Fargo HDP100 User manual

HDP100 High Definition Card
Printer/Encoder User Guide (Rev.
Beta); Sections 1 to 3 (modified)
Armstrong 1x (single-Side)
Armstrong 2x (dual-Side)
Armstrong 1x L (single-side + lamination)
Armstrong 2x L (single-side + lamination)
Armstrong 2x L (dual-side + lamination)
User Guide Part Number: L000950

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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) ii
HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta), property of Fargo
Electronics, Incorporated
Copyright 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. 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 Beta 1 January 2007 HDP100 High Definition Card
Printer/Encoder User Guide
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, 625 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]
FAX: [phone]
www.fargo.com
E-mail: [e-mail]

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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) iii
Table of Contents
Section 1: Printer Overview __________________________________________________ 1
How to use the guide___________________________________________________________________1
Safety Messages (review carefully)________________________________________________________2
HDP100 Overview ____________________________________________________________________3
Reviewing the HDP100 Block Diagram__________________________________________________3
Reviewing the HDP100 Sequence of Operations___________________________________________4
Reviewing the HDP100 Boot up Sequence _______________________________________________7
Reviewing the Lamination Module Sequence of Operations __________________________________8
Reviewing the Lamination Module Boot up Sequence _____________________________________10
Section 2: Specifications_____________________________________________________ 1
Safety Messages (review carefully)________________________________________________________1
Introduction__________________________________________________________________________2
Reviewing the HDP100 Printer Overview table ______________________________________________2
Reviewing the HDP100 Package _______________________________________________________3
Reviewing the HDP100 (front)_________________________________________________________3
Reviewing the HDP100 Card Printer ____________________________________________________4
Regulatory Compliances, Agency Listings and FCC Rules _____________________________________5
Regulatory Compliances ________________________________________________________________5
Agency Listings_______________________________________________________________________6
FCC Rules ________________________________________________________________________6
Technical Specifications ________________________________________________________________7
Functional Specifications ______________________________________________________________13
Printer Components: Resin Thermal Transfer to USB Interface Port __________________________14
Printer Components: LCD and Softkey Control Pad_______________________________________16
Printer Components: Print Ribbons____________________________________________________21
Printer Components: Blank Cards _____________________________________________________22
Printer Components: Card Input and Output Hoppers______________________________________23
Printer Components: Card Output Hopper and Reject Hopper _______________________________23
Printer Unit: Reviewing the Card Lamination Module _____________________________________24
Printer Components: Transfer Roller___________________________________________________25
Reviewing the Overlaminates ___________________________________________________________26
Reviewing the Thermal Transfer Film and PolyGuard Overlaminates__________________________26
Reviewing the CR-80 Patch Size ______________________________________________________27
Reviewing the Overlaminate Design ___________________________________________________27
Section 3: General Troubleshooting ___________________________________________ 1
LCD Messages _______________________________________________________________________1
Troubleshooting LCD Messages__________________________________________________________2
General Troubleshooting Guide _______________________________________________________14
Magnetic and E-card Troubleshooting Guide_____________________________________________19
Communications Errors________________________________________________________________22
Resolving the Communication Errors___________________________________________________22
Card Feeding Errors __________________________________________________________________24
Resolving an Unable to Feed Card Error ________________________________________________24
Resolving a Card Not Fed Error (Two (2) or more card feed at the same time)___________________27
Resolving a Card Hopper Empty Error__________________________________________________29
Resolving a Card Output Hopper Full __________________________________________________30
Resolving a Card Not Fed Error (Cards will not feed off the Hopper)__________________________31
Resolving a Card Jam Error __________________________________________________________32
Resolving a Card Jam (Encoder) Error__________________________________________________33
Resolving a Card Jam (Flipper) Error___________________________________________________34
Resolving a Card Jam (Laminator) Error ________________________________________________36

