NBS Technologies ImageMaster D-40 Operation Manual

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ImageMaster™ D-40

Card Personalization

System

Operation Guide

NBS-1020-080205

P/N 13456

Revision —

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Proprietary Notice

All drawings and information herein contained are the sole property of NBS Technologies Inc., (NBS) and must be returned at the request of NBS. You may not reproduce, store or convert this material in any form, either mechanical or electronic, without the written permission of an authorized representative of NBS Technologies Inc.

We have made every effort to ensure the accuracy of this material as of the time of printing. However, as this equipment and this manual are subject to change without notice, NBS assumes no responsibility or liability for any errors or inaccuracies that may appear in this manual. NBS assumes no responsibility what so ever for the uses made of this material or decisions based on its use. This manual is supplied for informational use only and should not be construed as a commitment by NBS.

NBS Technologies Inc., the NBS Technologies logo, ImageMaster and SmartSys are trademarks of NBS Technologies Inc.

All other brand or product names are the trademarks or registered trademarks of their respective holders.

NBS equipment is manufactured under one or more of the following U.S. patents, their foreign equivalent or patents pending:

4,686,898; 4,754,787; 4,755,069; 4,784,059; 4,789,420; 4,866,545; 4,900,168; 4,969,760; 5,406,422; 5,503,514; 5,837,991; 6,089,457; 6,131,817; 6,142,370; 6,439,567; 6,588,673; 6,352,206 B1; 6,484,780 B2; 54,726,719, (EP462,201);

Address for:

NBS Technologies Inc.

Corporate Headquarters Canada 703 Evans Avenue Toronto, Ontario M9C 5E9 Canada tel: +1 416.621.1911 fax: +1 416.621.8875

Website: http://www.nbstech.com

Customer Service: +1 416-840-8620 / 800-524-0419

Canada Only: +1 416-840-8627/ 800-565-9033

United States 70 Eisenhower Drive Paramus, New Jersey United States 07652 tel: +1 201.845.7373 fax: +1 201.845.3337

United Kingdom 7 Byfleet Technical Centre Canada Road, West Byfleet, Surrey KT14 7NB United Kingdom tel: +44 01932.351531 fax: +44 01932.351382

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D-40 Operation Guide i

Table of Contents

Chapter 1 Introduction .................................................... 1-1

1.1 Product Description ............................................. 1-1

1.2 Installation .................................................... 1-2

1.3 Familiarization with Unit .......................................... 1-2

1.4 Input Hopper .................................................. 1-4

1.5 Card transport System........................................... 1-4

1.6 Card Cleaning System ........................................... 1-4

1.7 Optional Magnetic Encoding ...................................... 1-5

1.8 Optional SmartCard Programming .................................. 1-5

1.9 Flipper Mechanism ............................................. 1-5

1.10 Thermal Printing ............................................... 1-5

1.11 Output Stacker - Reject Area...................................... 1-5

1.12 Liquid Crystal Display ........................................... 1-6

1.13 Operator Control Panel .......................................... 1-6

Chapter 2 Main Menu - Basic Functioning .................................... 2-1

2.1 General ...................................................... 2-1

2.2 Keyboard and LCD Display ....................................... 2-1

2.3 Power-up and Fundamentals ...................................... 2-1

2.4 Front Panel Switches ............................................ 2-2

2.5 Main Menu Selections ........................................... 2-2

2.6 Print Option ................................................... 2-3

2.7 Layout Option ................................................. 2-3

2.8 Online Option.................................................. 2-4

2.9 Utility Option .................................................. 2-4

2.10 Counters Option ............................................... 2-4

2.11 Start-up ...................................................... 2-4

Chapter 3 Printing Cards .................................................. 3-1

3.1 External Printer ................................................ 3-1

3.2 Standalone Printer ............................................. 3-1

3.3 Print Command ................................................ 3-1

Chapter 4 Creating Layouts ................................................ 4-1

4.1 File Sub-menu ................................................. 4-1

4.2 Card Layout Considerations ...................................... 4-2

4.3 Layout (Create & Edit) Sub-menus ................................. 4-4

4.4 File (Create & Edit) Commands - Type Selection ....................... 4-4

4.5 Change to Next Field ............................................ 4-5

4.6 Utility/File/Create or Edit/Layout (Font Parameters) ..................... 4-8

4.7 Utility/File/Create or Edit/Layout (Barcode Parameters) .................. 4-15

4.8 Utility/File/Create or Edit/Layout (Encode Parameters) .................. 4-21

4.9 Utility/File/Create or Edit/Layout (Image Parameters) ................... 4-24

4.10 Utility/File/Copy & Delete Commands ............................... 4-25

4.11 Utility/File/Download & Upload Commands ........................... 4-25

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4.12 Utility/File/SelBoot .............................................. 4-27

4.13 Utility/File/Status ............................................... 4-28

Chapter 5 Operator Maintenance ............................................ 5-1

5.1 General Cleaning ............................................... 5-1

5.2 Cleaning the Print Head .......................................... 5-1

5.3 Card Stock.................................................... 5-1

5.4 Ordering Consumable Supplies .................................... 5-2

5.5 Loading Cards ................................................. 5-2

5.6 Unloading Cards ............................................... 5-3

5.7 Replacing Printing Foil........................................... 5-4

5.8 Replacing Cleaning Tape ......................................... 5-5

Chapter 6 Error Messages ................................................. 6-1

Revision History ........................................................ RH-1

Critique Form .......................................................Last Page

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D-40 Operation Manual 1-1

Chapter 1 - General Description

The following is provided to introduce your new ImageMaster™ D-40 printer.

1.1: Product Description

The ImageMaster™ D-40 printer is a table top, high speed, thermal card printer. The D-40 offers dual sided printing with parallel card processing capability. The D-40 is capable of producing cards at speeds up to 4000 cards per hour (cph) single sided and 1200 cph in dual sided mode. The D-40, as an option, supports magnetic strip encoding and programming of the embedded chip on a Smart Card. It has 500 card capacity input and output hoppers. It features large capacity roll of printing ribbon, capable of printing up to 12,000 cards per roll (with 3" (7.62cm) of printing per card).

Physical Dimensions

Height: 23 inches (585 mm) Width: 24 inches (610 mm) Depth: 16 inches (407 mm)

Power requirements

Weight: 70 lbs (23.6 kg)

110-230VAC, 50/60 Hz, ? Amp Slow-Blow FCC Class B, CE, and ETL approved

Operating Environment

Temperature range: 580 F to 800 F (150 C to 300 C) Relative humidity: 20 to 65% non-condensing

Storage temperature: 230 F to 1580 F (-50 C to 700 C) Storage humidity: 20% to 70% non-condensing

Plastic Cards Accepted

Type: PVC & composite PVC - including breakaway, key cards, & clear cards Card Size: ISO 7810 (CR-80) - 3.375" x 2.125" (86 mm x 54 mm) Card Thickness: 0.024" to 0.030" (0.61 mm to 0.76 mm)

Print Resolution

300 dots per inch (dpi) (11.8 dots per mm) monochrome printing - up to 4000 single sided cph or 1200 dual sided cph

Maximum Print

0.100" +/- 0.010" from side edges of card

0.100" +/- 0.015" from top and bottom edges of card

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Connectivity

Serial IP Ethernet

Encoding/Programming

Magnetic

3 Tracks : ISO /IEC 7811 Write Speed: ?.? inches/second Read Speed: ?.? inches/second

SmartCard

!SO7816 personalization

Clear Card

1.2: Installation

The D-40 printer is meant to be used in an office type environment, on top of a table or desk. If the environment is comfortable for the operator the D-40 Series printer will work just fine. See “Operating Environment” above. Adequate working space must be provided around unit, especially for proper ventilation of internal components. The exhaust fan at rear of unit must never be blocked. Should repairs be needed and to perform normal operating functions – changing foil, loading cards, etc., a minimum of 10 inches, all around the unit, is recommended.

The D-40 Series printer will be installed by an NBS or Authorized Dealer trained technician. The technician will also train the operator in the basic function of the system. The end user will be asked to sign off on the final installation when completed to end user satisfaction.

1.3: Familiarization with Unit

The following identifies the major components of interest to operators.

Figure 1-1 shows the front of the unit, while Figure 1-2 shows the rear of the unit. Except for turning unit on, the operator mainly interfaces with the front of the unit via the keyboard, the LCD panel, the switch panel. Other functions, such as loading and unloading cards, changing printer foil and cleaning tape are also accomplished from the front of the unit, some requiring the top front cover to be opened.

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D-40 Operation Manual 1-3

Open Top Cover

Print Ribbon Supply

Print Ribbon Ta ke - up

Print Head

Reject Tray

Flipper

Keyboard

Output Hopper

Input Hopper

Cleaning Tape Supply

Cleaning Tape Ta k e- u p

Magnetic Encoding

SmartCard Programming

Switch Panel

LCD Display

Figure 1-1 Front of ImageMaster™ D-40

Fan

AC Input

On / Off Switch

Fuse

Communication PORT Connectors (4 Serial)

Figure 1-2 Rear of ImageMaster™ D-40 unit

LAN Connector

Keyboard Connector

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The ON/OFF switch is located at the rear of the unit, along with the various communication connections. The depressed side of the rocker switch is the enabled function. With the “I” depressed the system is ON. With the “O” depressed the unit is OFF.

