Confirm the correct installation of the Printer Driver.

class 133 MHz computer with

a. Close the software program and check the Printer Driver. b. Reboot the computer. c. Make sure the Printer Driver is installed correctly. (Note: Especially if an

obsolete Driver was recently removed.) d. Be sure the correct setup options within the Printer Driver are selected. e. Confirm that the Driver is current by checking at: www.fargo.com

3 Verify the use of an inadequate data cable.

a. Use a double-shielded parallel cable (no longer than six feet in length).

(Note: Data transmission failure can be attributed to a long or faulty

parallel cable.) b. Use a double-shielded, I-EEE 1284 compliant cable to reduce the effect

of radio emissions from computers, monitors and other equipment that

may broadcast Radio frequency interference (RFI).

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving the Communication Errors (continued)

Step Procedure

4 Determine if there is interference from an external device.

a. Do not use an A/B switch box, dongle key or other peripheral in line with

the parallel cable. b. If using a switch box, dongle key or other peripheral, remove it while

testing communication between the computer and the Printer. c. If needed, replace the switch box, dongle key or other peripheral (once it

is determined that the cause of the interference is not the switch box or

peripheral). d. Alternative: Add a second parallel port into the computer (if a second

Printer is required).

5 Determine the problem with printing from the application.

a. Print a self-test from the Printer as described in the Printing a Test Image

procedure in Section 8, page 132, to verify that the Printer (itself) is

functioning properly. b. Print the Windows test page that is located in the General tab of the

Driver. c. Use WordPad (a Windows 95/ 98/ ME/ NT/ 2000/XP word processing

program in the Accessories Program Group).

• Open the program and type: This is a Test.

• Select File > Page Setup and click on the Printer button.

• Ensure that the HDP800 Series Card Printer is selected and click

OK.

• Change all the margin settings to zero (0) and click OK.

• Select File > Print on the Menu Bar.

6 Determine if the parallel port mode is set correctly or incorrectly

a. Verify that the parallel port is set to Enhanced Communication Port

(ECP) mode. (Note: Determine the port mode by checking the Device

Manager tab in the system control panel.) b. Change the port mode to ECP in the computers BIOS if the port mode is

not set correctly. (Note: Refer to the computer manual for instructions

on how to change Parallel Port mode.)

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

Continued on the next page

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving the Communication Errors (continued)

Step Procedure

7 Determine whether there is adequate or inadequate hard drive space.

Caution: A large volume of temporary files on the computer can

cause communications errors. Access temporary files by following this process:

• Search for all folders called TEMP. Once found, clear out the contents of

the folders.

• Use a disk cleanup utility (such as Disk Cleanup found in the System

Tools folder of the Start menu) or use a third party application.

• If using Windows 98Se/ME/2000/XP, run the system utility Disk

Defragmenter found in the Accessories folder of the Start Menu.

Printing from a network. (Note: Some network configurations can cause communications issues with the Printer.)

a. Disconnect the Printer from the network jack. b. Directly connect the Printer to a parallel port on a computer to determine

if the network is the source of communications problems.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Firmware Errors

Resolving the Upgrade Failed error

Symptom: An Upgrade Failed error is displayed on the LCD during the upgrade process

Step Procedure

1 Determine if there is interference from an external device.

a. Do not use an A/B switch box, dongle key or other peripheral in line with

the parallel cable.

b. If using a switch box, dongle key or other peripheral, remove it while testing

communication between the computer and the Printer.

c. If needed, replace the switch box, dongle key or other peripheral (once it is

determined that the cause of the interference is not the switch box or peripheral).

d. Alternative: Add a second parallel port into the computer (if a second

Printer is required).

2 Ensure that the proper procedure is being used.

a. Be sure to follow the instructions on the attached HDP Firmware Upgrade

Guide to insure that the correct data is being transferred to the Printer.

b. It is possible that the Firmware Update Program is corrupt. In this case, the

entire program should be uninstalled from the PC and the newest version of the program should be downloaded and installed from Fargo’s web site:

http://www.fargo.com

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving an Upgrade Failed error (continued)

Step Procedure

3 Ensure that the proper procedure is being used.

a. Be sure to follow the instructions on the attached HDP Firmware Upgrade

Guide to insure that the correct data is being transferred to the Printer.