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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) iv
Resolving a Card Eject Error _________________________________________________________38
Resolving a No Flipper Table Module Error _____________________________________________39
Resolving a Flipper Jam Error ________________________________________________________40
Magnetic Encoding Errors______________________________________________________________42
Resolving a Magnetic Verify Error ____________________________________________________42
Resolving a No Magnetic Encoder Installed Error_________________________________________45
Resolving a No Magnetic Strip Present Error_____________________________________________47
E-card Encoding Errors________________________________________________________________48
Resolving a No Smart Card Encoder Error_______________________________________________48
Resolving a No Prox Card Encoder Error _______________________________________________49
Film Errors _________________________________________________________________________50
Resolving a Film Not Installed Error ___________________________________________________50
Resolving a Film Sensor Not Calibrated Error____________________________________________51
Resolving a Film Out Error __________________________________________________________52
Printing Process Errors ________________________________________________________________53
Resolving a Ribbon Sensor Error (Ribbon Miscue)________________________________________53
Resolving a Ribbon Break/Jam Error___________________________________________________55
Resolving a Ribbon Out Error ________________________________________________________57
Resolving a No Ribbon Installed Error__________________________________________________58
Resolving a Invalid Ribbon Error______________________________________________________60
Resolving a Wrong Ribbon Error______________________________________________________62
Resolving a Headlift Motor or Sensor Error______________________________________________64
Resolving the Cover Open Error Message _______________________________________________66
Resolving the Blank Output issues_____________________________________________________68
Card Lamination Errors________________________________________________________________71
Resolving a Laminator (General Error) _________________________________________________71
Resolving the Laminator (Check Power) Error ___________________________________________72
Resolving the Laminator (Heater Off) Error _____________________________________________73
Resolving the Wrong Overlaminate Installed Error ________________________________________74
Resolving Check Lamination Material Error _____________________________________________75
Resolving LAM Heater Times Out Error________________________________________________76
Printing a Test Image _________________________________________________________________77
Reviewing the Gray/Align YMC/K Self-Test ____________________________________________77
Reviewing the Color/Resin YMCK Self-Test ____________________________________________78
Reviewing the Color Bars YMC Self-Test_______________________________________________78
Reviewing the Card Count Self-Test ___________________________________________________79
Reviewing the Magnetic Test option ___________________________________________________79
Reviewing the Lamination Color/Resin YMCK+L Self-Test ________________________________80

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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) 1
Section 1: Printer Overview
How to use the guide
The HDP100 High Definition Card Printer/Encoder User Guide (Rev. 1.0) is designed to
provide installers and technicians with quick, efficient lookup of related procedures,
components and terms. The Guide can be used effectively either in soft or hard copy,
depending on the preference of the installer or technician.
Manual Description
Glossary of Terms and
Technical/Functional
Specifications (hyper-linked)
You can go directly to the Glossary of Terms, Technical
Specifications and Functional Specifications to learn how
to use the processes, procedures, functions and windows
for the HDP100 within concise, correlative tables.
Table of Contents (hyper-
linked) You can use the automated Table of Contents to quickly locate, for example, an error message, a procedure, the
index or an appendix.
Cross-Referencing (hyper-
linked) You can use the cross-referencing links to quickly locate, for example, an error message or a procedure.
Comprehensive Index
(hyper-linked) You can use the Comprehensive Index to quickly locate information on the HDP100, 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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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) 2
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 left).
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 left).
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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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) 3
HDP100 Overview
Reviewing the HDP100 Block Diagram
The HDP100 Block Diagram will be created and added to this service document at a future
date. Should consider breaking Printer and flipper into separate block diagrams.
1 Card Input 13 Ribbon Panel Sensor 32 Card Cartridge
2 Flipper Stepper 14 Ribbon Encoder 33
3 Transfer Stepper 15 Print Headlift 34
4 Print Stepper 16 Thermistor 35
5 Transfer Headlift 17 Cover Interlock 36
6 Film Supply 18 Card Input Roller 37
7 Film Take Up 19 Cleaning Roller 38
8 Ribbon Supply 20 Flipper Table Roller 39
9 Ribbon Take Up 21 Flipper Table 40
10 Print Headlift 22 Encoding Module 41
11 Card Detection? 23 Card Feed Roller 42
12 Flipper Table Card 24 Card Feed Roller 43
13 Encoding TOF 25 Transfer Platen Roller 44
14 Flipper Home 26 Card Feed Roller 45
15 Card TOF 27 Flattener Cooling Fan 46
16 Film Transfer 28 Transfer Roller 47
17 Film Take Up
Encoder 29
Print Platen Roller 48
18 RTD (Resistive
Thermal Device) 30
Printhead 49
19 Film - Print 31 Printhead Cooling Fan 50