The basic D-40 printer consists of the following major components:

• Card input hopper

• Card transport mechanism

• Card cleaning mechanism

• An optional magnetic encoder

• An optional SmartCard programming station

• Flipper mechanism

• Thermal printer

• Card output hopper

• Reject tray

• Forty (40) character each two (2) line LCD display

• Four button control switch panel

• Four serial 9 pin female PORT Communication connectors

• Network port connector

• AT style keyboard and connector

An Imagemaster™ D-40 configuration may also include a PC acting as a host or source of the data used to produce cards.

The following brief descriptions are presented in the order of card movement through the unit.

1-4 Input Hopper

The INPUT HOPPER accepts CR-80 cards, with the capacity to hold at least 500 blank cards (amount depending on thickness). The base of the hopper contains a Card Picker Assembly.

Fingers should never be placed into the hopper when the system is

! Caution:

ATTENTION!

in operation. Fingers can be injured by this mechanism when it is pushing a card out of the hopper and into the Transport System.

Les doigts ne devraient jamais être placés dans le distributeur lorsque le système est en marche. Les doigts peuvent être blessés par ce mécanisme quand il pousse une carte hors du distributeur vers le système de transport.

1.5: Card Transport System:

The CARD TRANSPORT SYSTEM consists of transport motors, a series of sprockets and belts, and rubber rollers that will move the card in either direction as required.

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D-40 Operation Manual 1-5

1.6: Card Cleaning System:

As the card enters the Transport System, both sides of the card are cleaned by a set of rollers and a brush. The top roller of the set is softer and more adhesive than the bottom roller. Any dust or debris that accumulates on the lower roller is transferred to the top roller.

Periodically, the cleaning tape comes in contact with the top roller, transferring any foreign matter from the top roller to the cleaning tape. By default the cleaning cycle occurs after every 5 cards, but the timing of this process is user adjustable.

The Cleaning Brush is constructed of nylon (90%) and brass (10%) bristles

NOTE:

mounted in a galvanized steel channel. The purpose of the brush is to remove large pieces of debris and to discharge any static electricity from the passing cards.

1.7: Optional Magnetic Encoding

ISO magnetic encoding is available for tracks 1, 2, and 3. During the encoding process information is first written on the desired track(s), then it is read and verified. If the information encoded does not verify with what was written, a retry of the entire write and read process is made. The number of retries is user defined. If the card cannot be verified within the set number of retries, the card will be sent to the reject tray, and a error message is displayed on the LCD Screen. Operator intervention is required.

1.8: Optional SmartCard Programming

As the card is positioned in unit a solenoid is activated bringing the programming head in contact with the card chip. SmartCard programming is a pass through operation - the D-40 positions the card, an external source is used to program the chip.

1.9 Flipper Mechanism

This mechanism can flip the card so that the reverse side of card can be processed.

1.10: Thermal Printing

As the card is sensed entering the print area, the PRINT HEAD is lowered. The foil starts moving, and the PRINT HEAD prints the first vertical line across the width of the card. The density is 300 DPI. Raster data is sent to the head one line at a time, turning on respective dots on the Print Head to apply heat to the foil in the correct locations to form the picture, letter, or barcode. When the last line is printed, the head is raised and the foil stops moving. The card is moved to the next operation.

The large capacity printing foil roll is loaded on spools present on the unit itself.

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1.11: Output Stacker - Reject Area

The OUTPUT STACKER is a vertical storage device. The upper portion holds all of the acceptably produced cards. If the card is a reject it falls into the lower reject area. The stacker can hold 500 acceptable .030" cards. The Reject tray holds fifteen rejected cards.

Fingers should never be placed into the hopper when the system is in

! Caution:

ATTENTION!

operation. Fingers can be injured by this mechanism when it is pushing a card up into the hopper.

1.12: Liquid Crystal Display:

The LIQUID CRYSTAL DISPLAY (LCD) is a two line, eighty (80) character display (2 lines of 40 characters each), installed on the front of the machine. It is used to provide operator prompts, selection options during the utilities command functions, error messages, and the like. When used for data entry it displays keyboard entries.

1.13: Operator Control Panel

The operator control panel consists of four (4) push button switches as shown in Figure 1-3 and their functions are defined in Table 1-1.

D-40 Front Panel Button Selection

Command Button Button Function

WAIT

ONLINE Places unit online to a host over a network.

SW1 Application specific.

RESETS Resets the print mechanism and menu. (The machine can also

Suspends machine operation AFTER the current card.

be reset by pressing [CTRL] + [A] keys.)

Table 1-1

General Description Chapter 1 Page 6

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D-40 Operation Manual 1-7

LED for “Wait” button on steady when in wait mode.

Print Layout Online Utility Counters

Front Panel Display

Figure 1-3 Front Panel

LED flashing on “Reset” button when the unit is waiting for operator response. This indicates that the machine is operating normally.

WAIT ONLINE SW1 RESET

Panel Buttons

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D-40 Operation Manual 2-1

Chapter 2 - Main Menu - Basic

Functioning

2.1: General

This chapter explains the various Main Menu settings and functions of the D-40 printer and demonstrate basic operator functions.

2.2: Keyboard and LCD Display

The D-40 printer requires a 101 enhanced AT keyboard for data entry. All input from the keyboard as well as menu options are displayed on two 40 character lines (a total of 80 characters) Liquid Crystal Display (LCD). The LCD is installed on the front of the unit. Beside the description above, it provides the user with prompts, layout and format information, utility parameters, as well as warnings and error messages.

2.3: Power-up and Fundamentals:

Apply power by depressing the “I” side of the power rocker switch located on rear of unit. Immediately after powering the unit up, the software version is displayed for several seconds. This is then followed by the initial or Main Menu. (Refer to Figure 2-1.)

Print Layout Online Utility Counters

Print a card using active layout

Figure 2-1: LCD Display of Main Menu

The blinking cursor indicates the currently highlighted menu option on the first line (as well as an underscore below the first letter of the highlighted menu). The second line describes

the highlighted option’s function. In Figure 2-1, the highlighted menu option is “Print”, while the description is “Print a card using active layout”.

Operation of the system relies on accessing the desired option or setting through a hierarchy of menus and sub-menus. Some sub-menus or items may change, be added to, or subtracted from based on previous choices within an option. The hierarchy may consist of many or few levels depending on user decisions and requirements of the selected operation.

There are six keys on the keyboard that can be considered control keys when navigating through the menus. They are:

• Right Arrow – Moves cursor right to next operation or selection.

• Left Arrow – Moves cursor left to previous operation or selection.

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• Down Arrow – Moves cursor down to next operation or selection.

• Up Arrow – Moves cursor up to previous operation or selection.

• Enter – Selects current or highlighted operation or selection.

• Escape – Returns to previous menu (from a sub-menu).

However, the Arrow keys work either horizontally or vertically (depending on the current menu or option). For example, a user can only scroll through the Main Menu options by either the Left or Right Arrow keys (horizontal direction), not the Up or Down Arrow keys (vertical direction).

Another way to access the menus is through use of the Number Lock Key Pad. When the Number Lock is disabled, the pad can be used for navigation or enter commands. When the Number Lock is enabled, the pad is used to enter numbers (when required) for data entry.

2.4: Front Panel Switches

The front panel of the D-40 printer has four pushbutton switches. (Refer to Figure 2-2.) These buttons will illuminate when activated by either the operator or the unit. These buttons are defined as follows:

• WAIT - Suspends machine operation AFTER the current card.

• ONLINE - Places unit online to a host over a communication network.

• SW1 - Application specific.

• RESET - Resets the print mechanism and menu. (The machine can also be reset by pressing [CTRL] + [A] keys.)

2.5: Main Menu Selections

As explained previously, the Main Menu appears after the machine has booted up. From this point, the user selects the operation to be performed through the hierarchy of menus.

LED for “Wait” button on steady when in wait mode.

Print Layout Online Utility Counters

Front Panel Display

Figure 2-2: Illustration of Front Panel

LED flashing on “Reset” button when the unit is waiting for operator response. This indicates that the machine is operating normally.

WAIT ONLINE SW1 RESET

Panel Buttons

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D-40 Operation Manual 2-3

The top line of the screen displays the menu selection. Placement of the cursor (using the Arrow keys) determines the menu highlighted and the comment seen on the second line of the display:

• PRINT - Print a card using active layout.

• LAYOUT - Select local card layout.

• ONLINE - Enter online mode.

• UTILITY - System utilities.

• COUNTERS - Production counters.

Menu selection can also occur through use of the keyboard. By pressing the first letter of any of the options, the machine highlights that particular option. Pressing the [ENTER] key while that option is highlighted, selects that option. For example, on pressing the letter [U] and [ENTER] key, the “Utility” option is selected; on pressing the letter [L] and [ENTER] key, the “Layout” option is selected.

Once a Main Menu option has been selected, the Arrow keys can then be used (in conjunction with other keys) to enter data, turn variables on/off, switch between multiple choices of variables, and navigate through the hierarchy of menus.

