FARGO electronics HDP820 User manual

HDP800 Series Card Printer/Encoders
Service Manual (Rev. 5.0)
•HDP820 (Dual-Sided Card Printer/Encoders)
•HDP820-LC (Dual-Sided Card Printer/Encoders)
•HDP825 (Dual-Sided Card Printer/Encoders)
•HDP825-LC (Dual-Sided Card Printer/Encoders)
Part Number: L000307

RESTRICTED USE ONLY FARGO Electronic, Inc.
HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) ii
HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0), property of FARGO
Electronics, Incorporated
Copyright 2002, 2003, 2004, 2005, 2006 by FARGO Electronics, Incorporated. All rights
reserved. Printed in the United States of America. Exclusive permission is granted to
authorized resellers of FARGO products to reproduce and distribute this copyrighted document
to authorized FARGO customers, who have signed a “no disclosure agreement” regarding the
restricted, proprietary use of said document.
The revision number for this document will be updated to reflect changes, corrections, updates
and enhancements to this document.
Revision Control
Number
Date Document Title
Revision 5.0 1 January 2004 HDP800 Series Card Printer/Encoders
Service Manual (Rev. 5.0)
These reference documents were thoroughly reviewed to provide FARGO with professional and
international standards, requirements, guidelines and models for our technical, training and user
documentation. At all times, the Copyright Protection Notice for each document was adhered to
within our FARGO documentation process. This reference to other documents does not imply
that FARGO is an ISO-certified company at this time.
•ANSI/ISO/ASQ Q9001-2000 American National Standard,(sub-title) Quality Management
Systems - Requirements (published by the American Society of Quality, Quality Press, P.O.
Box 3005, Milwaukee, Wisconsin 53201-3005)
•The ASQ ISO 9000:2000 Handbook (editors, Charles A. Cianfrani, Joseph J. Tsiakals and
John E. West; Second Edition; published by the American Society of Quality, Quality Press,
600 N. Plankinton Avenue, Milwaukee, Wisconsin 53203)
•Juran's Quality Handbook (editors, Joseph M. Juran and A. Blanton Godfrey; Fifth Edition,
McGraw-Hill)
Any questions regarding changes, corrections, updates or enhancements to this document
should be forwarded to:
FARGO Electronics, Incorporated
Support Services
6533 Flying Cloud Drive
Eden Prairie, MN 55344 (USA)
[phone]
[phone]
FAX: [phone]
www.fargo.com
E-mail: [email protected]

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) iii
Reviewing the HDP800 Series Printers Overview table
HDP800 Series Input
Hoppers
Card
Capacity
Accepted
Card Size
Encoding
Modules
Lamination
Module
HDP820 (Dual-Sided
Card Printer/Encoders)
1250 CR-80,
CR-90 &
CR-100
Optional Optional
HDP820-LC (Dual-
Sided Card
Printer/Encoders)
1250 CR-80,
CR-90 &
CR-100
Optional Included
HDP825 (Dual-Sided
Card Printer/Encoders)
2200 CR-80 Optional Optional
HDP825-LC (Dual-
Sided Card
Printer/Encoders)
2200 CR-80 Optional Included

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) iv
How to use the manual
The HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) is designed to provide
installers and technicians with quick, efficient lookup of related procedures, components and
terms. The manual can be used effectively either in soft or hard copy, depending on the
preference of the installer or technician.
Manual Description
Sequence of Operations,
Glossary of Terms and
Technical/Functional
Specifications (hyper-linked)
You can go directly to the Sequence of Operations,
Glossary of Terms, Technical Specifications and
Functional Specifications to learn how to use the
processes, procedures, functions and windows for the
HDP800 Series Card Printer/Encoders within concise,
correlative tables.
Table of Contents (hyper-
linked)
You can use the Table of Contents to quickly locate an
error message, a procedure, the index or an appendix.
Troubleshooting,
Replacement, Removal,
Diagnostic and Navigation
Procedures (in hyper-linked
Sections)
You can go directly to Specifications, General
Troubleshooting, Printer Adjustments, Parts Replacement,
Printer Packing, Board Level Diagnostics, LCD On-Line
Menu Navigation and Firmware Updates to find
troubleshooting, removal and replacement procedures.
The section titles are always labeled according to their
function for consistent usage.
Cross-Referencing (hyper-
linked)
You can use the cross-referencing links to quickly locate
an error message or a procedure.
Comprehensive Index
(hyper-linked)
You can use the Comprehensive Index to quickly locate
information on the HDP800 Series card Printer, relating
to a specification, a procedural step, a window or screen, a
component, a term, a qualifier or a related feature to this
Printer.

