Entrust Sigma DS4 User manual

November 2020
528061-001, Rev A
User’s Guide
Sigma DS4 and DS4-ES1 Instant Issuance System

ii
Notice
Please do not attempt to operate or repair this equipment without adequate
training. Any use, operation or repair you perform that is not in accordance
with the information contained in this documentation is at your own risk.
Trademark Acknowledgments
Entrust, Sigma and the hexagon design are trademarks, registered trademarks
and/or service marks of the Entrust Corporation in the United States and other
countries.
Datacard is a registered trademark and service mark of Entrust Corporation in
the United States and other countries.
MasterCard is a registered trademark of MasterCard International Incorporated.
Visa is a registered trademark of Visa International Service Association.
All other product names are the property of their respective owners.
Proprietary Notice
The design and information contained in these materials are protected by US
and international copyright laws.
All drawings and information herein are the property of Entrust Corporation. All
unauthorized use and reproduction is prohibited.
Entrust Corporation
1187 Park Place
Shakopee, MN 55379
Phone: [phone]
Fax: [phone]
www.entrust.com
© 2020 Entrust Corporation. All rights reserved.

iii
Safety
The following basic safety tips are given to ensure safe installation, operation and maintenance of
equipment.
• Connect equipment to a grounded power source. Do not defeat or bypass the ground lead.
• Place the equipment on a stable surface (table) and ensure floors in the work area are dry and
non-slip.
• Know the location of equipment branch circuit interrupters or circuit breakers and how to turn
them on and off in case of emergency.
• Know the location of fire extinguishers and how to use them. ABC type extinguishers may be
used on electrical fires.
• Know local procedures for first aid and emergency assistance at the customer facility.
• Use adequate lighting at the equipment location.
• Maintain the recommended temperature and humidity range in the equipment area.
Safe Human Interface
• Use proper lifting techniques when moving or installing the equipment.
• Use standard electrostatic discharge (ESD) precautions when working on or near electrical
circuits.
• Do not defeat or disconnect safety interlocks on covers.
Liability
The WARNING and CAUTION labels have been placed on the equipment for your safety. Please do
not attempt to operate or repair this equipment without adequate training. Any use, operation,
or repair in contravention of this document is at your own risk.
California Prop
Warning: This product contains chemicals, including lead, known to the State of California to
cause cancer, and birth defects or other reproductive harm. Wash hands after handling.
Warning: To avoid a possible electric shock, always unplug the system before servicing.

iv

v
Revision Log
Revision Date Description of Changes
A November 2020 First release of this document

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Contents
Chapter 1: Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
About this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter 2: About the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
About the Sigma Card Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Printer Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Printer Left Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Printer Front and Right Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Single-Hopper Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
The Printer Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Multi-Hopper Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Multi-Hopper Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inside the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Print Ribbons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ribbon Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Prefilled Print Ribbon Cassette. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ES1 Emboss Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Printer Configuration Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 3: Using the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Printer Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Tasks and Users. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Secure Encryption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Printer Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Down Arrow, Up Arrow, and Enter Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LCD Panel Icons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LCD Panel Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Retrieve the Printer’s Network IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Retrieve an IPv4 Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Retrieve an IPv6 Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Print a Test Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Load and Replace Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Load Cards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Single-Hopper Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Use the Exception Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Multi-Hopper Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Use the Multi-Hopper Exception Slide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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Replace the Print Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Load the Print Ribbon Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Install the Prefilled Print Ribbon Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Use the Printer Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Chapter 4: Print Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Print Cards from CardWizard Issuance Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Chapter 5: System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Maintain the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Clean the Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Single-Hopper Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Multi-Hopper Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Run the Cleaning Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Prepare the Printer for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Clean the Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Empty the Reject Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Chapter 6: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Locate a Problem Within the Card Production System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Locate a Problem with Basic Printer Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Installation Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Network Installation Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Card Appearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Something did not print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
The color printing has flaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
The printing is too light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
The printing is too dark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
The monochrome printing has flaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Magnetic Stripe Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Use Advanced Troubleshooting Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Clear a Card Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Repair a Broken Ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Messages and Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Messages on the Printer LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Messages in the Printer Dashboard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Other Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Respond to Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Printer Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Close and lock doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
100: Request not supported. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
101: Job could not complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
102: Card not in position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
103: Printer problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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104: Critical problem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
105: Magstripe data error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
106: Magstripe data not found . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
107: Magstripe read data error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
108: Magstripe read no data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
109: Print ribbon problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
110: Print ribbon out or missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
111: Card not picked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
112: Card hopper empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
113: Close cover to continue. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
114: Cover opened during job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
116: Magstripe not available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
117: Reader not available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
118: Print ribbon type problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
119: Print ribbon not supported . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
120: User paused the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
121: Print ribbon not identified. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
122: Magstripe format problem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
123: Insert new card side 1 up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
124: Insert same card side 2 up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
149: Option not installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
150: Print while unlocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
151: Failed to lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
152: Insert new card side 2 up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
153: Insert same card side 2 up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
170: Insert new card side 1 up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
171: Insert same card side 1 up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
172: Insert cleaning card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
173: Improper shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
245: Configuration error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
275: Multi-hopper error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
276: Multi-hopper card jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
277: Multi-hopper pick error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
294: Cleaning Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
295: Settings error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
297: Option Tag Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
298: Option Tag Success . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Driver-Only Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
518: Unable to Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