2.6: Print Option

The Print option is probably the operator’s most commonly used feature. Whether the unit has been reset or just turned on, the last layout in use will be available for printing. If this layout is the one desired, depressing the [ENTER] key while the “P” in “Print” is highlighted will start the printing process. Refer to next chapter for printing instructions. If it is not the desired layout use the Layout command to select one of the other preprogrammed layouts. Refer to paragraph 2.7 - Layout Option below to change layouts.

To create new layouts refer to Chapter 4 - Creating Layouts.

2.7: Layout Option

This main menu option is selected only to switch between the existing layouts stored in the memory of the machine. To change the “Layout” option, move the cursor until it highlights the “L” in “Layout” (in the Main Menu) and depress the [ENTER] key. The display screen in Figure 2-4 will then appear. (All layouts are user defined. All layout names shown in Figure 2-3 are for illustration purposes only.)

Please select the current layout Layout 1 Layout 2 Layout 3 Layout 4

Figure 2-3: Typical Front Panel Display for Layout selection

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As many layout names that there are room for will be displayed. However, if there are more than can be shown, the list is scrolled through using either the left or right Arrow keys. The list will then shift as you move through it, the first letter of each layout being highlighted. Once the layout has been decided upon, it can be chosen by pressing the [ENTER] key. Immediately after pressing the key, the user is returned to the Main Menu. The selected layout becomes the “Active” layout – the one used to produce cards.

2.8: Online Option

This option is selected to allow a host computer to print using the D-40 printer, turning over all control to the host. The communication link is established either via serial port or network connection. During this process, the D-40 printer will emulate a HP Laserjet III printer.

To select the “Online” option, perform one of the following:

• By pressing the [O] button on the keyboard (while in the Main Menu) and then pressing the [ENTER] key.

• Using the Arrow keys to highlight the letter “O”(while in the Main Menu) and then pressing the [ENTER] key.

• By pressing the [ONLINE] button on the Front Panel.

2.9: Utility Option

The “Utility” option defines all operating parameters for the D-40 printer system. The “Utility” option is not typically an operator function. Access to the Utility functions can be password restricted This function is used to create, modify, or delete card layouts described later in this manual. It is also used to activate and program system functioning. These Utility functions, typically service technician functions, are defined in the D-40 Service manual.

2.10: Counters Option

The “Counters” option allows the viewing of the two production counters only. There is no other associated function with this option.

2.11: Start-up

At Start-up, the D-40 Series automatically does a file check, looking for bad or missing files. Also at this point, by holding down any key while the unit is “booting-up”, a boot menu will appear. This menu allows the operator to switch between the several firmware versions that may be resident in memory. (All new firmware upgrades in the field are downloaded to the D-40 system by use of the “NBS Dashboard Program”.)

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D-40 Operation Manual 3-3

Chapter 3 - Printing Cards

Printing cards is the basic function of the ImageMaster™ D-40. Cards are printed in one of two basic modes of operation—as a standalone printer or as an external printer connected to a PC or Host computer.

3-1 External Printer

When the D-40 is connected to a PC or other Host computer for all intense purposes it acts like any other printer, excepting information from the PC and printing as instructed. The operator interface is mostly with a software program loaded into the host computer – such as the NBS SmartSys™ program and printer driver. The D-40 is selected as the active output printer and gets it’s data and layout information from the Host computer. The basic operator interface with the D-40 is to load and remove cards, change printer ribbon and cleaning foil when needed. The printing instruction come from the Host computer when the computer is directed to print cards. This connection is explained in the Card programing software manuals – such as NBS SmartSys Operating Manual – and is not covered in this chapter. This chapter is mostly concerned with Standalone Printer operation

3-2 Standalone Printer

When used as a standalone printer operator interface is mostly with the D-40 printer and the keyboard. The card layouts are created within the D-40 firmware. The fields in the layout are created expecting to see certain types of input data – fixed, variable, or host.

• Fixed data is permanent data entered in a field at the time of the card layout creation and is the same for all cards.

• Variable data is keyboard entered data. It is unique data for each card but means cards are printed one at a time.

• Host data is data coming from some external source, usually a PC over a network or direct connect to the D-40. This is different from the “external printer” explanation above in that the layout is within the D-40, only the data is coming from the external source.

Creating card layouts is not the purpose of this chapter and is described elsewhere.

3-3 Print Command

The Print command on the main menu assumes that the active layout is the desired layout for card creation. The last layout used will be the active layout when the unit is powered up. Refer to Chapter 2- Main Menu description for instructions to change the active layout from among the pre-designed layouts resident in the D-40.

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With the desired layout as the active layout simply pressing the keyboard [ENTER] key while the “P” in “Print” is highlighted on the Main Menu starts the printing or card production cycle.

The type of data field (Fixed, Variable, Host) used in the layout determines the next prompt. Once all data fields entries are completed the final prompt is: “# fo Cards”. (Refer to Figure 3-1)

Fixed

# of Cards

Echos keyboard entry

Type of

Data

Vari able

Keyboard Field 1 Prompt

Echos keyboard entry

Keyboard Field 2 Prompt

Echos keyboard entry

Last Keyboard Field Prompt

Echos keyboard entry

Host

Enter

Print Scrn

waiting Host Data

Data

Received

From

Host

etc.

The user enters a variable number from 1 to 9999. (For example, enter “20” as the amount of card copies from the present layout you wish to print.) After the number has been typed in,

pressing the [ENTER] key will validate the number and begin the printing process.

As the printing occurs, the display tracks the printing process. This continues until either the machine is stopped, or the number of total cards (number entered) is reached.

Printing Cards Chapter 3 Page 4

Enter

Prints

Figure 3-1 Print Display Screens

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D-40 Operation Manual 3-5

The machine is “Busy” during printing and can be stopped by pressing the [RESET] button on the Front Panel. If the keyboard [ESC] button is pressed, the machine will continue printing the current card before stopping and returning to the Main Menu. To interrupt and immediately stop the machine during printing, press the [WAIT] button on the Front Panel. This will temporarily stop the printing until the [WAIT] button is pressed again to resume the operation.

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Printing Cards Chapter 3 Page 6

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Chapter 4 - Creating Layouts

Layouts are created starting with the Utility option on the Main Menu. This function can be password restricted.

4.1: File Sub-menu

The “Utility / File” sub-menu is displayed by first moving the cursor until it highlights the “U” in the “Main” menu. Next, the [ENTER] key is depressed. The Utility menu screen will then appear. (See Figure 4-1.) Ensuring that the “F” (for File) in the “Utility” menu is highlighted by the cursor in the second screen, the [ENTER] key is pressed once more. The “Create” sub-menu screen will then appear.

Enter

From the Utility / File sub-menu, the user can:

• Create an new card layout.

• Edit an existing card layout.

• Copy an existing card layout, font, image, or firmware file.

• Delete an existing card layout.

• Download an existing host layout, font, image, Kanji, or firmware.

• Upload an existing D-40 printer layout, font, image, Kanji, or firmware.

Print Layout Online Utility Counters System Utilities

File Comm System User Exit Create or modify a card layout.

Figure 4-1 Going to “File” sub-menu

Main Menu

Utility Menu

• SelBoot - select a boot file.

• Status - display the file system status.

• Exit the current menu.

As with all other menus, highlight the desired option with the cursor and depress the [ENTER] key. The D-40 printer will immediately display the option’s sub-menu.

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4.2: Card Layout Considerations

Before attempting to create or edit a layout, decisions must be made as to what the finished card will look like (formatting the card). Some considerations that should be considered are listed below. However, this is not intended as an all inclusive list.

• What specific fields will be used: Font, Barcode, Image, Encode, etc.?

• What should the fields contain?

• Where should the fields appear on the card?

• What field length is allowed?

• What is the minimum number of characters in a particular field?

• Is the text to be fixed?

• What field names are to be used?

• What are the allowable characters: digits, alpha, all?

• Is Mod 10 to be used?

• Are there transfer fields: source or destination?

• What is the barcode orientation?

• What type of barcode is to be used?

• Should the barcode be human readable?

• Is data coming from a host?

• What is to be used for card layout creation: Conquest Lite™ or the resident firmware?

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D-40 Operation Manual 4-3

UTILITIES / FILE MENU

Create Edit Copy Delete Download Upload SelBoot Status Exit

Display file system status

Select boot file

Upload file to host via serial port

Download file from host via serial port

Delete file

Copy file to new name

Edit existing file

Create a file

Layout Exit

Please select a layout to edit: ( )

Enter new layout name: ( )

Type :

Font / Barcode / Encode / Image

enter 16 characters

Typ e:

Font / Barcode / Encode / Image

Chapter 4 Page 3 Creating Layouts

Figure 4-2: Utility Menu Overview

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4.3: Layout (Create & Edit) Sub-menus

The “Create” function menu is used to design a new card layout, while the “Edit” function menu is used to modify an existing design. With exception of the first screen, selecting

either will bring up the exact same menu screens. (However, to select a layout for immediate printing, it must be chosen from “File” under the Main Menu. See Figure 4-2.)