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) v
Safety Messages (review carefully)
Symbol Critical Instructions for Safety purposes
Danger: Failure to follow these installation guidelines can result in death or
serious injury.
Information that raises potential safety issues is indicated by a warning
symbol (as shown to the below).
•To prevent personal injury,refer to the following safety messages
before performing an operation preceded by this symbol.
•To prevent personal injury,always remove the power cord prior to
performing repair procedures, unless otherwise specified.
•To prevent personal injury,make sure only qualified personnel
perform these procedures.
Caution: This device is electrostatically sensitive. It may be damaged if
exposed to static electricity discharges.
Information that raises potential electrostatic safety issues is indicated
by a warning symbol (as shown to the below).
•To prevent equipment or media damage,refer to the following
safety messages before performing an operation preceded by this
symbol.
•To prevent equipment or media damage,observe all established
Electrostatic Discharge (ESD) procedures while handling cables in
or near the Circuit Board and Printhead Assemblies.
•To prevent equipment or media damage,always wear an
appropriate personal grounding device (e.g., a high quality wrist
strap grounded to avoid potential damage).
•To prevent equipment or media damage,always remove the
Ribbon and Cards from the Printer before making any repairs,
unless otherwise specified.
•To prevent equipment or media damage,take jewelry off of
fingers and hands, as well as thoroughly clean hands to remove oil
and debris before working on the Printer.

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) vi
HDP
800 Series Card Printer/Encoders Overview
Reviewing the HDP
800 Series Block Diagram
1
2
3
4
5
6
7
8
910
11
12
13
14
15
16
17
18
20
22 23
24
25
26
27
28
29
30
31
33
32
33
34
35
36
37
38
39
40
41
43
44
45
46
47
48
49
50
Motors Sensors Parts
1Card Input 13 Card Low 32 Card Input Roller
2Card Feed Stepper 14 Card Detection 33 Cleaning Cartridge
3Flipper Stepper 15 Flipper Table Card 34 Flipper Table Roller
4Lamination Stepper 16 Encoding TOF 35 Flipper Table
5Print Stepper 17 Flipper Home 36 Encoding Module
6Lamination Headlift 18 Card TOF 37 Encoding Feed Roller
7Film Supply 19 Lower Film 38 Card Feed Roller
8Film Take Up 20 Film Take Up Encoder 39 Card Feed Roller
9Ribbon Supply 21 Thermocouple 40 Platen Roller
10 Ribbon Take Up 22 Film Supply Encoder 41 Flattener Roller
11 Print Headlift 23 Upper Film 42 Card Feed Roller
12 Stacker Lift 24 Ribbon Sensor Array 43 Flattener Cooling Fan
25 Ribbon Encoder 44 Lamination Roller
26 Print Headlift 45 Transfer Platen Roller
27 Thermistor 46 Printhead
28 Stacker Lift 47 Printhead Cooling Fan
29 Stacker Full 48 Film Cooling Fan
30 Cover Interlock 49 Card Input Hopper
31 Release Lever 50 Card Output Stacker

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) vii
Reviewing HDP
800 Series Card Printer - Sequence of Operations
The following sequence describes a dual sided full color print job with magnetic encoding. This
Printer also has an optional Card Stacker installed. (Note: The HDP825/825-LC Printers have
two (2) Card Input Hoppers that load 100 cards in each Hopper.)
Step Process
1The File information is received from the PC.
2The Heater warms up and/or maintains the heat on the hot Roller using the
Thermocouple to help maintain the desired temp.
3The Ribbon Drives turn ON and move until the correct panel is found by the Print
Ribbon Sensor array (5 reflective). All stop. (Note: The Print Ribbon Encoder is
active during this step.)
4The Film Ribbon Drive turns ON until the Film is positioned with the Film alignment
Sensor. All stop. (Note: The Film Ribbon Encoder is active during this step.)
5The Headlift Motor engages, moving the Printhead down until Headlift Sensor is
activated. All stop.
Continued on the next page
LCD Display
LED Light
Softkey Buttons
Card Cleaning
Assembly
Card Input Hopper
Card Thickness
Adjustment Knob
Front Access Door
Card Output
Hopper
Print Station
Release Lever
Transfer Station
Film Tension
Knobs
Printhead
Access
Card Slot
Scroll Buttons