1
Sigma DS4 and DS4-ES1 Instant Issuance System 1
Chapter 1: Introduction
About this Manual
This manual provides user information for the Sigma DS4 and DS4-ES1 Instant Issuance Systems.
The manual includes:
 An overview of printer components and options, and a description of the system label.
 How to use the printer, including how to power the printer on and off, how to use the front
panel and LCD menus, card processing basics, how to print a test card, and how to load and
replace supplies.
 How to perform routine maintenance and troubleshooting tasks.
An additional Installation and Administrator’s Guide is available for use by administrators or other
professionals responsible for printing cards.
Intended Audience
The manual is intended for the printer operator who prints cards, loads and replaces supplies,
maintains the printer, and performs troubleshooting.
Technical Support
Use the following to contact Entrust Technical Phone Support.
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2 Introduction

2
Sigma DS4 and DS4-ES1 Instant Issuance System 3
Chapter 2: About the Printer
About the Sigma Card Printers
The card printer applies images, text, and encoded data to plastic cards. It can print full-color and
monochrome images, depending on the type of print ribbon installed.
The printer can be ordered with a variety of options, depending on your site requirements and
your printer model. Options include a magnetic stripe encoder, contact or contactless smart card
reader, locks, and duplex printing.
A 125-card input and 25-card output hopper are standard. An optional multi-hopper with six
input hoppers, each with a 125-card capacity also is available.
In addition, optional upgrade kits allow you to install a Wi-Fi Dongle.
The configuration label on the printer shows the options installed. Refer to “Printer Configuration
Label” on page 13 for more information about identifying the factory-installed options on your
card printer.

4 About the Printer
Printer Components
Use the following sections to become familiar with the printer.
Printer Left Side
Wi-Fi USB Port The Wi-Fi port allows you to insert the optional Wi-Fi Dongle in
the printer.
Cable Lock Receptacle The receptacle allows you to insert the security plate before
attaching the optional cable lock.
Power Connection The power connection provides a plug-in connector for the
printer power supply.
USB Connection The USB connection allows you to connect the printer directly
to a computer.
Data Port The data port allows you to connect the printer to another
component, such as a embosser.
Ethernet Connection The network connection allows you to connect the printer to an
Ethernet network.
Wi-Fi USB Port
USB Connection
Power
Connection
Cable Lock
Receptacle
Data Port
Ethernet
Connection

Sigma DS4 and DS4-ES1 Instant Issuance System 5
Printer Front and Right Side
Single-Hopper Printer
Input Hopper The input hopper holds cards for printing. The hopper holds up to
125 cards (0.030 in. or 0.762 mm thickness).
The input hopper can be removed from the printer for secure
storage.
Input Hopper Release
Buttons
The release buttons allow you to remove the input hopper from the
printer. Push in the buttons, squeeze the cartridge, and pull it out
from the printer.
Exception Slot Use the exception slot to insert a single card, such as a different card
type than those loaded in the input hopper.
Front Panel Use the front panel to work with the printer. The LCD panel displays
printer messages and status information. The buttons allow you to
power the printer on and off, and navigate the printer menu system.
Output Hopper The output hopper holds up to 25 completed cards.
LED Light Bar The LED light bar blinks to indicate a printer error status. It is a solid
color when the printer is in Ready status.
Output
Hopper
Input Hopper
Input
Hopper Lock
Printer Lock
Reject Tray
LED Light Bar
Exception
Slot
Front Panel
Input Hopper
Release Buttons

6 About the Printer
The Printer Cover
Use the cover latch handle to open the printer cover.
Input Hopper Lock The input hopper lock unlocks the input hopper.
Reject Tray Unfinished cards or cards not processed properly are placed in the
reject tray. An administrator can change the reject card location to
the output hopper using the Printer Dashboard. Refer to the Printer
Dashboard Help for more information.
Printers without a reject tray always place unfinished cards in the
output hopper.
Printer Lock The printer lock unlocks the printer cover and reject tray.
Printer Cover Open the printer cover to access the printhead and ribbon.
Cover Latch Handle Lift the latch handle to open the printer cover.
Cover Ridges Press down on the ridges when closing the cover to make sure that it
latches completely on both sides.
Cover Ridges
Cover Latch
Handle
Printer Cover