To access either of these preferences from the “File” sub-menu, highlight the desired function with the cursor and press the [ENTER] key. A new screen will appear on the LCD Display as shown in Figure 4-3.

Create Edit Copy Delete Download Upload SelBoot Status Exit Create a file

First screen for (File) Create selection

Create Edit Copy Delete Download Upload SelBoot Status Exit Edit existing file

First screen for (File) Edit selection (The layout names used are for illustration purposes only.)

Figure 4-3: First screens for (Layout) Create and Edit menus

4.4: File (Create & Edit) Commands - Type Selection

The list of Create and Edit commands varies with the initial selection made with the “TYPE” field parameter. “Type” is the second screen of either the Create or Edit Commands and identifies the kind of field being programmed. With this parameter, there are several options to chose from: Font, Barcode, Encode, Image. Each of these selections have their own unique set of defaults and alternative choices. Subsequent sub-menus or item selections

will change based on which choice is made.

Regardless of what item the user is addressing in the “Type” parameter, the first line will remain the same. (Used for information, identification, and byte availability.)

The first line —“Field: 001 of 001 (NAME), FREE = 64481”— signifies that the user is creating/editing the “first” character field “of” a “total amount” of one existing character fields, of the “Layout Name” and 64,481 bytes of free RAM memory for layout manipulation. (This number will decrease as fields, images and layouts are added.)

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A better way to state this is:

(Current Field Number to Total Number of Fields) – (Assigned Layout Name) – (Free

Amount of Space Available for Programming.)

NOTE:

To make a selection, go to the menu screen with the “Type” parameter. The cursor will be blinking under the current selection; e.g. the letter “F” in the word “Font”. Parameter selection of the “Type” field is done by using the “Left Arrow” key [<–] or “Right Arrow” key [–>], or using the [SPACEBAR] to switch between multiple choice item options. After deciding on an option, press the [ENTER] key.

There can be several fields per line when laying out a card, however, only one font type per field is allowed.

4.5: Change to Next Field

To generate a new layout field for “Create” or “Edit”, press the [SHIFT]+[INSERT] keys. The top of the field screen will now show a numerical change and increase (example: “002 of 002” and so on) each time the [SHIFT]+[INSERT] keys are pressed. (See Figure 4-4.)

Shift

Field: 001 of 001 (Layout Name) Free xxxxx (bytes available)

Insert

To “Edit” an existing field, press the [PAGE UP] or [PAGE DOWN] keys to navigate through the existing fields until the desired field is displayed.

If a field needs to be deleted, display the desired field and press the [SHIFT]+[DELETE] keys. The field count of the screens will then change. An example of this is illustrated in Figure 4-5. In this example, the field count has changed from “004 of 008” to “004 of 007”. In effect, the fifth field has now become the fourth field, while the screen total has been reduced by one.

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Field: 002 of 002 (Layout Name) Free xxxxx (bytes available)

Figure 4-4: Creating a new field

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Shift

Field: 004 of 008 (Layout Name) Free xxxxx (bytes available) Type Font

Delete

Once all changes have been made and the layout is considered complete, depress the [ESC] key. A new screen (Save Layout Screen) will then appear. (See Figure 4-6.)

Save Layout to EEPROM (y/n) ?

After selecting either “Yes” or “No”, the “Layout” screen is then displayed again. (If “yes” is selected, all changes are saved. If “no” is selected, no changes will be saved.)

Field: 004 of 007 (Layout Name) Free xxxxx (bytes available) Type Font

Figure 4-5: Deleting a field

Figure 4-6: Save Layout Screen

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UTILITIES / FILE / CREATE or EDIT / LAYOUT /

FONT MENU

Typ e: Font

Font Name

X coordinate

Y coordinate

Justify from - -

Rotation - -

Card Side

Trans fe r - -

Left / Center / Right

Horizontal / Vertical / Reverse Hor / Reverse Vert

Top / Bottom

Off / Destination on / Source on

Destination ID

Trans f e r Ty pe - -

Strip Space - - Yes / No

Normal / Name

Source ID

ccept - -

Fixed Text Max. Char.

Fixed / Variable / Host

Accept - - Fixed / Variable / Host

Fixed Text Max. Char.

Pad Char. - - None / Space

Auto Advance - - No / Yes

Prompt - - (35 Char. Max)

Min. Characters

Max. Characters

Default Text - - (45 Char. max)

Allow - - Digits / Alpha / All

Increment by - (3 digit max)

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Mod 10 - - No / Yes

Figure 4-7: Font Field Type Overview

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4.6: UTILITY / FILE / CREATE or EDIT / LAYOUT (Font Parameters)

TYPE.................... Font / Barcode / Encode / Image

Font name.......... ******** (List of fonts in the font card shown)

X coordinate....... 0.29

Y coordinate....... 0.29

Justify from........

Rotation..............

Card Side............

Transfer..............

Accept.................

Left / Center / Right

Horizontal / Vertical / Reverse Hor / Reverse Vert

Top / Bottom

Off / Destination on / Source on

Fixed / Variable / Host

Figure 4-8: Basic Default Menu for Font Parameters

4.6.1: Font Name

“Font Name” identifies the font to be used in this field. The available fonts are listed. These may be determined by pressing the [SPACEBAR] until the desired font name is displayed. The fonts displayed are those that are resident in memory (e.g. Simplex, Blocco, OCR).

4.6.2: X & Y Coordinates

The next two parameters – “X & Y coordinates” – work together to determine the starting points of the field in inches. They are referenced in relation to an imaginary point (origin) in the upper left hand corner of the card. The placement of the field (along with font size) affects the number of characters, which may be printed. The “X & Y coordinates” refers to its baseline position.

4.6.3: Justify

The “Justify” parameter provides a point of reference for the “X coordinate”. The selections are: Left ,Center, or Right. This determines if the characters are to be placed to the left, right, or centered on the X coordinate.

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4.6.4: Rotation

The “Rotation” parameter allows the D-40 to print in any of the four orientations in reference to the “X” location. These are: horizontal, vertical, reverse horizontal, and reverse vertical.

4.6.5: Card Side

The “Card Side” parameter specifies what side of the card the printing is to occur on. The choices are “TOP” or “BOTTOM”.

4.6.6: Transfer

The “Transfer” parameter is used to identify a field as the source of data to be transferred or the destination to which data is transferred. However, in order to transfer data, the source must be identified first. Regardless, when a source or destination is chosen, another submenu will appear. (Refer to Figure 4-9, and Figure 4-10.) The name of the source and destination must be 4 characters long, and must match in order for the data to be sent from the source to the destination. If no data is to be transferred, however, this parameter can be turned off.

Transfer.............

Source ID.......... _ _ _ _ (four characters maximum)

Accept................

Transfer..............

Destination ID... _ _ _ _ (four characters maximum that must match the source

Transfer type...... Normal / Name field

Strip spaces........ No / Yes

Source on / Off / Destination on

Fixed / Variable / Host

Figure 4-9: “Source” Transfer fields

Destination on / Source On / Off

name)

Figure 4-10: “Destination” Transfer Fields

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4.6.6.a: Source & Destination Id

This parameter is used to identify the field as either the source or destination of transferred data. Its naming convention, however, will only allow a maximum of four characters. The destination name must match the source name.

4.6.6.b: Transfer Type

This parameter refers to the data associated with the field/s to be transferred. The “Normal” selection means that the data field is transferred as it has been entered (verbatim). The “Name” selection means that first and last names are reversed when this option is selected.

4.6.6.c: Strip Spaces

This parameter designates whether spaces in the data are removed (stripped away) during the data transfer.

4.6.7: Accept

The “Accept” parameter designates how data will be “accepted” by the field. Data is “Fixed”, “Variable”, or from a “Host”. (Refer to Figure 4-11.)

If the source is “Fixed”, the exact text will be stored along with the layout in the unit. This text is entered after the “Fixed Text” prompt during field creatation. Once stored, it can only be changed by “editing” the layout.

If the choice is “Variable”, the field can only be filled in using keyboard data entries at the time of printing. However, the “Variable” fields are only temporarily stored in the system’s RAM and require new data be entered for each card.

If “Host” is chosen, the field is populated with data from a host computer connected to an identified communication port. However, the host protocol (as well as other communication settings) must be identified and set under the “Communication’s” options prior to usage.

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Accept............... Fixed

Fixed Text......... _ _ _ _ _ _ _ _ _ _ _ _ _(Typed in when field is created.)

“Fixed” Accept fields

Accept............... Variable

Pad character.....

Auto advance......

Prompt................ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ (up to 35 characters)

Min characters... _ _ _

Max characters.. _ _ _

Default text....... _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ (up to 45 characters)

Allow..................

Accept............... Host

Max characters.. _ _ _

None / Space

No / Yes

All / Digits / Alpha

“Variable” Accept fields

“Host” Accept fields

Figure 4-11 Accept fields

4.6.7.a: Pad Character

“Pad characters” are the characters used to fill in the maximum character locations when the data entered does not meet the maximum size of the field. Choices for this parameter are either “None” or “Spaces”.