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) viii
Reviewing HDP
800 Series Card Printer - Sequence of Operations (cont.)
Step Process
5The Fan turns ON as required to keep head cool.
6The Ribbon Drives, Film Ribbon Drive and Stepper turn ON and the Printhead
burns the image data until the image data is depleted. All stop. (Note: The
Ribbon Encoders are active during this step.)
7The Headlift Motor engages, moving the Printhead up until the Headlift Sensor is
activated. All stop.
8The Ribbon Drives and Film Ribbon Drive advance until the Print Ribbon Encoder
sees acceleration at release. (Note: The Ribbon Encoders are active during this
step.)
9The Ribbon Drives move until the Print Ribbon Position Sensor finds the next
panel. All Motors stop. (Note: The Ribbon Encoder is active during this step.)
10 The Film ribbon drive turns ON until the images portion of the Film is positioned
before the Printhead, using the Film Alignment Sensor. All stop. (Note: The
Ribbon Encoder is active during this step.)
11 The Headlift Motor engages, moving printhead down until the Headlift Sensor is
activated. All stop.
12 Ribbon Drive, Film Ribbon Drive and Stepper all turn ON and the Printhead burns
image data until the image data is depleted. All stop. (Note: The Ribbon
Encoders are active during this step.)
13 The Headlift Motor engages, moving the Printhead up until the Headlift Sensor is
activated. All stop.
14 The Ribbon Drive and Film Ribbon Drive engage until print ribbon encoder sees
acceleration at release. (Note: The Ribbon Encoders are active during this step.)
15 Repeat Steps 9 to 14 for the appropriate number of color/heat seal panels.
Continued on the next page

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) ix
Reviewing HDP
800 Series Card Printer - Sequence of Operations (continued)
Step Process
16 The Ribbon Drives turn ON to advance the printed portion of the Film to a position
near the heated lam Roller using the Lamination Film Alignment Sensor.
The Ribbon Drive stays ON for a certain number of additional clicks after turns
OFF t
ocreate a slack region between the Printer and Laminator sections. All stop.
(Note: Ribbon encoders and dancer zero position switch are active during this
step.)
17 The Ribbon Drive is used with the Lamination Film Alignment Sensor to locate the
printed Film more precisely under the hot Roller. All stop.
18 This is simultaneous to Steps 1 to 17 and then Steps 19 to 24 will occur.
19 The DC Motor and Stepper Motor turn ON and run until a card is seen by the card
Sensor, which will cause the Card Input Motor to stop.
The Stepper will continue to run a certain number of steps to position the card on
the Flipper Table. All stop. Card Low Sensor will check for cards in Input Hopper.
20 Stepper will turn ON, causing the Flipper to turn to the magnetic angular position.
The Flag Sensor and counted steps are used to determine the angular position.
All stop.
21 Stepper will engage to drive the card past the Mag Card Sensor and the Mag
Head.
22 Stepper engages to drive the card to a centered position on the Flipper Table
using the Mag Card Sensor and a step count. All stop.
23 Stepper will turn ON, causing the Flipper to turn to the default (flat) position. The
Flat Sensor and counted steps are used to determine the angular position. All
stop.
24 Steppers engage to move the card OFF the Flipper and to a position near the hot
Roller, using Card Feed Sensors and a step count. All stop.
25 Stepper engages to move the card to a position directly under the hot Roller. The
Top of Form Sensor determines card edge and number of steps to position card.
All stop.
Continued on the next page

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) x
Reviewing HDP
800 Series Card Printer - Sequence of Operations (continued)
Step Process
26 If the heater is not at the required temperature yet, the job will pause.
27 The Headlift Motor turns ON to lower the hot Roller and will stop when the Headlift
Sensor is activated. All off.
28 The Stepper and Ribbon Drive engage to laminate the printed Film onto the card.
They will turn off after a given number of steps based on the position given by the
card Sensor. All stop. (Note: The Ribbon Encoder is active during this step.)
29 The Headlift Motor turns on to raise the hot Roller, stopping when the Headlift
Sensor is activated.
30 The Ribbon Drive and Stepper turn ON for a given number of clicks based on
ribbon encoder, until the ribbon is released.
31 The Stepper turns ON to move the card through the flattening section and into the
output hopper (based on steps from a known position). All stop.
32 The Heater and Thermocouple are maintained at a set temperature at all times
when the Printer is ON. The cooling fan is ON when the Printer is ON.
33 The Stacker Lift Motor engages until the Stacker Lift Sensor is activated.
34 The Stacker Full Sensor checks for presence of cards.