4 a. It is possible that the Firmware Update Program is corrupt. In this case, the

entire program should be uninstalled from the PC and the newest version of the program should be downloaded and installed from Fargo’s web site:

http://www.fargo.com

5 Update from the 32-bit Print Spooler.

a. Install and open the 32-bit Print Spooler program. b. Click on File in the menu and select the Open option. c. Then point this window to the directory of where the latest HDP Firmware is

located on the PC. (This Firmware file will always have a *.s19 extension)

d. Once the Firmware file is selected, the HDP needs to be restarted into

SYSTEM UPGRADE mode:

• At the PRINTER READY screen, select the “menu” option.

• Then press the DOWN arrow, until the brackets are around the System

Upgrade.

• Then press the Select option.

• When the screen Displays “Are you sure you want to continue?” Select

YES.

• When the Printer reboots, it will be in System Upgrade mode and will

begin to count down from 60 seconds to 0 sec.

• As the HDP LCD display begins its countdown, click the “Print” button

on the 32-bit Print Spooler.

e. The HDP Display should then run through its Update process. After it has

completed, reboot the Printer. Turn the power off and then back on and then test.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Card Feeding Errors

Resolving the Card Feeding problem (HDP820/820-LC)

Symptom: Two or more cards are feeding at the same time or cards are not feeding

properly

Step Procedure

Remove the stack of cards. (Note: Ensure that the cards are not sticking together. Manually separate them if needed.)

Caution: Do not touch the surface of the card because dirt or oil from

the hands can damage card quality.

Slide the left wall of the Input Hopper to the proper location. (Note: The wall of the card hopper should be within .030” (.75mm) of the stack of cards.)

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

6 0 m

30mil

Resolving a Card Feeding problem (HDP820/820-LC) (continued)

Step Procedure

3 When loading cards, ensure that Card Thickness Adjustment Knob is properly

set to ensure that the Printer feeds in only one card at a time. a. Open the Front Access Door b. Locate the Card Thickness Adjustment Knob. c. Adjust this knob to the setting that matches the card thickness. For fine

scale changes, see the Fine Tuning the Card Separator Adjustment

Assembly (D840995) procedure in Section 3, page 165.

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving a Card Feeding problem (HDP820/820-LC) (continued)

Step Procedure

4 Clean the Cleaning Rollers.

a. Open the Front Access Door of the Printer. b. Depress the Cleaning Roller Lock. c. Pull the Cleaning Roller Assembly out of the Printer. d. Clean the rollers with one of the adhesive-backed Cleaning Cards from the

Printer Cleaning Kit.

e. Remove the card's adhesive backing paper and slide the card between the

rollers until all dust particles are removed.

f. Flip over the Cleaning Card to clean both the top and bottom Cleaning

Rollers. (Note: Alternatively, placing the assembly under lukewarm water may clean the Cleaning Roller.)

g. Once cleaned, replace the Cleaning Roller Assembly and close the Front

Access Door. (Caution: Ensure that the Cleaning Roller Assembly is completely dry before reinstalling into the Printer.)

5 Inspect the Card Feed Motors for proper operation.

a. Leave the power ON and open the Print and Transfer Stations. b. Press the FORWARD button to advance the card or the BACK button to

reverse the card. Use these buttons to move the card through the Printer.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving the Card Feeding Errors (HDP825/825-LC)

Symptom: Two or more cards feed at the same time or the cards will not feed at all.

Step Procedure

1 Clean the Input Roller.

a. Open the Printer's top covers and remove all cards and print Ribbons from

the Printer. b. Leave the Printer power ON and the top covers open throughout this

procedure. (Note: The card-cleaning cartridge can also remain within the

Printer during this cleaning process.) c. Use a cleaning card from the Printer Cleaning Kit and remove its adhesive

backing paper. d. Insert the cleaning card into the Exception Card Slot until the card stops.