Sigma DS4 and DS4-ES1 Instant Issuance System 7
Multi-Hopper Printer
Input Hoppers 1–6 Each hopper cartridge in the multi-hopper holds up to 125 cards
(0.030 in. or 0.762 mm thickness).
The hopper cartridges can be removed from the printer for secure
storage.
Hopper Lock Bars The lock bars rotate to the left to allow access to the hopper
cartridge doors, so that you can load cards into the cartridges.
Output Hopper The output hopper holds up to 25 completed cards.
Multi-Hopper Lock The multi-hopper lock secures all six input hoppers. The lock can be
opened using a key or a command from your card personalization
software.
Sending a command to open the lock opens all locks on the printer
and on any attached component.
Lock Bar Release
Button (B1)
The release button (B1) releases the lock bars in front of the input
hopper cartridges. Slide the button to the left to release the bars.
You must have unlocked the multi-hopper using the key or a
software command before the lock bars can be released.
Cartridge Release
Buttons
Exception Slide
Input Hoppers 1–6
Hopper Lock
Bars
Output
Hopper
Lock Bar Release
Button (B1)
Multi-Hopper
Lock

8 About the Printer
Multi-Hopper Cartridge
The multi-hopper cartridges can be pulled out from the multi-hopper unit. You can remove the
cartridges with the cards inside and store them securely, if necessary.
Cartridge Release
Buttons
The cartridge release buttons allow you to remove the cartridge
from the multi-hopper unit. Push in the buttons, squeeze the
cartridge, and pull it out from the multi-hopper.
You do not need to remove a hopper cartridge to load cards.
Exception Slide The exception slide allows you to insert a single card into the printer
without unlocking the multi-hopper or opening a hopper cartridge.
Refer to “Use the Multi-Hopper Exception Slide” on page 28.
Cartridge Door
Release Button
The door release button allows you to open the cartridge door. Press
down on the release button.
Cartridge Door The cartridge door swings down to provide access to the cartridge to
load cards.
Card Weight The card weight maintains a downward pressure on the loaded cards
so that they enter the printer properly. Lift the card weight to the
top of the cartridge and gently pull it forward until it locks in
position. A diagram inside the cartridge shows how to position the
card weight and load cards.
Note: Do not place the cards on top of the card weight.
Label Retainer The label retainer allows you to insert a paper label inside the
cartridge door. Use a label to identify the cartridge number or the
type of cards loaded in each cartridge. Use a flathead screwdriver to
open the label retainer door.
Cartridge Door
Release Button
Cartridge
Door
Card Weight
Label Retainer

Sigma DS4 and DS4-ES1 Instant Issuance System 9
Inside the Printer
Printhead The printhead transfer the card images to the card using the print
ribbon.
Manual Advance
Knob
The knob moves a card in the track to clear a card jam.
Ribbon Cartridge
Handle
Lift up the handle on the ribbon cartridge or cassette to remove it
from the printer.
Ribbon Cartridge or
Cassette
The ribbon cartridge or cassette holds the print ribbon and cleaning
roller.
Ribbon Cartridge
Handle
Manual Advance
Knob
Printhead
Ribbon Cartridge
or Cassette

10 About the Printer
Print Ribbons
Depending on the printer model, the print ribbon is available as a replaceable roll that is loaded
on the ribbon cartridge, or as part of a prefilled print ribbon cassette.
Ribbon Cartridge
The ribbon cartridge holds a roll of ribbon that you can replace when it runs out. The cartridge
also holds a cleaning roller that is replaced with each ribbon change. Refer to “Load the Print
Ribbon Cartridge” on page 29.
Ribbon Cartridge The ribbon cartridge holds a replaceable print ribbon.
Print Ribbon The print ribbon is used to apply images to the card.
Cleaning Roller The replaceable cleaning roller removes dust and other particles
from the cards as they move into the printer.
Cleaning Roller
Retainer
Pull up on the retainer to load the cleaning roller on the print ribbon
cartridge. Release the retainer to secure the roller in position.
Ribbon Cartridge
Handle
Use the handle to remove the ribbon cartridge from the printer.
Cleaning
Roller
Ribbon Cartridge
Handle
Print Ribbon
Ribbon Cartridge
Cleaning Roller
Retainer

Sigma DS4 and DS4-ES1 Instant Issuance System 11
Prefilled Print Ribbon Cassette
The prefilled print ribbon cassette is an all-in-one, one-time-use print ribbon, cleaning roller, and
ribbon cartridge.
Print Ribbon The print ribbon is used to apply images to the card.
Ribbon Cassette
Handle
Use the handle to remove the cassette from the printer.
Cleaning Roller The cleaning roller removes dust and other particles from the cards
as they move into the printer. The cleaning roller is pre-installed on
the cassette.
Ribbon Cassette The ribbon cassette is shipped in a closed position and must be
extended to its fully open position before installing it in the printer.
Refer to “Install the Prefilled Print Ribbon Cassette” on page 30.
Ribbon Cassette
Handle
Ribbon Cassette
Print Ribbon
Cleaning
Roller