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) xi
Reviewing the HDP
800 Series Card
Printer/Encoders - Boot up Sequence
Step Process
1The Card feed stepper turns ON (to check for a card on the Flipper table).
2The Lam Headlift turns until the head up position is returned from the Headlift
Sensor).
3The Film transfer take-up Motor turns ON to take up any slack in the dancer (and
runs until the Dancer Down Sensor is activated).
4The Print Headlift turns until head up position is returned from Headlift Sensor.
5The Print Ribbon moves forward until it finds the yellow panel, pauses, advances
to magenta, then backs up to yellow (the Ribbon Sensor detects marks on the
ribbon).
6The Transfer Ribbon advances forward two panels from supply (advances until
the Print Film Sensor senses 2 marks on the Film).
7The Transfer Ribbon advances forward one panel onto take up (advances until
the Transfer Film Sensor senses 1 mark on the Film)
8The Transfer Ribbon advances forward one panel from supply (advances until
the Print Film Sensor senses 1 mark on the Film).
9The Transfer Ribbon advances forward one panel onto take up (advances until
the transfer Film Sensor senses 1 mark on the Film).
10 The Transfer Ribbon reverses for one panel from take up (reverses until transfer
the Film Sensor senses 1 mark on the Film).
11 The Transfer Ribbon reverses for one panel onto supply (reverses until the Print
Film Sensor senses 1 mark on the Film).
12 The Transfer Ribbon reverses for one panel from take up (reverses until the
Transfer Film Sensor senses 1 mark up on the Film).
13 The Transfer Ribbon reverses for one panel onto supply (reverses until the Print
Film Sensor senses 1 mark on the Film).

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) xii
Reviewing the Lamination Module Sequence of Operations
The LAM sequence of operations begins after printing has occurred with the Card Printer.
Step Process
1The card is fed onto the Lamination Module Flipper Table.
2The card is fed to the Card Position Sensor.
3The Lamination Ribbon Motor begins cycling until the Upper Lamination Sensor
detects the mark.
4The Card Feed Motor activates to center the card on the Platen Roller.
5The Lamination Roller Lift Motor cycles until the Lamination Roller Lift Sensor
detects state change.
Continued on the next page
Lamination
Top Cover
Securing
Latches
Lamination Station
Lamination
LED Light
Cancel
Button
Resume
(pause) Button
Rejection
Card Hopper
Card Output
Hopper

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) xiii
Reviewing the Lamination Module Sequence of Operations (continued)
Step Process
6The Card Feed Motor and the Lamination Ribbon Motor activate for the length of
the card.
7The Lamination Roller Lift Motor cycles until the Lamination Roller Lift Sensor
detects state change.
8The card is fed back to the Flipper Table.
9The Flipper Table Clutch engages.
10 The Flipper Table Motor activates until the Card is inverted based on the Flipper
offset setting.
11 The Flipper Table Clutch disengages.
12 The card is fed off the Flipper Table.
13 The Flipper Table Clutch engages.
14 The Flipper Table Motor activates until the Flipper Table is homed.
15 The Flipper Table Clutch disengages.
16 Repeat Steps 2 through 7.
17 The card is fed out of the Printer.

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) xiv
Reviewing Lamination Module Boot up Sequence
Step Process
1The Lamination Headlift turns until the head up position is returned from Headlift
Sensor.
2The Lamination Ribbon Motor activates to determine the presence of a roll of
lamination.
3The Lamination Flipper table homes itself.
4The Card Sensor checks for the presence of a card and ejects it if found.