• Verify that the longest non-adhesive end of the cleaning card enters the

Printer first and that the sticky side is facing DOWNWARD

e. Press the FORWARD button several times to feed the Cleaning Card all

the way through the Printer.

Continued on the next page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving the Card Feeding Errors (HDP825/825-LC) (continued)

Step Procedure

2 Ensure the Card Thickness Lever is set correctly, as shown below.

a. Press the Card Thickness Lever Lock and then push the Card Thickness

Lever up or down to the appropriate setting.

b. with any of the Card Thickness settings, move the slide slightly toward a

higher setting until the cards begin feeding (if the Printer seems unable to feed cards at the selected setting).

c. Move the slide slightly toward a lower setting (if the Printer seems to

double-feed cards). (Note: The card thickness slide is adjustable to accommodate card thickness variations that often occur even within standard card sizes.)

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Insert cards neatly stacked.

Card Feed Roller

Resolving the Card Feeding Errors (HDP825/825-LC) (continued)

Step Procedure

4 Ensure that the cards are loaded properly in the Input Hopper.

5 Verify that the Hopper Lift (A000124) is operational.

a. Check for static build up between cards. (Note: Occasionally, a static

charge will build up between the surfaces of two or more cards causing them to stick together.)

b. Reduce or eliminate this static charge by separating the cards manually

before placing them in the input hopper.

a. Load the cards into the Printer by inserting them straight into the hopper

and setting them on the feed Roller.

a. Reset Power to the Printer. b. Open the Card Hopper Door and watch to verify that the Hopper Cycles

on startup.

c. If the Hopper does not cycle on startup, remove the top cover and verify

that the Hopper Lift Motor is plugged in properly.

d. If the Hopper Lift Motor is plugged in, disconnect it and attach a 9-volt

battery to the leads.

e. If the Motor turns, replace the Main Board (as needed).

Card Hopper

(side view)

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

Cards

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving the stalled Cards on or at the Feed Rollers

Step Procedure

1 Clear the stalled card.

a. Open the Print and Transfer Station. b. Use the arrows on the LCD panel to move the card forward or backward to

free the card.

2 Inspect the Card Feed Roller Motors for proper operation.

a. Leave the power ON and open the Print and Transfer Stations. b. Press the FORWARD button to advance the card or the BACK button to

reverse the card. (Note: Use these buttons to move the card through the Printer.)

c. Verify that there is nothing obstructing the card as it travels through the

Printer.

Resolving the jammed Cards on the Flipper Table

Step Procedure

1 Clear the jammed card.

a. Open the Print and Transfer Station. b. Use the arrows on the LCD panel to move the card forward or backward to

free the card.

2 Inspect the Card Feed Roller Motors for proper operation.

a. Leave the power ON and open the Print and Transfer Stations. b. Press the FORWARD button to advance the card or the BACK button to

reverse the card. (Note: Use these buttons to move the card through the Printer.)

3 Adjust the Flipper Offset.

a. Select the Menu on the LCD Display. b. Select the Setup Printer. Scroll down to the Flipper Offset. c. Change the setting on small increments. (Note: A positive adjustment will

lower the side of the Flipper Table closest to the Exit Hopper.)

d. Press Select to save the new value.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving the Flipper Alignment Error Message

Symptom: A Flipper Alignment error was displayed on the LCD.

Step Procedure

1 Check for any obstruction.

a. Open the Front Access Door. b. Ensure that there are no obstructions.

2 Verify Motor Operation.

a. Test the Flipper Table Home Sensor (140407) by entering the FLIPPER

OFFSET in the PRINTER SETUP menu on the LCD display. b. Without making any adjustment, press the Select button. (Note: This should cause the Flipper Table to attempt to home itself. If this is

not the case, continue to Step 3, below.)