4.6.7.b: Auto Advance

The “Auto advance” parameter refers to moving the cursor to the next field automatically when data is typed in at the time of card production, rather than having to manually depress the entry key to do the same thing. When enabled, the auto advancement only takes place after the maximum character amount for the field is reached. Choices for this parameter are either “No” or “Yes”.

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4.6.7.c: Prompt

This parameter allows entry of up to 35 characters of instructions or other pertinent information that will appear in the prompt field and guide the operator’s entry of data.

4.6.7.d: Min Characters

This parameter sets the minimum number of characters allowed in a field.

4.6.7.e. Max Characters

This parameter sets the maximum number of characters allowed in a field, affecting the size of the field. The maximum number will influence (or be influenced by) the point size of the font used.

4.6.7.f: Default Text

The “Default text” parameter allows entry of text that will be printed in the field if keyboard entries are not made at the time of card production. (“Default Text” acts similar to “Fixed Text”, but can be overridden by operator entry.) A maximum of 45 characters is permitted.

4.6.7.g. Allow

The “Allow” parameter is considered a validation mechanism. Its function is to minimize incorrect keyboard entry by type of characters.

• If “Digits” is chosen, only digits (0-9) can be used.

• If “Alpha” is chosen, only letters (a-z) can be used.

• If “All” is chosen, not only can letters and numbers be typed in the field, but any printable character. This includes spaces, commas, symbols, etc.

The last two parameters are also dependent on what is selected for the “Allow” option. “Mod 10” and “Increment by” are only shown if “Digits” is selected.

4.6.7.g.1: MOD 10

The “Mod 10” option can only be used when “digits” have been selected for the “Allow” option. This is because “Mod 10” stands for “Modulus 10 Check” – a validation test.

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4.6.7.g.2: INCREMENT BY

The “Increment by” option also can only be used when “digits” have been selected for the “Allow” option. The system can only increment the number by a single whole number between 1 and 9.

4.6.7.h: Maximum Chars

This parameter sets the maximum number of characters allowed in a field, affecting the size of the field. The maximum number will influence (or be influenced by) the point size of the font used.

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UTILITIES / FILE / CREATE or EDIT / LAYOUT /

BARCODE MENU

Typ e: Ba rc ode

Barcode Name - -

Code 39 / UPC-A / CODABAR / Code 128 / 2 of 5 / EAN 13 / EAN 8 / New UPC-A

X coordinate

coordinate

Height

Guard Height

Ratio

Density

Gap

Orientation - -

Human Readable - -

Card Side - -

Transfer - -

Horizontal / Vertical / Reverse Hor / Reverse Vert

Yes / N o

To p

/ Bottom

Off / Destination on / Sourc e on

Destination ID

Tra nsfer Typ e - -

Normal / Name

Source ID

Accept - -

Fixed / Variable / Host

Strip Space - - Yes / No

- - Fixed / Variable / Host

Fixed Text Max. Char.

Pad Char. - - None / Space

Auto Advance - - No / Yes

Prompt - - (35 Char. Max)

Min. Characters

Max. Characters

Default Text - - (45 Char. max)

Allow - - Digits / Alpha / All

Mod 10 - - No / Yes

Increment by - (3 digit max)

Figure 4-12: Barcode Field Type Overview

Fixed Text Max. Char.

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4.7: Utility / File / Create or Edit / Layout (Barcode Parameters)

Barcode Name.........

X coordinate............ 0.25

Y coordinate............ 0.25

Height...................... 0.40

Guard Height.......... 0.50

Ratio......................... 3.00

Density..................... 3

Gap........................... 3

Orientation..............

Human Readable...

Card Side.................

Transfer...................

Accept......................

Figure 4-13: Basic Default Menu for Barcode Parameters

Code 39 / UPC-A / Codabar /Code 128 / 2 of 5 / EAN 13 /

EAN 8 / New UPC-A

Horizontal / Vertical /Reverse Hor / Reverse Vert

No / Yes

Top or Bottom

Off / Destination on / Source on

Fixed / Variable / Host

4.7.1: Barcode Name

Similar to “Font Name”, “Barcode Name” gives a list of all available barcode formats stored in the firmware of the D-40 printer. Any may be selected by pressing the left/right arrow keys until the desired barcode format is displayed.

4.7.2: X & Y Coordinates

The next two parameters – “X & Y coordinates” – work together to determine the starting points of the field in inches. They are referenced in relation to an imaginary point (origin) in the upper left hand corner of the card. The placement of the field (along with font size and steps) affects the number of characters, which may be printed. The “X & Y coordinates” refers to its baseline position.

4.7.3: Height

“Height” refers to the height of the barcode line. (This relates to the Y coordinate.) The maximum any line can be is 2.25 inches.

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4.7.4: Guard Height

The “Guard Height” parameter is only available for UPC-A, NEW UPC-A, EAN 8, and EAN

13. “Guard Height” refers to the height of the guard lines. Guard lines are the portions of the

barcode that extends below and into the number field. (See Figure 4-14.) This parameter allows the user to adjust and customize the height.

Lines

Barcode

Guard Height

Guard

Lines

Figure 4-14 Guard Height Parameter

4.7.5: Ratio

“Ratio” is the width of a wide line vs. the width of a thin line. (The “Ratio” parameter is not available for UPC-A, or NEW UPC-A.)

4.7.6: Density

“Density” is the parameter that controls the width of a thin line. Each bar can be one of four possible thickness, varying from 1 module to 4 modules.

4.7.7: Gap

“Gap” is the parameter that controls the space between lines. Each space can one be of four possible thickness, varying from 1 module to 4 modules.

4.7.8: Orientation

The “Orientation” parameter allows the D-40 printer to print the barcode in any of the four area directions around the X and Y Coordinates. These are: horizontal, vertical, reverse horizontal, and reverse vertical. (It should be understood that some barcodes cannot be read backwards or upside down.)

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4.7.9: Human Readable

The “Human Readable” parameter refers to the number field that is apart of the barcode. Certain barcodes such as Codabar, Code 2 of 5, and Code 128 do not contain this option (or field). If “No” is selected, the menu goes to the “Transfer” parameter. If “Yes” is selected, the user will be asked for a font name to be associated with the field.

4.7.10: Card Side

The “Card Side” parameter specifies what side of the card the printing is to occur on. The options are TOP or BOTTOM.

4.7.11: Transfer

The “Transfer” parameter is used to identify a field as the source of data to be transferred or the destination to which data is transferred. However, in order to transfer data, the source must be identified first. Regardless, when a source or destination is chosen, another sub-menu will appear. (Refer to Figure 4-9, and Figure 4-10.) The name of the source and destination must be 4 characters long, and must match in order for the data to be sent from the source to the destination. If no data is to be transferred, however, this parameter can be turned off.

4.7.11.a: Source & Destination Id

4.7.11.b: Transfer Type

This parameter refers to the data associated with the field(s) to be transferred. The “Normal” selection means that the data field is transferred as it has been entered (verbatim). The “Name” selection means that first and last names are reversed when this option is selected.

4.7.11.c. Strip Spaces

This parameter designates whether spaces in the data are removed (stripped away) during the data transfer.

4.7.12. Accept

The “Accept” parameter designates how data will be “accepted” by the field. Data is “Fixed”, “Variable”, or from a Host. (Refer to Figure 4-11.)

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If the source is “Fixed”, the exact text will be stored along with the layout in the D-40. This text is entered after the “Fixed Text” prompt as the field is created. Once stored, it can only be changed by “editing” the layout.

If the choice is “Variable”, the field can only be filled in using keyboard data entry at the time of printing. However, the “Variable” fields are only temporarily stored in the system’s RAM and require new data be entered for each card.

4.7.12.a: Pad Character

4.7.12.b: Auto Advance

4.7.12.c: Prompt

This parameter allows entry of up to 35 characters of instructions or other pertinent information that will appear in the prompt field and guide the operator’s entry of data.

4.7.12.d: Min Characters

This parameter sets the minimum number of characters allowed in a field.

4.7.12.e: Max Characters

The maximum number of characters allowed in a field, affecting the size of the field. The maximum number will influence (or be influenced by) the point size of the font used.

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4.7.12.f: Default Text

4.7.12.g: Allow

The “Allow” parameter is considered a validation mechanism. Its function is to minimize incorrect keyboard entry by type of characters.

• If “Digits” is chosen, only digits (0-9) can be typed in the field.

• If “Alpha” is chosen, only letters (a-z) can be typed in the field.

• If “All” is chosen, not only can both letters and numbers can be typed in the field, but all printable characters. This includes spaces, commas, symbols, etc.

The last two parameters are also dependent on what is selected for the “Allow” option. “Mod 10” and “Increment by” are only shown if “Digits” is selected.

4.7.12.g.1: MOD 10

The “Mod 10” option can only be used when “digits” have been selected for the “Allow” option. This is because “Mod 10” stands for “Modulus 10 Check” – a validation test.

4.7.12.g.2: Increment by

The “Increment by” option also can only be used when “digits” have been selected for the “Allow” option. The system can only increment the number by a single whole number between 1 and 9.

4.7.12.h: Maximum Chars

This parameter sets the maximum number of characters allowed in a field, affecting the size of the field. The maximum number will influence (or be influenced by) the point size of the font used.