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) 1
Table of Contents
Section 1: Specifications _________________________________________________ 10
Reviewing the HDP800 Series Printers Overview table ________________________ 10
Regulatory Compliances ________________________________________________ 11
Agency Listings _______________________________________________________ 11
Technical Specifications ________________________________________________ 12
Functional Specifications________________________________________________ 16
Printer Components: Access Card Slot to Parallel Interface Port_______________ 17
Printer Components: LCD and Softkey Control Pad ________________________ 25
Printer Components: Centronics-Type Parallel Interface _____________________ 31
Printer Components: Print Ribbons _____________________________________ 32
Printer Components: Blank Cards_______________________________________ 33
Printer Components: Card Input Hopper (HDP820/820-LC) __________________ 34
Printer Components: Card Input Hopper (HDP825/825-LC) __________________ 35
Printer Components: Card Output Hopper ________________________________ 36
Printer Components: Lamination Roller__________________________________ 37
Reviewing the Card Lamination Module____________________________________ 38
Reviewing the Lamination Top Cover and Station __________________________ 39
Reviewing the Securing Latches and Lamination LED Light __________________ 40
Reviewing the Cancel button ___________________________________________ 41
Reviewing the Resume (pause) button____________________________________ 42
Reviewing the Rejection Card Hopper and Card Output Hopper _______________ 43
Reviewing the Module and Printer interaction _____________________________ 44
Reviewing the Module and LCD Display interaction ________________________ 45
Reviewing the Module’s Programmed Default Temperature __________________ 46
Reviewing the Laminator Temperature Adjustment _________________________ 47
Reviewing the Overlaminates ____________________________________________ 48
Reviewing the Thermal Transfer Film and PolyGuard Overlaminates ___________ 48
Reviewing the CR-90 or CR-100 Patch Size _______________________________ 49
Reviewing the Overlaminate Design _____________________________________ 49
Section 2: General Troubleshooting _______________________________________ 50
LCD/SmartGuard Messages______________________________________________ 50
Reviewing LCD Messages_____________________________________________ 50
Reviewing SmartGuard™ Error and Status Messages _______________________ 58
Communications Errors _________________________________________________ 60
Resolving the Communication Errors ____________________________________ 60
Firmware Errors _______________________________________________________ 63
Resolving the Upgrade Failed error ______________________________________ 63
Card Feeding Errors ____________________________________________________ 65
Resolving the Card Feeding problem (HDP820/820-LC) _____________________ 65
Resolving the Card Feeding Errors (HDP825/825-LC)_______________________ 68
Resolving the stalled Cards on or at the Feed Rollers ________________________ 71
Resolving the jammed Cards on the Flipper Table __________________________ 71
Resolving the Flipper Alignment Error Message____________________________ 72
Resolving the Cards being fed improperly off the Flipper Table _______________ 73

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) 2
Resolving the Card Jam Error Message___________________________________ 74
Resolving the Card Jam: Lam Error Message______________________________ 75
Magnetic Encoding Errors _______________________________________________ 76
Resolving the No ENC Response Error Message ___________________________ 76
Resolving the No Magnetic Encoder Error Message_________________________ 76
Resolving the Failed Magnetic Encode Error Message _______________________ 77
Removing the Card jam in the Printer’s Magnetic Encoding Area ______________ 78
Resolving the Printer being unable to read Encoded Magnetic track Data problem _ 79
Resolving the magnetic stripe Data being printed on a Card problem ___________ 80
E-card Encoding Errors _________________________________________________ 81
Resolving the Job Mismatch error _______________________________________ 81
Removing the Card jam in the Printer’s Smart Card Encoding Area ____________ 82
Resolving the No Prox Encoder Error Message ____________________________ 83
Resolving the No Smart Encoder Error Message ___________________________ 83
Resolving the Failed Smart Encode Error Message__________________________ 84
Printing Process Errors__________________________________________________ 85
Resolving the Ribbon Alignment Error Message ___________________________ 85
Resolving the Print Ribbon Jam_________________________________________ 86
Resolving the Print Ribbon Error Message ________________________________ 86
Resolving the Print Ribbon Out Error Message_____________________________ 87
Resolving the Wrong Print Ribbon Error Message __________________________ 87
Resolving the Unknown Ribbon Type Error Message _______________________ 88
Resolving the Headlift Error Message ____________________________________ 88
Resolving the Printer pausing between Panels problem ______________________ 89
Resolving the Printhead Temp Error Message______________________________ 90
Resolving the Printer Open Error Message ________________________________ 90
Transfer Process Errors _________________________________________________ 91
Resolving the Upper and Lower Film errors _______________________________ 91
Resolving the Film Sensor errors________________________________________ 93
Resolving the Transfer Cooling error ____________________________________ 97
Resolving the Card Jam Error Message___________________________________ 98
Resolving the Temperature Timeout Error Message _________________________ 99
Resolving the Transfer Lift Error Message ________________________________ 99
Resolving the Output Stacker errors ____________________________________ 100
Card Lamination Errors ________________________________________________ 101
Resolving the Overlaminate Jam _______________________________________ 101
Resolving the Card Lamination Placement errors __________________________ 103
Resolving the Lam Error/Out Error Message _____________________________ 104
Resolving the Lamination (not adhering to the card surface) problem __________ 106
Diagnosing the Image Problems _________________________________________ 108
Resolving the Pixel failure problems ____________________________________ 108
Resolving the Card surface debris problems ______________________________ 110
Resolving the incorrect Image Darkness problems _________________________ 113
Resolving the Ribbon wrinkle problems _________________________________ 115
Resolving the excessive Resin Printing problems __________________________ 117
Resolving the incomplete Resin Printing problems_________________________ 118

