ID badges Millennium 560 Operating manual

SERIES

Notices
The information in this document is subject to change without notice.
NO WARRANTIES OF ANY KIND ARE MADE WITH REGARD TO THIS MATERIAL,
INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
The manufacturer shall not be liable for errors contained herein or for incidental
damages in connection with the furnishing, performance, or use of this material.
This document contains proprietary information which is protected by copyright. All
rights are reserved. No part of this document may be photocopied, reproduced, or
translated into another language without the prior written consent of the printer
manufacturer.
Patent Pending
Trademark Acknowledgments
Windows and Microsoft are registered trademarks of Microsoft Corporation. All other
trademarks are the property of their respective owners.
Printing History
Edition 1.0, #981211
P/N SL1111
© Copyright 1999
All rights reserved.

SECTION 1: INTRODUCTIONSECTION 1: INTRODUCTION
1.01 Scope Of This Manual.....................................................................................................1
1.02 Description Of MILLENNIUM Series Printers............................................................1
1.03 Regulatory Compliances.................................................................................................3
1.04 Technical Specifications..................................................................................................4
SECTION 2: DIAGNOSTICS AND CALIBRATIONSECTION 2: DIAGNOSTICS AND CALIBRATION
2.01 Running A Self Test.........................................................................................................5
2.02 Calibration Procedures...................................................................................................9
2.03 Intensity Level Adjustment..........................................................................................11
2.04 Card Offset Adjustment................................................................................................14
2.05 Magnetic Card Offset....................................................................................................15
2.06 Magnetic Intensity Adjustment...................................................................................18
2.07 Parallel Interface Information......................................................................................20
2.08 Macintosh Interface Information.................................................................................23
SECTION 3: PARTS REPLACEMENTSECTION 3: PARTS REPLACEMENT
3.01 Introduction....................................................................................................................26
3.02 Cover – Top Removal....................................................................................................29
3.03 Assembly – Front Cover Removal...............................................................................29
3.04 Cover – Rear Removal..................................................................................................30
3.05 Assembly – Board Parallel Replacement...................................................................31
3.06 Assembly – Power Adapter Replacement..................................................................31
3.07 Assembly – Main Board 4250 Replacement...............................................................31
3.08 Assembly – Sensor Headlift Replacement..................................................................32
3.09 Assembly – Lid Sensor Replacement..........................................................................32
3.10 Assembly – Printhead Replacement...........................................................................32
3.11 Assembly – Headlift Replacement..............................................................................33
3.12 O-Ring 1-024 Replacement...........................................................................................33
3.13 Spring – Head Replacement.........................................................................................34
3.14 Assembly – Cable Printhead Harness Replacement.................................................34
3.15 Assembly – Slotted Sensor Mount replacement........................................................35
3.16 Assembly – Board Ribbon ID Sensor Replacement...................................................35
3.17 Assembly – Ribbon Drive Replacement.....................................................................36
Table of Contents

3.18 Assembly – Ribbon Sensor Lower...............................................................................36
3.19 Assembly – Card sensor Replacement........................................................................37
3.20 Roller – Card Feed Replacement.................................................................................37
3.21 Assembly – Card Feed Drive Replacement................................................................38
3.22 Assembly – Stepper Motor Replacement...................................................................39
3.23 Roller – Card Feed Prn Replacement..........................................................................39
3.24 Card Feed Mag Replacement.......................................................................................40
3.25 Platen Roller Replacement...........................................................................................40
3.26 Conn-Smart Card, Amphenol C702-2 Replacement.................................................42
3.27 Assembly – Lid Sensor (SC) Replacement.................................................................42
3.28 Assembly – Mag SC Motor Replacement...................................................................42
3.29 Assembly – Mag Head High Co. Replacement.........................................................43
3.30 Assembly – Mag Head JIS II Replacement.................................................................43
3.31 Main Board 4250 Cable Connector Locations.......... .......................................44

1
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1.01 Scope Of This Manual
This manual is intended for use by service and maintenance personnel who desire more
technical information than is contained in the MILLENNIUM 560/575x User’s Manual.
The information included relates to diagnostics, calibration and parts replacement
procedures for MILLENNIUM Series printers. For instructions on general setup,
installing supplies and standard operation, please refer to the User’s Manual included
with the printer.
1.02 Description Of MILLENNIUM Series Printers
MILLENNIUM Series printers utilizes two different, yet closely related printing
technologies to achieve its direct-to-card output — dye-sublimation and resin thermal
transfer. The following describes how each of these technologies works:
Dye-sublimation is the process used to print smooth, continuous-tone images
that look truly photographic. This process uses a dye-based ribbon roll that is
partitioned by a number of consecutive color panels. The panels are grouped in a
repeating series of the four process colors — yellow, magenta, cyan and black — along
the entire length of the ribbon. The printer always prints the yellow panel first,
followed by the magenta panel, the cyan panel and finally the black panel.
As the ribbon and card pass simultaneously beneath the Printhead, hundreds of thermal
elements within the Printhead heat the dyes on the ribbon. When these dyes are heated,
they vaporize and diffuse into the surface of the card. By varying the heat intensity of
each thermal element within the Printhead, it is possible for each transferred dot of
Introduction