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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) 4
Reviewing the HDP100 Sequence of Operations
The following sequence describes a dual sided full color print job with magnetic encoding.
Step Process
1 The File information is received from the PC.
2 The Heater warms up and/or maintains the heat on the hot Roller using the RTD
(Resistive Thermal Device) to help maintain the desired temp.
3 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
under the Card Feed/Position Sensor.
4 For a magnetic print job, the Stepper will continue moving the card until the trailing
edge is positioned under the Mag Head. All stop.
5 Stepper will turn ON in reverse direction and encode card. All stop.
6 Stepper will again turn on and position the trailing edge of the card under the Mag
Head. All stop.
7 Stepper will turn ON in reverse direction and verify data encoded onto mag stripe.
8 Stepper continues transporting card until the trailing edge is positioned under the
Card Feed/Position Sensor. All stop.
9 The Ribbon Drives turn ON and move until the correct panel is found by the Print
Ribbon Sensor. All stop. (Note: The Print Ribbon Encoder is active during this
step.)
This step occurs simultaneously with Step 10 (below).
10 The Film Drives turn ON until the Film is positioned with the Film Print Alignment
Sensor. (Note: This is the closest Sensor to the Print Platen Roller.)
All stop. (Note: The Film Ribbon Encoder is active during this step.)
11 The Headlift Motor engages, moving the Printhead down until Headlift Sensor is
activated. All stop.
Continued on the next page

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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) 5
Reviewing HDP100 Series Card Printer –Sequence of Operations (continued)
Step Process
12 The Fan turns ON as required to keep head cool.
13 The Ribbon Drives, Film Drive and Print Platen Stepper turn ON and the Printhead
burns the image data until the image data is depleted. All stop. (Note: The Ribbon
Encoders and Film Encoders are active during this step.)
14 The Headlift Motor engages, moving the Printhead up until the Headlift Sensor is
activated. All stop.
15 Repeat Steps 9 to 14 for the appropriate number of color/heat seal panels.
Continued on the next page

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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) 6
Reviewing HDP100 Series Card Printer –Sequence of Operations (continued)
Step Process
23 The Film Drives turn ON to rewind the printed portion of the Film into position at
the heated Transfer Roller using the Lamination Film Alignment Sensor.
24 If the heater is not at the required temperature yet, the job will pause.
25 Stepper engages to move the card to a position directly under the hot Roller. The
Card Feed/Position Sensor determines card edge and number of steps to position
card. All stop.
26 The Headlift Motor turns ON to lower the hot Roller and will stop when the Headlift
Sensor is activated. All stop.
27 The Stepper and Film 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 Film Encoder is active during this step.)
28 The Headlift Motor turns ON to raise the hot Roller, stopping when the Headlift
Sensor is activated.
29 The Film Drive and Stepper turn ON for a given number of clicks based on Film
Encoder, until the film is released.
30 The Stepper turns ON to move the card into Flipper Module to flip the card to the
opposite side. After flipping the card is transported back to the Card Feed/Position
Sensor to repeat Steps 9 to 14. Upon completion of print all print cycles the card
is transported to the Output Hopper (based on steps from a known from Flipper
Card Position Sensor). All stop.
31 The Heater is maintained at a set temperature by the RTD when the Printer is ON.
The cooling fan is ON when the Printhead is ON or hot.

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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) 7
Reviewing the HDP100 Boot up Sequence
Step Process
1 The Card feed stepper turns ON (to check for a card on the Flipper table).
2 The Lam Headlift turns until the head up position is returned from the Headlift
Sensor).
3 The Film transfer take-up Motor turns ON to take up any slack in the film.
4 The Print Headlift turns until head up position is returned from Headlift Sensor.
5 The Print Ribbon moves forward until it finds the yellow panel, pauses, advances
to magenta, then backs up to yellow (the Ribbon Sensor detects marks on the
ribbon).
6 The Transfer Ribbon advances forward two panels from supply (advances until
the Print Film Sensor senses 2 marks on the Film).
7 The Transfer Ribbon advances forward one panel from supply (advances until
the Print Film Sensor senses 1 mark on the Film).
8 The Transfer Ribbon reverses for one panel onto supply (reverses until the Print
Film Sensor senses 1 mark on the Film).
9 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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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) 8
Reviewing the Lamination Module Sequence of Operations
(Should this entire section be removed and added to the SEALS user manual or is the
Armstrong+flipper+SEALS to be contained in one all-inclusive manual?)
The LAM sequence of operations begins after printing has occurred with the Card Printer.
Step Process
1 The card is fed onto the Lamination Module Flipper Table.
2 The card is fed to the Card Position Sensor.
3 The Lamination Ribbon Motor begins cycling until the Lamination Sensor detects
the mark.
4 The Card Feed Motor activates to center the card on the Platen Roller.
5 The Transfer Roller Lift Motor cycles until the Transfer Roller Lift Sensor detects
state change.
Continued on the next page