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) 3
Resolving the HDP Film wrinkle problems_______________________________ 119
Resolving the incomplete Transfer problems _____________________________ 121
Resolving an incomplete transfer on the leading edge problem _______________ 122
Resolving an incomplete transfer on the trailing edge problem _______________ 122
Resolving the Image Placement problems ________________________________ 123
Resolving the poor Image Quality problems ______________________________ 127
Resolving the Image washout on Film problems___________________________ 128
Resolving the Registration problems ____________________________________ 129
Resolving the Card Skewed Image problems _____________________________ 131
Printing a Test Image __________________________________________________ 132
Reviewing the Gray/Align YMC/K Self-Test _____________________________ 132
Reviewing the Color/Resin YMCK Self-Test _____________________________ 133
Reviewing the Color Bars YMC Self-Test _______________________________ 133
Reviewing the Card Count Self-Test ____________________________________ 134
Reviewing the Magnetic Test option ____________________________________ 134
Reviewing the Lamination Color/Resin YMCK+L Self-Test _________________ 135
Section 3: Card Lamination Module______________________________________ 136
Safety Messages (review carefully) _______________________________________ 136
Opening the Card Lamination Module __________________________________ 137
Loading the Overlaminate ____________________________________________ 140
Adjusting the Card Lamination Module ___________________________________ 143
Adjusting the Card Flattener __________________________________________ 143
Adjusting the Card Guide Rail_________________________________________ 145
Adjusting the Internal Card Guide ______________________________________ 149
Attaching the Card Lamination Module _________________________________ 152
Section 4: Printer Adjustments __________________________________________ 164
Safety Messages (review carefully) _______________________________________ 164
Adjusting the Card Size ________________________________________________ 165
Adjusting the Card Input Guide ________________________________________ 166
Adjusting the Card Stacker Output Guide ________________________________ 170
Adjusting the Internal Card Guide ______________________________________ 173
Adjusting the Card Thickness Knob ____________________________________ 176
Fine-Tuning the Card Separator Adjustment Assembly (D840995) ______________ 177
Printing on Alternate Card stocks ________________________________________ 178
Selecting the Right Cards and optimize the HDP Print Process _______________ 178
Selecting the Appropriate HDP Printer Driver settings ______________________ 179
Conducting the Tape Adhesion Test ____________________________________ 181
Printer Driver Options _________________________________________________ 184
Installing Printer Driver Updates _______________________________________ 184
Setting Up the Printer Driver ____________________________________________ 186
Setting up Windows 98SE/Windows Millennium __________________________ 186
Setting up Windows NT/Windows 2000/Windows XP______________________ 186
Using the Device Options tab ___________________________________________ 187
Adjusting the Ribbon Type ___________________________________________ 188
Adjusting the Film Type _____________________________________________ 189
Adjusting for the color matching _______________________________________ 190