3 Test the Flipper Home Sensor (140407).

a. Remove the screws from the rear cover. b. Tilt the back cover outwards from the Printer c. Using a Digital Voltmeter, connect the negative lead to its ground. d. Connect the positive lead to Pin 4 of J58 on the Lamination Board.

• If covered, the voltage should read approximately .9 VDC.

• If uncovered, the Sensor should read 3.0 to 3.3 VDC.

e. If the voltages from the Flipper Home Sensor do not match, replace the

Sensor.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving the Cards being fed improperly off the Flipper Table

Symptom: Cards feed off the Flipper Table over the card feed path or under the card feed

path.

Step Procedure

1 Adjust the Flipper Offset.

a. Select Menu on the LCD Display. b. Select Setup Printer and Flipper Offset. c. Change the setting in small increments. (Note: A positive adjustment will

lower the side of the Flipper Table closest to the Exit Hopper.) d. Press Select to save the new value.

2 Ensure the roller tension Spring is tensioned properly.

a. Manually insert a card under the Flipper Table Roller. b. There should be sufficient resistance from the tensioning Spring to hold the

card in place when rotating the Flipper Table perpendicular to the card feed

path. c. If the card falls off the Flipper Table when rotated, flip the Flipper Table

over and inspect the U-Shaped Spring (810480) that holds the white

tensioning roller in place. d. Either replace the U-shaped Spring or remove and attempt to bend the

arms of the Spring down to provide more tension.

3 Verify Card Thickness

a. Ensure that the card stock that is being used conforms to the accepted

card thickness specification. (Note: Cards should be between 0.030” and

0.070” (.762mm to 1.778mm).)

4 Test the Flipper Home Sensor (140407).

a. Remove the screws from the rear cover. b. Tilt the back cover outwards from the Printer c. Using a digital voltmeter, connect the negative lead to its ground. d. Connect the positive lead to Pin 4 of J58 on the Lamination Board.

• If covered, the voltage should read approximately .9 VDC.

• If uncovered, the Sensor should read 3.0 to 3.3 VDC..

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving the Card Jam Error Message

Symptom: If a card becomes jammed inside the Printer, the LCD Display will indicate

approximately where it is jammed. At this point you can either try to correct the problem and continue printing with the same card or remove the card completely and start the print job over.

Step Procedure

1 Leave the power ON and open the Print and Transfer Stations.

2 If you would like to try to correct the problem and continue printing with the

same card, do so by pressing the FORWARD button to advance the card or the BACK button to reverse the card. Use these buttons to help free the card from its jam. Try not to move the card too far from where it was just before the jam occurred. Once the jam is cleared, replace media, close the Printer and press the RESUME button to resume printing.

3 If you would like to remove the jammed card completely, do so by using the

FORWARD and BACK buttons to manually eject the card. Then, close the Printer. Press the CANCEL button to reset the Printer and cancel all jobs within the Printer's memory. In this case, you must also cancel and resend the print job from the computer. (Note: For best results, cancel the job from the computer first and then press the Printer's CANCEL button.)

4 If the Printer is equipped with the Card Lamination Module and a card is

jammed in this area, open the Lamination Module's Top Cover and Lamination Station. Push the Module's Cancel or Resume buttons to move the Lamination Module's rollers and clear the card jam.

• If you only slightly moved the card to clear the jam, close the Lamination

Module and press its Resume button to try laminating again.

• If you completely removed the card, press the Lamination Module's Cancel

button to reset the Lamination Module for the next card. The Lamination

Module buttons only affect the card in the Lamination section. The Printer's

LCD softkey buttons affect any card in either the Print Station or the

Lamination Station (e.g., the Lamination Module's Cancel button cancels

only the Lamination job; the Printer's CANCEL softkey button cancels both

the print and Lamination jobs).

• If both the Print Station and Lamination Station are open, the LCD's

FORWARD and BACK softkey buttons will move ALL rollers.