2
color to vary in hue, thus blending one color smoothly into the next and producing
photo-realistic images.
Resin Thermal Transfer is the process used to print sharp black text and crisp
bar codes which can be read by both infra-red and visible-light bar code scanners.
It is also the process used to print ultra-fast, one-color ID cards. Like dye-sublimation,
this process uses the same thermal Printhead to transfer color from the ribbon roll
to the card. The difference, however, is that solid dots of color are transferred in the form
of a resin-based ink which fuses to the surface of the card when heated. This produces very
durable, single-color images.
MILLENNIUM Series Printers will print from any IBM-PC
®or compatible running
Windows®3.1x, Windows 95/98, Windows NT or any Macintosh®. This means you are
able to print from nearly any Windows or Macintosh application program,which allows
you to configure your page setup to your desired card size.

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1.03 Regulatory Compliances
FCC: MILLENNIUM printers complywith the requirements in Part 15 of the FCC
rules for a Class A digital device. These requirements are designed to provide
reasonable protection against harmful interference in a residential installation. If,
however, operation of this equipment in a residential area causes unacceptable
interference to radio and TV reception, the operator is required to take whatever steps
are necessary to correct the interference.
UL: MILLENNIUM printers are listed under UL 1950 INFORMATION
TECHNOLOGY EQUIPMENT, file number E145118.
CSA: The printer manufacturer has been authorized by UL to represent MILLENNIUM
Series printers as CSA Certified under CSA Standard C2.2, file number E145118 .
TÜV-GS: MILLENNIUM printers have been tested and complywith IEC950,
EN60950 and bear the TÜV-GS mark. License Number: S9871855
TÜV-EMC: MILLENNIUM printers have been tested and complywith CISPR 22-13
and EN55022 standards for EMI emissions and have been tested and complywith
IEC801,-2,-3,-4 standards for susceptibility, Class B. License Number: V871861
Based on the above testing, the printer manufacturer certifies that MILLENNIUM
Series printers comply with all current EMC directives of the European Community
and have placed the CE mark on MILLENNIUM printers.
1.04 Technical Specifications
Printing Method: Dye-sublimation/resin thermal transfer
Resin Thermal Transfer
Printing Resolution: 300 x 300 dpi (11.8 dots/mm)
Colors: Up to 16.7 million (using 4-color dye sublimation ribbons)
Single colors (using monochrome resin ribbons)
Print Speed: Approximately 6 seconds per card (K)
Approximately 35 seconds per card (YMCKO)

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Printing Area: Accepted Card Width:
1" to 2.63” W (25mm to 67mmW) 575X 2.15" x 2.63" 560
Accepted Card Length:
3” x 3.8" to 3.8 x 10"” L 575X (96.52mm to 254mmL) 3.0 x 3.38 560
Accepted Card Thickness:
.010” to .060” (.254mm to .75mm) 560 and 575X
Maximum Print Area:
2.14" (54.5mm) W x 10" (254mm) L Resin only 575X 2.14 x 3.3 560
Card Types: dcs approved media
Card Capacity: Accepts up to 100 .030" or 50 .060"
Software Driver: Windows 95/98, Windows NT and
Macintosh
Interface: Standard 8-bit Centronics-type parallel (ECP compatible) or
Macintosh serial
Operating Temperature: 65ºF to 80ºF (18ºC to 27ºC)
Humidity: Non Condensing 20% - 60%
Dimensions: 8.4” H x 13.6” W x 12.7” D
(213mmH x 345mmW x 323mmD)
Weight: 16.3 lbs. (7.4kg)
Agency Listings: Safety standards: UL 1950, CSA C2.2 and TÜV-GS (IEC-950)
Emissions standards: FCC Class A, CRC c1374, Class A and
TÜV-EMC (IEC-801 -2, -3, -4; CISPR 22, Class B), CE.
Supply Voltage: 100-240 VAC
Supply Frequency: 50 Hz/60 Hz

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2.01 Running A Self Test
A self test should be performed after initial setup of the printer, after a calibration
procedure has been conducted or after a part has been replaced to check for proper
operation of the printer. The procedure described below is an alternative method than
is found in the User’s Manual. A sample of the self test print is shown on the following
page.
1. If power is on, remove the power cable from the printer’s rear panel. Verify that a
full-color ribbon is installed and that cards are properly loaded.
2. Press and hold the Pause/Resume button.
3. While holding down the Pause/Resume button, plug the power cable back into the
printer.
4. Once the On LED illuminates, release the button. Within a few seconds, the printer
will begin printing a 3-color, process gray scale image. The overlay pass is NOT
printed during the self test.
The card will be ejected from the left side of the printer.
Diagnostics And
Calibration

6
Standard self test Print
In addition to the standard self test, there are several other test modes available by
changing the DIP switch settings within the printer. Below is an illustration of the Main
Circuit Board showing the location of the DIP switches and how to activate them. To
remove the rear cover to expose the Main Circuit Board, refer to section 3.04. To find
the DIP switches on the Main Circuit Board, see figure 2.01-A. For an illustration of
how to activate the DIP switches, refer to figure 2.01-B.
Figure 2.01-A: Main Circuit Board
DIP Switch
location
PN nnnnnn