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) 4
Adjusting for the Resin Dither _________________________________________ 191
Using the Print Both Sides option ______________________________________ 192
Using the Split 1 Set of Ribbon Panels option_____________________________ 193
Using the Print Back Side First option___________________________________ 194
Using the Print on Back Side Only option________________________________ 195
Using the Rotate Front 180 Degrees or Rotate Back 180 Degrees options _______ 196
Using the Print in Single Card Mode option ______________________________ 197
Using the Link Card to Print Job option _________________________________ 198
Using the Disable Printing option ______________________________________ 199
Using the Image color tab ______________________________________________ 200
Using the Image Transfer tab____________________________________________ 204
Adjusting the Image Position controls ___________________________________ 205
Adjusting the Transfer Dwell Time and Temperature _______________________ 207
Adjusting the Flattener Temperature ____________________________________ 208
Using the K Panel Resin tab_____________________________________________ 209
Selecting the Full Card with the K Panel Resin tab_________________________ 210
Selecting the Defined Area(s) with the K Panel Resin tab ___________________ 211
Selecting the Undefined Area(s) with the K Panel Resin tab _________________ 212
Defining the Area to activate the Card Grid ______________________________ 213
Measuring the Total Card area_________________________________________ 214
Measuring the Area to be positioned on the Card __________________________ 215
Selecting the Print YMC under the K and Print K Only options_______________ 216
Using the Magnetic Encoding tab ________________________________________ 218
Using the Encoding Mode option ______________________________________ 219
Encoding the Mode/Coercivity/Magnetic Track Selection ___________________ 221
Reviewing the Magnetic Track Options _________________________________ 222
Reviewing the Enable MLE Support checkbox____________________________ 223
Reviewing the Verification options _____________________________________ 224
Reviewing the Shift Data Left _________________________________________ 225
Reviewing the ISO Track Locations ____________________________________ 226
Sending the Track Information ________________________________________ 227
Reviewing the Sample String__________________________________________ 228
Reviewing the ASCII Code and Character Table __________________________ 229
Using the Card tab ____________________________________________________ 230
Selecting the Card Size from CR-80, CR-90 or CR-100 _____________________ 231
Selecting the Custom Card Size________________________________________ 233
Selecting the Card Type______________________________________________ 234
Reviewing the Orientation ____________________________________________ 236
Specifying the Copies _______________________________________________ 236
Clicking on the About button__________________________________________ 237
Using the Lamination tab (only with Card Lamination Module) ________________ 238
Selecting the Lamination Position ______________________________________ 239
Selecting the Lamination Side _________________________________________ 240
Selecting the Lamination Type ________________________________________ 241
Adjusting the Transfer Dwell Time and Transfer Temperature________________ 242
Selecting the Sensors button and Defaults button __________________________ 242

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) 5
Selecting the Sensors button and Defaults button __________________________ 243
Section 5: Cleaning ____________________________________________________ 244
Using the Required Supplies __________________________________________ 244
Safety Messages (review carefully) _______________________________________ 245
Cleaning inside the Printer____________________________________________ 246
Cleaning outside the Printer___________________________________________ 246
Cleaning the Printhead _______________________________________________ 247
Cleaning the Cleaning Rollers _________________________________________ 248
Cleaning the Card Feed Rollers ________________________________________ 252
Cleaning the Platen Rollers ___________________________________________ 256
Section 6: Parts Replacement____________________________________________ 258
Safety Messages (review carefully) _______________________________________ 259
Reviewing the Printer Components _______________________________________ 260
Reviewing the Input Hopper Components________________________________ 260
Reviewing the Print Module Components ________________________________ 263
Reviewing the Transfer Station Components _____________________________ 265
Reviewing the Base Module Components________________________________ 266
Reviewing the Base Module Components________________________________ 267
HDP Main Board Cable Connections Reference___________________________ 269
HDP Lamination Board Cable Connections Reference______________________ 270
HDP Lamination Module Board Cable Connections Reference _______________ 272
Cover Removal Procedures _____________________________________________ 273
Removing the Print Station cover (840361) ______________________________ 273
Removing the Front Transfer Cover (840362)_____________________________ 274
Removing the Mid Pulley Cover (D840166)______________________________ 275
Removing the Base Module cover (840363) ______________________________ 276
Removing the Card Input Hopper cover (840167) _________________________ 277
Removing the Card Output Hopper cover (840167) ________________________ 277
Removing the Back cover ____________________________________________ 278
Control Panel Assembly Components _____________________________________ 279
Replacing the Control Panel Assembly Components _______________________ 279
Printhead Assembly Components ________________________________________ 281
Replacing the Printhead (D840854)_____________________________________ 281
Replacing the Fan Assembly (D840986) _________________________________ 282
Replacing the Head Force Spring - 2 (840272) ____________________________ 283
Replacing the Ribbon Deflector (D840638) ______________________________ 284
Print Station Components replacement ____________________________________ 285
Replacing the Headlift Drive O-Rings (140212) ___________________________ 285
Replacing the Ribbon Drive O-Ring behind the Encoder Wheel (810492) ______ 286
Replacing the Ribbon Sensor Board Assembly (140407) ____________________ 287
Replacing the Encoder Wheel (810492) _________________________________ 288
Replacing the Ribbon Sensor Array Assembly (840108) ____________________ 289
Replacing the Ribbon Supply Motor Assembly (D840980) __________________ 290
Replacing the Ribbon Take-Up Motor Assembly (D840980) _________________ 291
Replacing the Headlift Motor Assembly (D840980)________________________ 292
Replacing the Ribbon Supply Encoder Sensor Assembly (D840982)___________ 293