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Type: Encode

Field Name - -

Tra ck 1 / Trac k 2 / Track 3

Start Position - - (Either 0 for “relative” - or 1 and above for “absolute”.)

Track Format - - ISO / Old Bally / New Bally

Encoding Dir - -

Transfer - -

Forward / Reverse

Off / Destination on / Source on

Destination ID

Tran sf er Ty pe - -

Strip Space - - Yes / No

Normal / Name

/ JIS / Custom

Source ID

Accept - -

Fixed / Variable / Host

Fixed Text Max. Char.

Accept - - Fixed / Variable / Host

Fixed Text Max. Char.

Pad Char. - - None / Space

Auto Advance - - No / Yes

Prompt - - (35 Char. Max)

Min. Characters

Max. Characters

Default Text - - (45 Char. max)

Allow - - Digits / Alpha / All

Mod 10 - - No / Yes

Increment by - (3 digit max)

Figure 4-15: Encode Field Type Overview

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4.8: UTILITY / FILE / CREATE or EDIT / LAYOUT

NCODE PARAMETERS)

4.8.1: Field Name

The “Field Name” specifies which magnetic track is to be written to. The operator has a choice between: Track 1, Track 2, and Track 3. This parameter is used in conjunction with the “Track Format” parameter. However, special caution should be taken when designating these two parameters, ensuring that they both match either industry standards or customer requirements.

4.8.2: Start Position

“Starting Position” refers to the location of the first digit of the encoding field on a track. There are two possible settings:

• “0" for Relative – The first digit is on the left margin of the encoding field, i.e., the position is relative to the margin.

• “1" for Absolute – The first digit is off-set to the right of the left margin by spaces equal to the number of digits entered, i.e., the encoding begins at an absolute number of spaces from the left margin.

4.8.3: Track Format

Similar to “Name” in the Barcode option, “Field Name” allows the user the choice of identifying the type of encoding format and its recording location on the magnetic strip. Any of these formats may be selected by pressing the [SPACEBAR] until the desired barcode format is displayed. The choices available:

• ISO

• Old Bally

• New Bally

• JIS

• Custom

4.8.4: Encoding Dir

The “Encoding Direction” specifies in which direction the magnet strip is to be written to. The operator has a choice between either Forward or Reverse.

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4.8.5: Transfer

The “Transfer” parameter is used to identify a field as the source of data to be transferred or the destination to which data is transferred. However, in order to transfer data, the source must be identified first. Regardless, when a source or destination is chosen, another sub-menu will appear. (Refer to Figure 4-9, and Figure 4-10.) The name of the source and destination must be 4 characters long, and must match in order for the data to be sent from the source to the destination. If no data is to be transferred, however, this parameter can be turned off.

4.8.5.a: Source & Destination id

4.8.5.b: Transfer Type

4.8.5.c: Strip Spaces

This parameter designates whether spaces in the data are removed (stripped away) during the data transfer.

4.8.6: Accept

The “Accept” parameter designates how data will be “accepted” by the field. Data is “Fixed”, “Variable”, or from a Host. (Refer to Figure 4-11.)

If the source is “Fixed”, the exact text will be stored along with the layout in the unit. This text is entered after the “Fixed Text” prompt as the field is created. Once stored, it can only be changed by “editing” the layout.

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4.8.6.a: Pad Character

4.8.6.b: Auto Advance

4.8.6.c: Prompt

This parameter allows entry of up to 35 characters of instructions or other pertinent information that will appear in the prompt field and guide the operator’s entry of data.

4.8.6.d: Min Characters

This parameter sets the minimum number of characters allowed in a field.

4.8.6.e: Max Characters

This parameter sets the maximum number of characters allowed in a field, affecting the size of the field. The maximum number will influence (or be influenced by) the point size of the font used.

4.8.6.f: Default Text

4.8.6.g: Allow

The “Allow” parameter is considered a validation mechanism. Its function is to minimize incorrect keyboard entry by type of characters.

• If “Digits” is chosen, only digits (0-9) can be typed in the field.

• If “Alpha” is chosen, only letters (a-z) can be typed in the field.

• If “All” is chosen, not only can both letters and numbers can be typed in the field, but any printable character. This includes spaces, commas, symbols, etc.

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The last two parameters are also dependent on what is selected for the “Allow” option. “Mod 10” and “Increment by” are only shown if “Digits” is selected.

4.8.g.1: Mod 10

The “Mod 10” option can only be used when “digits” have been selected for the “Allow” option. This is because “Mod 10” stands for “Modulus 10 Check”–a validation test.

4.8.g.2: Increment by

The “Increment by” option also can only be used when “digits” have been selected for the “Allow” option. The system can only increment the number by a single whole number between 1 and 9.

4.9: Utility / File / Create or Edit Layout (IMAGE PARAMETERS)

4.9.1: Accept from

This parameter designates from what source the image file is to be retrieved from. There are only two options: retrieve the “Stored File” from memory of the D-40 printer, or retrieve the file from the “Host”.

4.9.2: Image Name

This parameter designates the exact name of the file to be retrieved form a list of files.

4.9.3: X & Y Coordinates

The next two parameters – “X & Y coordinates” – work together to determine the starting points of the field. They are referenced in relation to an imaginary point (origin) in the upper left hand corner of the card. The placement of the field (along with font size and steps) affects the number of characters, which may be embossed. The “X & Y coordinates” refers to its baseline position.

4.9.4: Rotation

The “Rotation” parameter allows the D-40 to print in any of the four orientations in reference to the “X” location. These are: horizontal, vertical, reverse horizontal, and reverse vertical.

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4.9.5: Card Side

The “Card Side” parameter specifies what side of the card the printing is to occur on. The options are Top or Bottom.

4.10: Utility / File / Copy & Delete Commands (For Layout,

Font, Image, Kanji, Firmware)

As stated previously, the “Copy” sub-menu allows for the copying of an existing card layout and its renaming. (See Figure 4-16.) This is similar to the “Delete” sub-menu, which allows deletion of an existing card layout from memory. (Refer to Figure 4-17.) These screens are self explanatory and need no further clarification.

Enter

Please select a layout (etc.) to copy. VISA MC AMEX DISCOVER

Type new layout (etc.) name: (16 characters)

Figure 4-16: Copy Layout Screens

Please select a layout to delete. VISA MC AMEX DISCOVER

Delete file: (Name) Are you sure?

Figure 4-17: Delete Layout Screens

4.11: UTILITY / FILE / DOWNLOAD & UPLOAD

COMMANDS (For Layout, Font, Image, Kanji, Firmware)

The “Download” command is used to retrieve an existing file from the host computer, while the “Upload” command is used to transfer a file to the host computer from the D-40 Printer. These options are illustrated in Figure 4-18 and Figure 4-19. Both use an Xmodem* application for the file transfer.

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Xmodem is a communication’s protocol that allows a file-transfer between a computer and a host, utilizing a network. It uses blocks of 128bytes for the file,

NOTE:

and a single byte checksum (per block) for error correction. If an error is encountered, the block is then re-sent. This protocol is supported under the Hyper-term application using Windows XP.

The Dashboard application supplied with the D-40 Printer supports both uploading and downloading of files over an Ethernet TCP/IP network. This is the preferred method of file transfer(using Xmodem transfer protocol) if a network connection is unavailable.

UTILITY / FILE / DOWNLOAD MENU

Xmodem Exit Download file using Xmodem

Start up host Xmodem application

Figure 4-18: Download Menu Screens

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UTILITY / FILE / UPLOAD MENU

Layout Font Image Kanji Firmware All Exit Upload existing layout (etc.)

Choose All Exit Choose specific layout (etc.) to upload

Please select a layout (etc.) to upload (List of file names)

Xmodem Exit Upload file to host using Xmodem

Start up host modem application

Choose All Exit

4.12: UTILITY / FILE / SELBOOT

The “SelBoot” parameter specifies the boot file to be used the next time the D-40 printer is either re-started or reset. The file selection is made from a list of choices displayed on the LCD. (Refer to Figure 4 -20.) If the user has not chosen a boot file, then the D-40 will prompt the operator to chose a file that the unit will boot from every time it powers up.

Chapter 4 Page 27 Creating Layouts

Figure 4-19: Upload Menu Screens

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4-28 NBS Technologies Inc.

UTILITY / FILE / SELBOOT MENU

Please select boot firmware file: (List of file names)

Back to Utility Menu

Figure 4-20: SelBoot Menu Screens

4.13: UTILITY / FILE / STATUS

The “Status” is used to monitor the amount of Flash Memory available in the D-40. This memory space is used to store layouts, fonts, images, and firmware files. (See Figure 4-21.)

UTILITY / FILE / STATUS

File System Status

Free space available........xxxxxxxxx

File System Status

Used space........xxxxxxxxx

File System Status

Total space available........xxxxxxxxx

File System Status Total number of files

Creating Layouts Chapter 4 Page 28

Figure 4-21: Status Menu Screens

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D-40 Operation Manual 5-1

Chapter 5 - Operator Maintenance

A great aid in keeping the ImageMaster™ D-40 Printer functioning properly, is conducting routine inspections and maintenance on the system. Dirt and other contaminants will not only affect the quality of the cards produced, but also reduce the efficiency of the machine as well as increasing the card rejection ratio.