• If only the Lamination Module is opened, only the Lamination Module

buttons will move the Lamination rollers.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving the Card Jam: Lam Error Message

Symptom: The Card Jam: Lam Error is displayed on the LCD.

Step Procedure

1 Look for a jammed card in the Printer.

a. Open the Printer’s top cover. b. Remove the ribbon from the Printer. c. Check to see if a card is jammed in the Lam Station of the Printer. d. If a card is jammed in the Printer, use the Pause/Resume button and the

Cancel buttons to move the feed rollers and free the card. (Note: The card can then be fed out of the Printer.)

e. If no card was found in the Lam Station, continue to Step 2.

Test the TOF Sensor. (Note: If the Printer has begun laminating the card and then jams, it may be possible that the centering of the Lamination of the card has caused the jam.)

a. Inspect the card and determine if the Lamination is centered on the card. b. If the Lamination is hanging off the leading or trailing edge of the card, see

the Resolving the Card Lamination Placement errors page 103.

3 Test the Card Detection Sensor (D840624).

a. Remove the rear cover. b. Using a Digital voltmeter, connect the negative lead to ground. c. Connect the positive lead to Pin 1 of J6.

• If blocked, the voltage should read 4.9 to 5.5 VDC.

• If unblocked, the Sensor should read 0.15 to 0.18 VDC.

d. If the voltages do not read correctly, replace the Sensor.

procedure in Section 3,

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Magnetic Encoding Errors

Symptom: Either (a) no output is encoded, (b) it is unable to read encoded data on card or

Resolving the No ENC Response Error Message

Step Procedure

1 Verify connections.

a. Ensure that the two wires to J62 on Lamination Board are properly seated.

2 Verify if the Lamination Board is bad.

a. Replace the Lamination Board. See the Replacing the Lamination Board

(140402) procedure in Section 5, page 368.

b. See if the error repeats itself.

Resolving the No Magnetic Encoder Error Message

Symptom: The Printer is receiving encoding data, but the Printer is not configured with this

Encoder type.

Step Procedure

1 Verify if the LCD Setting is incorrect.

a. Press Select on the LCD. b. Select Setup Printer. Scroll down to Encoder Settings. c. Change the Mag Setting from None to Installed.

2 If the encoding data was sent in error, check the in-house, software user’s

manual for encoding instructions.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving the Failed Magnetic Encode Error Message

Symptom: The magnetic stripe was not encoded properly.

Step Procedure

1 Check to ensure that the cards are loaded with the magnetic stripe facing

down and towards the back of the Printer.

2 Check the Magnetic Offset Setting.

a. Press Menu on the LCD b. Select Setup Printer. Scroll down to Encoder Settings. c. Select Magnetic TOF d. Verify that the current value matches the default value listed on the back of

the Printer.

3 Verify the Driver Settings.

a. Ensure that the coercivity setting in the Driver corresponds to the type of

cards that are being used.

• High Coercivity = 2750 Oersted

• Low Coercivity = 300 Oersted

(Note: See the Using the Magnetic Encoding tab

218.)

procedure in Section 3, page

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Removing the Card jam in the Printer’s Magnetic Encoding Area

Symptom: A card is jammed in the magnetic encoding area of the Printer.

Step Procedure

1 Clear the jammed card.

a. Open the Print and Transfer Station. b. Use the arrows on the LCD panel to move the card forward or backward to

free the card.

2 Inspect the Card Feed Roller Motors for proper operation.

a. Leave the power ON and open the Print and Transfer Stations. b. Press the FORWARD button to advance the card or the BACK button to

reverse the card. Use these buttons to move the card through the Encoder.

3 Ensure that the cards are feeding into the Encoding Module properly.

a. Reset power on the Printer to clear any error messages. b. Open the Front Access Door. c. Select the Menu from the LCD. d. Select the Print Test Image from the menu. e. Select the Magnetic Test from the menu. f. A card is then fed from the input hopper onto the Flipper Table and rotated

into the Encoding Module. g. If the card appears to jam against the components of the encoding

assembly, the Flipper Offset may need to be adjusted.