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HDP800 Series Card Printer/Encoders Service Manual (Rev. 5.0) 6
Replacing the HDP 800 Series Ribbon Hub ______________________________ 294
Replacing the HDP 800 Series Ribbon Take up Roller Hubs _________________ 313
Replacing the HDP 800 Series Film Supply Hub __________________________ 315
Replacing the Headlift Sensor Assembly (D840983) _______________________ 322
Transfer Station Components Replacements ________________________________ 323
Replacing the Film Drive O-Rings (140212)______________________________ 323
Replacing the Film Drive Encoder Wheel - 2 (810492) _____________________ 324
Replacing the Stepper Motor Assembly (840123)__________________________ 325
Replacing the Supply Encoder Sensor Assembly (840135) __________________ 326
Replacing the Lamination Take-Up Encoder Sensor Assembly (840136) _______ 327
Replacing the Lower Film Sensor Assembly (840199)______________________ 328
Replacing the Upper Film Sensor Assembly (D841023)_____________________ 329
Replacing the Print Platen Roller (D840811) _____________________________ 330
Replacing the Transfer Peel Off Bar Assembly (D840698) __________________ 331
Replacing the Transfer Station Assembly (D841083) _______________________ 332
Replacing the Lamination Assembly (D841085)___________________________ 334
Replacing the Transfer Lift Sensor (A000126) ____________________________ 336
Replacing the Transfer Lift Motor (D840173)_____________________________ 337
Base Module Components Replacements __________________________________ 338
Replacing the Drive Belt – Platen Roller to Card Feed Roller (220071)_________ 338
Replacing the Drive Belt – Card Feed Roller to Card Feed Roller (220082) _____ 339
Replacing the Stepper Motor Assembly (D841045) ________________________ 340
Replacing the Pinch Roller Spring Plate-Front Input Side (D840865) __________ 341
Replacing the Pinch Roller Spring Plate-Front Output Side (D840865) _________ 342
Replacing the Pinch Roller Spring Plate-Back Input Side (D840865) __________ 343
Replacing the Pinch Roller Spring Plate-Back Output Side (D840865) _________ 344
Replacing the Drive Pulley - Back - 2 (D850190)__________________________ 345
Replacing the Gear - Card Transport - 2 (760330) _________________________ 346
Replacing the Compound Gear (D841032) _______________________________ 347
Replacing the Base Module (D841082)__________________________________ 348
Card Input Hopper Components Replacements______________________________ 350
Replacing the Input Hopper (D841087)__________________________________ 350
Replacing the Separator Adjustment Assembly (D840995) __________________ 351
Replacing the Flipper Table Sensor Board Assembly (140407) _______________ 352
Replacing the Card Low Sensor Board Assembly (140407) __________________ 353
Replacing the Cleaning Roller Drive Idler Gear - 2 (760401)_________________ 354
Replacing the Card Feed Gear - 3 (810271) on the Flipper Table Encoder Feed Motor
(E000062)_________________________________________________________ 355
Replacing the Card Feed Shaft Gear on the Cleaning Roller Assembly (810271) _ 356
Replacing the Feed/Encoding Motor Assembly (E000062) __________________ 357
Replacing the Cleaning Roller Assembly (840102)_________________________ 358
Replacing the Flipper Table Position Motor (840124) ______________________ 359
Replacing the Card Feed Motor Assembly (D841105) ______________________ 360
Replacing the Flipper Table Card Sensor Assembly (D840625)_______________ 361
Replacing the Card Feed Sensor (D840624) ______________________________ 362
Replacing the Magnetic Encoder Head (840104) __________________________ 363