This chapter contains a few helpful tips as well as a few maintenance measures for maintaining the functionality of the machine. However, should any technical problems arise, the user should contact their Authorized Dealer or NBS service representative for help.

5.1: General Cleaning

The cabinet should be wiped with a clean, damp cloth to remove any loose contaminants. Never use soap and water to remove dirt. This can possibly leave a residue, creating operational problems and aiding dirt to re-accumulate over time.

The interior of the cabinet should be inspected for shavings or other types of contaminants (residue from card production). If found use a vacuum cleaner to remove them. If not possible, then wipe away with a damp, clean cloth.

Primarily, most accumulations will be found in the area of the Encoder (Flipper) and rollers on either side of the print head. Wipe all rubber rollers off with a lint free cloth saturated in alcohol.

5.2: Cleaning The Print Head

Cleaning the Print Head is a service technician function and should not be attempted by operators. An indication that a build-up of contaminants may be occurring is if unusual folds or wrinkles appear on the foil as it is being taken up. These folds or wrinkles can be caused by increased friction from the accumulation of contaminants on the head, pulling and distorting the tape. If this occurs, contact your NBS or Authorized Dealer service technician.

5.3: Card Stock

The D-40 printer is capable of printing on a polished PVC card that is 0.030 inch thick. When placing cards into the Input Hopper, be sure that the magnetic strip (if applicable) is orientated correctly (face down and toward the rear of the machine).

Ensure that the cards are not “stuck” together. This is accomplished by rippling or fanning the cards before they are stacked in the Input Hopper. The purpose of this is not only to break apart any cards wedged together, but to reduce static electricity that causes attraction between card surfaces. It also may remove some of the dust or shavings on the cards, allowing them to feed more easily.

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5-2 NBS Technologies Inc.

Card stock that is bowed or bent may also cause feed problems. Most likely they will cause a “card jam”, where a card cannot move while being transported in the system. When this problem occurs, the simplest solution is to open the cabinet and remove the distorted card. However, if the card does not readily come out, do not force it out as it may damage the system. This will require your service representative to investigate and remedy the problem.

5.4: Ordering Consumable Supplies

Consumable Supplies are ordered by calling the Customer Service Department at 1-416-8408620 (globally), or 800-524-0419 (USA only).

Only the use of genuine NBS consumables can guaranty proper printer operation.

• Basic Blank card stock is available in either White or White with magnetic stripe.

White

White with Loco magnetic stripe

White with Hico magnetic strip

(Colors other than white are available on special order.)

• Printing foil is available in the following colors:

Gold Metallic Gold Burgundy

Silver Metallic Silver Orange

White Light Blue Brushed Silver

Dark Red Midnight Blue Yellow

Dark Blue Teal Scratch-off

Dark Green Purple

Black Red

• Cleaning tape is available using part number 5091.

5.5: Loading Cards

A major function of the operator is the loading of blank cards and the removal of personalized cards. Cards are loaded into the input hopper on the right side of the unit.

Operator Maintenance Chapter 5 Page 2

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D-40 Operation Manual 5-3

General rule:

5.5.1 Plain cards

Cards are normally placed so the front of the card is facing up and the top of the card is at the rear of the hopper.

Front up & top to rear

Smart Card:

Chip Up &

to left

5.5.2 Magnetic Strip Cards

When loading magnetic strip cards, they are normally placed with the mag strip down and towards the rear of the hopper.

5.5.3 Smart Cards

Smart Cards are normally loaded with the top of the card at rear of hopper with the front of the card facing up which places the smartcard chip towards left side of hopper.

Magnetic Stripe

ISO & JIS Type II-C: Down & to rear

JIS Type II-A:

Up & to rear

JIS Type II-B:

Up & to front

Figure 5-1 Card Orientation

Never place fingers into the Hoppers when cards are being produced. Always pause operation before adding or removing cards from the

! Caution:

Input or the Stacker hoppers. (Press “Wait” button on front panel). Moving parts, in the base of the input and stacker hoppers, can cause physical injury to fingers if care is not taken.

5.6: Unloading Cards

When cards are correctly personalized the are placed into the output Stacker on the left side of the unit. If a card is rejected during processing it is allowed to fall into the reject area under the output Stacker. The reject area holds about 15 cards. Monitor the reject area. Do not allow cards to build up here as they could jam the stacking process.

Chapter 5 Page 3 Operator Maintenance

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5-4 NBS Technologies Inc.

5.7: Replacing Printing Ribbon

Removing Old Ribbon

1. Pause unit operation (Press WAIT button on control panel). Never insert fingers into an operating unit.

2. Remove the retainer from each spool by turning retaining knob counter clockwise (Refer to Figure 5-2.) .

3. Remove the full core from the take-up spool and discard. Remove the empty core from the supply spool, and save for reuse.

Installing New Printing Ribbon

1. Mount the empty core, saved in step 3 above, to the take-up spool.

2. Mount the new ribbon on the supply spool so that it will uncoil from the top of roll in a counter clockwise direction as shown in Figure 5-2.

3. Thread the ribbon as shown in Figure 5-2 below. Place tape around left side and under roller 1 — across and over roller 2 — down and under guide rod — under the print head — to left outside of peel plate — left outside of roller 3 — and up to take-up spool. Tape the end of the ribbon to the empty take-up core. Caution must be taken to assure that the ribbon is mounted squarely, so that it will roll evenly as it is used.

4. Screw the retainers in place and tighten them so the cores do not slide on their respected spools. Ensure that the pin in the take-up spool locks into the hole in the retainer plate and that the screw is inserted into a notch in the cardboard core.

5. Once the ribbon is loaded, press [CTRL] + [W] to initiate movement. The take-up spool will run until the [CTRL] + [W] keys are pressed again. Ensure the ribbon is winding correctly, and that the ribbon moves freely and evenly.

Operator Maintenance Chapter 5 Page 4

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D-40 Operation Manual 5-5

TAKE -U

NEW ROLL

Low Ribbon Sensor

Roller 3

Peel Plate

d a e

H t n

r P

Figure 5-2 Printer Ribbon Path

Roller 1

Roller 2

Guide Rod

5.8 Replacing Cleaning Tape

Removing Old Tape

1. Pause unit operation (Press WAIT switch). Never place fingers into an operating unit.

2. Unscrew the retainer knob on the take-up spool by rotating it in a counter-clock wise direction. Next, remove the retainer plate. (Refer to Figure 5-3.)

3. Slide the full core from the take-up spool and discard.

Installing New Tape

1. Unscrew the retainer knob and remove the retainer plate from the source spool. Next, remove the empty core.

2. Mount the empty core on the take-up spool.

3. Unwind approximately 10” of tape from the new tape core.

4. While sliding the new tape core on the supply spool so that it will unwind in a clockwise direction; thread the tape under the guide rod, then around the cleaning roller, and up to the take-up spool core.

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5-6 NBS Technologies Inc.

5. After fixing the tape in place, remount the retainer and tighten to prevent the core from sliding.* Also, ensure that the screw is inserted into a notch on the cardboard core.

NOTE:

6. Press the [CTRL]+[K] keys to initiate the cleaning tape. It will continue to run until the [CTRL]+[K] keys are pressed again. Ensure that there is no slippage and that the tape

moves freely and evenly. However, movement of the tape will be “strained” due to the adhesive.

Retainer Knob

Retainer Plate

The take-up spool has a roll pin that must be inserted in the retainer plate when mounting. This is added insurance that the core will not slide on the spool.

Front View

Side View

Take-U p Spo o l

Retainer Knob

Retainer Plate

Retainer Knob

Spool Core

Retainer Plate

Supply Spool

Cleaning Tape Path

Guide Bar

Cleaning Roller

Blue Card Cleaning Roller

Figure 5-3 Cleaning Tape Assembly

Retainer Plate

Retainer Knob

Operator Maintenance Chapter 5 Page 6

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D-40 Operation Manual 6-1

Chapter 6 - Error Messages

The left column (LCD Error Messages) displays the error messages that can appear in the LCD Display during normal system operation. The right column defines the problem and suggests possible causes and operator remedies. Any problem that an operator can not solve or that obviously involves mechanical fixes, or hardware replacement should be referred to qualified service technician - either NBS, authorized Dealer, or authorized Service Provider technician. Unauthorized repairs performed by un-trained technicians can void your warranty.

Error Messages (Displayed on ImageMaster™ D-40 Printer)

LCD Error

Message

Broken or

missing foil

Card Pick Error

Card stuck in

transport

Description

Problem: No detected motion of Printer Foil.

Cause: Printer is out of foil, the foil is broken or not properly

threaded, Foil Motor bad, or sensor is bad.

Operator Replace foil or fix broken foil or re-thread. Action: For mechanical problems contact NBS Service Rep.

Problem: Hopper detected as being empty while trying to pick card.

Cause: Hopper empty, or bad sensor

Operator Re-load Hopper Action: For mechanical problems contact NBS Service Rep.

Problem: Card detected in transport after flush attempt.