4 Adjust the Flipper Offset.

a. Select the Menu on the LCD Display. b. Select the Setup Printer. Scroll down to the Flipper Offset. c. Change the setting on small increments. (Note: A positive adjustment will

lower the side of the Flipper Table closest to the Exit Hopper.) d. Press Select to save the new value.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving the Printer being unable to read Encoded Magnetic track Data problem

Step Procedure

1 Verify that the cards are loaded properly with the magnetic stripe facing down

and towards the back of the Printer.

2 Verify that the card is encoded with magnetic data by using a magnetic imager

or developer solution.

Use WordPad (a Windows 95/ 98/ ME/ NT/ 2000/XP word processing program in the Accessories Program Group).

a. Open the program and type: “~1%JULIEANDERSON^1234567890?” b. Select File > Page Setup and click on the Printer button. c. Ensure that the HDP800 Series Card Printer is selected and click OK. d. Change all the margin settings to zero (0) and click OK. e. Select File > Print on the Menu Bar. f. Go to File on Menu Bar and select Print. (Note: The Printer should then

feed a card into the Encoder and magnetically encode it.)

4 Ensure that the coercivity of the cards matches the setting in the Driver.

5 Compare the settings for the card reader to the settings in the Driver.

6 Ensure that the magnetic stripe on the card is free of scratches or voids.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving the magnetic stripe Data being printed on a Card problem

Step Procedure

1 Confirm that the application is formatting the magnetic string correctly. See the

Sending the Track Information

procedure in Section 3, page 227.

Use WordPad (a Windows 95/ 98/ ME/ NT/ 2000/XP word processing program in the Accessories Program Group).

feed a card into the Encoder and magnetically encode it.)

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

E-card Encoding Errors

Resolving the Job Mismatch error

Symptom: The Job Mismatch error is displayed on the LCD while running a batch print job

with E-card Encoding

Step Procedure

1 Cancel the current print job.

2 Remove any cards that are still in the Printer.

3 Visually check the last card that was printed properly.

4 Restart the print job using the last successfully printed card as a reference for

where to start.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Removing the Card jam in the Printer’s Smart Card Encoding Area

Symptom: A card is jammed in the smart card encoding area of the Printer.

Step Procedure

1 Clear the jammed card.

a. Open the Print and Transfer Station. b. Use the arrows on the LCD panel to move the card forward or backward to

free the card.

2 Inspect the Card Feed Roller Motors for proper operation.

a. Leave the power ON and open the Print and Transfer Stations. b. Press the FORWARD button to advance the card or the BACK button to

reverse the card. Use these buttons to move the card through the Encoder.

3 Ensure that the cards are feeding into the Encoding Module properly.

into the Encoding Module. g. If the card appears to jam against the components of the encoding assembly,

the Flipper Offset may need to be adjusted.

4 Adjust the Flipper Offset.

a. Select Menu on the LCD Display. b. Select Setup Printer and Flipper Offset. c. Change the setting on small increments. (Note: A negative adjustment will

lower the side of the Flipper Table closest to the Exit Hopper. d. Press Select to save the new value.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving the No Prox Encoder Error Message

Symptom: The Printer is receiving encoding data, but the Printer is not configured with this

Encoder type.

Step Procedure

1 Verify that the LCD Settings are correct.

a. Press Select on the LCD. b. Select Setup Printer. Scroll down to Encoder Settings. c. Change the Prox Setting from None to Installed.

2 Check the appropriate software user’s manual for specific encoding

instructions if the encoding data was sent in error.

Resolving the No Smart Encoder Error Message

Symptom: The Printer is receiving encoding data, but the Printer is not configured with this

Encoder type.

Step Procedure

1 Verify that the LCD Setting are correct.

a. Press Select on the LCD. b. Select Setup Printer. Scroll down to Encoder Settings. c. Change the Smart Setting from None to Installed.