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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) 9
Reviewing the Lamination Module Sequence of Operations (continued)
Step Process
6 The Card Feed Motor and the Lamination Ribbon Motor activate for the length of
the card.
7 The Transfer Roller Lift Motor cycles until the Transfer Roller Lift Sensor detects
state change.
8 The card is fed back to the Flipper Table.
9 The Flipper Table Clutch engages.
10 The Flipper Table Motor activates until the Card is inverted based on the Flipper
offset setting.
11 The Flipper Table Clutch disengages.
12 The card is fed off the Flipper Table.
13 The Flipper Table Clutch engages.
14 The Flipper Table Motor activates until the Flipper Table is homed.
15 The Flipper Table Clutch disengages.
16 Repeat Steps 2 through 7.
17 The card is fed out of the Printer.

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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) 10
Reviewing the Lamination Module Boot up Sequence
Step Process
1 The Transfer Headlift turns until the head up position is returned from Headlift
Sensor.
2 The Lamination Ribbon Motor activates to determine the presence of a roll of
lamination.
3 The Lamination Flipper table homes itself.
4 The Card Sensor checks for the presence of a card and ejects it if found.

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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) 1
Section 2: Specifications
The purpose of this section is to provide the User with specific information on the Regulatory
Compliances, Agency Listings, Technical Specifications and Functional Specifications for the
HDP100 and HDP100-LC Printers.
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 left).
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 left).
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.

RESTRICTED USE ONLY Fargo Electronics, Inc.
HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) 2
Introduction
The purpose of this section is to provide the User with specific information on the Regulatory
Compliances, Agency Listings, Technical Specifications and Functional Specifications for the
HDP100 Card Printer/Encoder.
Reviewing the HDP100 Printer Overview table
HDP100 Series Input
Hoppers
Card
Capacity Accepted Card
Size
Encoding
Modules Lamination Module
HDP100 (Single-
Sided Card
Printer/Encoder)
1 100
(100 per
Cartridge)
CR-80 Optional Optional
HDP100-LC (Single-
Sided Card
Printer/Encoder)
1 100
(100 per
Cartridge)
CR-80 Optional Included
HDP100 (Dual-Sided
Card
Printer/Encoder)
1 100
(100 per
Cartridge)
CR-80 Optional Optional
HDP100-LC (Dual-
Sided Card
Printer/Encoder)
1 100
(100 per
Cartridge)
CR-80 Optional Included

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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) 3
Reviewing the HDP100 Package
These items are included with your HDP100:
Unpacking Instructions and Training Video CD
Software Installation CD (includes Printer Driver)
Cleaning Roller
One (1) power supply with Printer; one (1) power supply with Laminator
Reviewing the HDP100 (front)

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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) 4
Reviewing the HDP100 Card Printer
Display - HDP100 Printer with attached Output Hopper

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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) 5
Regulatory Compliances, Agency Listings and FCC
Rules
The purpose of this section is to provide the User with specific information on the Regulatory
Compliances, Agency Listings and FCC Rules for this Printer.
Regulatory Compliances
Term Description
CSA
(cUL) The Printer manufacturer has been authorized by UL to represent
the Card Printer as CSA Certified under CSA Standard C22.2 No.
60950-1-03.
File Number: E145118
FCC The Card Printer complies with the requirements in Part 15 of the
FCC rules for a Class A digital device.
UL The Card Printer is listed under UL IEC 60950-1 (2001)
INFORMATION TECHNOLOGY EQUIPMENT.
File Number: E145118

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HDP100 High Definition Card Printer/Encoder User Guide (Rev. Beta) 6
Agency Listings
Term Description
Emissions
Standards CE, FCC, CRC c1374, EN 55022 Class A, FCC Class A, EN 55024: 1998, EN 61000-3-2 and EN 61000-3-3.
Safety Standards UL IEC 60950-1 (2001), CSA C22.2 No. 60950-1-03.
FCC Rules
This device complies with Part 15 of the FCC rules. Operation is subject to the following two
conditions:
(1) This device may not cause harmful interference.
(2) This device must accept any interference received, including interference that may cause
undesired operation.
Note: This equipment has been tested and found to comply with the limits for a Class A
digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio frequency
energy and, if not installed and used in accordance with the instruction manual, may cause
harmful interference to radio communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the user will be required to correct
the interference at his own expense.
Reference Safety Messages in this document.