Cause: Bent card, bad sensor, transport Motor bad, a “jumped”

drive belt, or “Flush Speed” at wrong setting.

Operator Remove bent or jammed card and try again. Check Action: “Flush Speed” setting if allowed. For mechanical

problems contact NBS Service Rep.

Problem: Problem occurred during cleaning process.

Cause: Low or broken cleaning tape, bad sensor, or bad

Cleaning Timeout

Operator Replace or fix cleaning foil. Action: For mechanical problems contact NBS Service Rep.

Problem: Start sentinel not found at correct position on track n,

Encoding Position

Error n

Chapter 6 Page 1 Error Messages

Cause: Bent card, Magnetic Encoder Head possibly out of

cleaning tape drive motor.

where n is number of encoding track with problem.

alignment, start sentinel has wrong setting (check

“Encode Start”, “Encode W/R Delay”, “Wheel Count to Edge”, and “Start Check Tolerance” parameters).

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6-2 NBS Technologies Inc.

LCD Error

Message

Encoding Position

Error n (con’t)

Encoding Timeout

Flipper Jam

Foil Jam

Description

Operator Remove bent card try again. Check settings and

Action: correct if needed. For mechanical problems contact NBS

Service Rep.

Problem: Encoded magnetic stripe data cannot be verified.

Cause: Bent card, not using magnetic cards, damaged card, or

transport problem.

Operator Remove bent/jammed card. Make sure Magnetic Action: cards are in use. For mechanical problems contact

NBS Service Rep.

Problem: Flipper mechanism did not move when activated.

Cause: Jammed card (possibly due to wrong “Handoff Position”

or “Flip Count” setting), bad Flipper motor,

Operator Remove jammed card & check settings Action: For mechanical problems contact NBS Service Rep.

Problem: Detection of motion of Printer Foil when there shouldn’t be.

Cause: Foil caught in transport system or bad sensor.

Operator Reposition Foil Action: For mechanical problems contact NBS Service Rep.

Please Calibrate

Printer

Print Head data

under run

Print Head too hot

Problem: Printer requires calibration.

Cause: Printer not calibrated

Operator Go to < UTILITY / SYSTEM / TEST / CAL > to Action: run a card for calibration.

Problem: Transport speed is too fast for printer causing a data

under-run to occur.

Cause: “Print Speed” at wrong setting, or transport motor

defective.

Operator Correct Print Speed setting Action: For mechanical problems contact NBS Service Rep.

Problem: Print Head temperature is too high.

Cause: “Head Resistance” setting wrong, or bad Print Head

(either internal thermistor or Print Head itself bad).

Operator Let unit cool down. If password allows, check and Action: correct “Head resistance” setting. For mechanical

problems contact NBS Service Rep.

Error Messages Chapter 6 Page 2

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D-40 Operation Manual 6-3

LCD Error

Message

Print Head

Watchdog Error

Printing Timeout

Print Ramp Error

Description

Problem: Occurs when transport is jammed while Print Head is

energized.

Cause: A card jam or a jammed drive belt.

Operator Remove jammed card. For mechanical problems Action: contact NBS Service Rep.

Problem: Problem occurred during printing process.

Cause: Jammed card, bad Print Head Motor, or bad Print Head.

Operator Remove jammed card. For mechanical problems Action: contact NBS Service Rep.

Problem: Print speed still changing while trying to print.

Cause: “Head Down Count” needs to be increased.

Operator If password allows, check and correct “Head Down Action:

Problem: Communications error between Main Logic Board and

Count” as required.

Servo Board.

Servo Comm

Error

Stacker or Picker

Jam

Stacker or Picker

Timeout

Cause: Bad or loose cable, bad Servo Board, bad Main Logic

Board.

Operator For mechanical problems contact NBS Service Rep. Action:

Problem: Picker or Stacker motion not detected.

Cause: Card jammed in the transport system, or a Bad motor, or

a bad sensor.

Operator Remove jammed card(s). For mechanical problems Action: contact NBS Service Rep.

Problem: Card did not try to move when trying to pick or stack.

Cause: Jammed card, bad sensor, or empty Hopper (for Picker).

Operator If Hopper is empty load more blank cards, remove Action:

jammed card(s). For mechanical problems contact

NBS Service Rep.

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6-4 NBS Technologies Inc.

LCD Error

Message

Track Encoding

Error N

Transport Jam

Description

Problem: Error detected while verifying magnetically encoded card

on track n, where n is the number of the encoding track reporting error.

Cause: Bad card, Magnetic Encoder Head possibly out of

alignment, start sentinel has wrong setting (check

“Encode Start”, “Encode W/R Delay”, “Wheel Count to Edge”, and “Start Check Tolerance” parameters).

Operator Remove card and try again, check settings Action: For mechanical problems contact NBS Service Rep.

Problem: Transport servo reports a jammed condition.

Cause: Jammed card sometimes occurs when there is

resistance to running the transport, also can occur if “Max Speed” set too high (typically above 65), or a jammed drive belt.

Operator Remove jammed card, check and correct settings. Action: For mechanical problems contact NBS Service Rep.

Error Messages Chapter 6 Page 4

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D-40 Operation Manual RH-1

Revision History

Page # Rev Date Description/Change

Cover — 15 May 08 Initial release - Binder Cover

Spine — 15 May 08

Forward

Title Pg — 15 May 08 Initial release

Inside — 15 May 08 Initial release

i — 15 May 08 Table of Contents - Initial release

ii — 15 May 08 Table of Illustrations - Initial release

Chapter 1 - Introduction

1-1 — 15 May 08 Initial release

1-2 — 15 May 08 Initial release

1-3 — 15 May 08 Initial release

1-4 — 15 May 08 Initial release

1-5 — 15 May 08 Initial release

1-6 — 15 May 08 Initial release

Chapter 2 - Main Menu - Basic Functioning

2-1 — 15 May 08 Initial release

2-2 — 15 May 08 Initial release

2-3 — 15 May 08 Initial release

2-4 — 15 May 08 Initial release

2-5 — 15 May 08 Initial release

2-6 — 15 May 08 Initial release

Chapter 3 - Printing Cards

3-1 — 15 May 08 Initial release

3-2 — 15 May 08 Initial release

3-3 — 15 May 08 Initial release

3-4 — 15 May 08 Initial release

Chapter 4 - Creating Layouts

4-1 — 15 May 08 Initial release

4-2 — 15 May 08 Initial release

4-3 — 15 May 08 Initial release

4-4 — 15 May 08 Initial release

4-5 — 15 May 08 Initial release

4-6 — 15 May 08 Initial release

4-7 — 15 May 08 Initial release

4-8 — 15 May 08 Initial release

Initial release - Binder Spine

Chapter RH Page 1 Revision History

Page 59

RH-2 NBS Technologies Inc.

Page # Rev Date Description/Change

4-9 — 15 May 08 Initial release

4-10 — 15 May 08 Initial release

4-11 — 15 May 08 Initial release

4-12 — 15 May 08 Initial release

4-13 — 15 May 08 Initial release

4-14 — 15 May 08 Initial release

4-15 — 15 May 08 Initial release

4-16 — 15 May 08 Initial release

4-17 — 15 May 08 Initial release

4-18 — 15 May 08 Initial release

4-19 — 15 May 08 Initial release

4-20 — 15 May 08 Initial release

4-21 — 15 May 08 Initial release

4-22 — 15 May 08 Initial release

4-23 — 15 May 08 Initial release

4-24 — 15 May 08 Initial release

4-25 — 15 May 08 Initial release

4-26 — 15 May 08 Initial release

4-27 — 15 May 08 Initial release

4-28 — 15 May 08 Initial release

Chapter 5 - Operator Maintenance

5-1 — 15 May 08 Initial release

5-2 — 15 May 08 Initial release

5-3 — 15 May 08 Initial release

5-4 — 15 May 08 Initial release

5-5 — 15 May 08 Initial release

5-6 — 15 May 08 Initial release

Chapter 6 - Error Messages

6-1 — 15 May 08 Initial release

6-2 — 15 May 08 Initial release

6-3 — 15 May 08 Initial release

6-4 — 15 May 08 Initial release

Revision History

RH-1 — 15 May 08 Initial release

RH-2 — 15 May 08 Initial release

Critique Form

Form — 15 May 08 Initial release

Revision History Chapter RH Page 2

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ImageMaster™ D-40 Operation Guide

NBS -1020-080205

Critique Form

P/N 13456

Name: Title:

Company:

Address:

City: State/Prov: ZIP/Post Code:

Phone: Email: Fax:

Every effort was made to document the operation of the ImageMaster™ D-40 Unit in a manner to simplify your job, yet keep you fully informed. If we missed the mark, we want to know.

Was the Manual: YES NO

Readable?

Understandable?

Organized?

Illustrated Well?

Detailed Enough?

Comments: Please include page numbers, figure numbers and the like for our reference.

Complete?

Use reverse or another page(s) for added space. Thank you.

Forward completed form to: NBS Technologies Inc. Email: [email protected]

Technical Writer Fax: 201-845-3337 (USA) 70 Eisenhower Drive Paramus, NJ, USA 07652