2 Check the software user’s manual for encoding instructions if the encoding

data was sent in error.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving the Failed Smart Encode Error Message

Symptom: The card's smart chip was not encoded properly.

Step Procedure

1 Check to ensure that the cards are loaded with the smart chip facing up and

are being fed into the Printer first.

2 Verify that the card is entering the E-card Docking station properly.

a. Open the front access door. b. Send an encoding print job from the computer. c. Watch the card feed into the Printer and enter the E-card Docking Station. d. If the card is not feeding into the E-card Docking Station properly, the

Flipper Offset may need to be adjusted. See Resolving the Cards being fed

improperly off the Flipper Table in Section 2, page 73.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Printing Process Errors

Resolving the Ribbon Alignment Error Message

Step Procedure

1 Check that the ribbon is loaded properly and completely seated on the Hubs.

2 Check that the marks on the ribbon are complete.

4 Test the Ribbon Sensor.

6 Clear the jam and reboot the Printer if the ribbon is jammed.

Check the motor operation to ensure that the ribbon moves in both Forward and Backward directions on Power Up.

a. Remove the back cover and locate the connector labeled J65 on the main

Board. b. Check the voltage for each of the five (5) Ribbon Sensors (140404 and

140407) at their connection to the main Board.

c. Use a Multimeter to ground the negative lead to the chassis and put the

positive lead on pins 3, 5, 7, 9 and 11 of J65 on the main Board. d. Place a RibbonTraq™ mark over the Ribbon Sensor. (Note: The voltage

should be less than 1 VDC.) e. Remove the RibbonTraq mark from the Ribbon Sensor. (Note: The

voltage should be greater than 3.5 VDC.) f. Replace the Sensor if the voltages are incorrect.

Install a new ribbon and press the Resume button to continue if the ribbon is out.

7 Repair the ribbon if the ribbon breaks.

a. Repair the ribbon by taping it back on to the take-up core if the ribbon is

broken. b. Press the Resume button to continue or Cancel to reset the Printer.

8 Ensure that the ribbon is not stuck to the film.

a. Open the Print and Transfer Stations. b. Verify that the ribbon is not stuck to the transfer film. c. If the ribbon is stuck to the transfer film, increase the ribbon tension in

increments of +5.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

RESTRICTED USE ONLY Fargo Electronics, Inc.

Resolving the Print Ribbon Jam

Symptom: If the print ribbon becomes stuck to the HDP film or jammed inside the Printer,

the LCD Display will indicate that it is jammed. Refer to the following steps to clear the jam:

Step Procedure

1 Leave the power ON and open the Print and/or Transfer Stations.

2 Remove the Take-Up core (the side with used ribbon on it) from in between the

two black Drive Hubs.

3 Steadily pull the print ribbon free from where it is jammed.

• If stuck to the HDP film, pull the ribbon off the film. Do not jerk the ribbon to

free it, since this will increase the chance of breaking it.

• If it does happen to break, simply tape the broken end of the Supply Roll

directly onto the Take-up roll. Then, wind a few inches worth of ribbon from

the supply roll onto the Take-up roll. Be sure the print ribbon is passing behind both the Supply and Take-up rolls.

4 Once the jam is cleared, replace media and close the Printer. At this point, the

LCD Display will prompt you to either press the RESUME button or the CANCEL button.

• Press the RESUME button to retry printing (depending on the error and

how far the card or ribbon have been moved, this may not be possible).

• Press the CANCEL to reboot the Printer and cancel all jobs within the

Printer's memory. In this case, cancel and resend the print job from the

computer. For best results, cancel the job from the computer first, then press the Printer's

CANCEL button.

Resolving the Print Ribbon Error Message

Symptom: The Print Ribbon is not installed properly or has run out, jammed, broken or

been damaged.

Step Procedure

1 See the Resolving the Ribbon Alignment Error Message procedure in

Section 2, page 10, for details.

HDP 800 Series Card Printer/Encoders Service Manual (Rev. 5.0)

FARGO electronics HDP820, HDP820-LC, HDP825 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual