Magicard Rio Pro User manual

Issue 2 10/12/2010
Colour ID Card Printer MAGICARD®Rio Pro Maintenance Manual
Ultra Electronics Card Systems
www.magicard.com
Magicard Rio Pro single sided colour ID Card Printer - 3633-9001
Magicard Rio Pro Duo double sided colour ID Card Printer - 3633-9021
Magicard Rio Pro Mag single sided colour ID Card Printer - 3652-9002
Magicard Rio Pro Duo Mag double sided colour ID Card Printer - 3652-9022
Magicard Rio Pro single sided colour ID Card Printer with Smart Encoder - 3652-9005
Magicard Rio Pro Duo double sided colour ID Card Printer with Smart Encoder - 3652-9025
Magicard Rio Pro Mag single sided colour ID Card Printer with Smart Encoder - 3652-9006
Magicard Rio Pro Duo Mag double sided colour ID Card Printer with Smart Encoder - 3652-9026
Duplex Upgrade Kit - 3633-0052
Standard
Option
Option
Standard
Standard
Standard
Standard
Standard
Option
Option

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CONTENTS
Contents............................................................................................................................................................................. - 2 -
Conventions.............................................................................................................................................................................................................- 4 -
Warnings, Cautions and Notes.................................................................................................................................................................................- 4 -
Safety Instructions ............................................................................................................................................................. - 5 -
SECTION 1 INTRODUCTION TO THE PRINTING PROCESS................................................................................... - 6 -
section 1.1 Card design limitations...................................................................................................................................................................- 8 -
section 1.2 badge design .................................................................................................................................................................................- 8 -
section 2 KEY FEATURES OF THE MAGICARD RIO PRO....................................................................................... - 9 -
section 2.1 specification of the Magicard Rio Pro ...........................................................................................................................................- 10 -
section 3 COMPONENT LAYOUT ............................................................................................................................ - 11 -
section 4 DYE FILM OPTIONS ................................................................................................................................. - 14 -
Section 4.1 loading the dye film......................................................................................................................................................................- 15 -
Section 4.2 Cards...........................................................................................................................................................................................- 16 -
section 5 single / double-sided upgrade.................................................................................................................... - 18 -
section 6 PHILOSOPHY............................................................................................................................................ - 19 -
section 6.1 repair and maintenance................................................................................................................................................................- 19 -
section 6.2 the warranty.................................................................................................................................................................................- 20 -
Section 6.3 Internet support...........................................................................................................................................................................- 21 -
section 6.4 recommended tools.....................................................................................................................................................................- 21 -
section 7 CLEANING THE PRINTER........................................................................................................................ - 22 -
section 7.1 cleaning is important ....................................................................................................................................................................- 22 -
section 7.2 cleaning supplies..........................................................................................................................................................................- 22 -
section 7.3 cleaning the printer Rollers...........................................................................................................................................................- 23 -
section 7.4 replacing the cleaning roller..........................................................................................................................................................- 24 -
section 7.5 cleaning the print head.................................................................................................................................................................- 25 -
SECtion 8 MAGICARD RIO PRO DRIVER................................................................................................................. - 26 -
section 8.1 installation instructions for Windows 2000/xp/2003 server & VISTA .............................................................................................- 26 -
section 8.1 installation instructions for Windows 2000/xp/2003 server & VISTA and Windows 7 continued…..............................................- 28 -
section 8.2 un-installing the driver for windows 2000 / xp / 2003 server..........................................................................................................- 29 -
section 8.3 un-installing the driver for windows vista / windows 7...................................................................................................................- 30 -
section 8.4 driver description..........................................................................................................................................................................- 31 -
Section 9 PRINTER DISPLAY ................................................................................................................................... - 32 -
section 9.1 menu options ...............................................................................................................................................................................- 32 -
section 9.1.1 1. clean rollers.............................................................................................................................................................................- 33 -
section 9.1.2 2. test card..................................................................................................................................................................................- 33 -
section 9.1.3 3. info..........................................................................................................................................................................................- 34 -
section 9.1.4 4. hand feed................................................................................................................................................................................- 34 -
section 9.1.5 5. mag self test............................................................................................................................................................................- 35 -
section 9.1.6 6. reset printer.............................................................................................................................................................................- 35 -
section 9.2 maintenance mode.......................................................................................................................................................................- 36 -
section 9.2.1 soak test mode.............................................................................................................................................................................- 36 -
section 9.2.2 Sensor test Mode.........................................................................................................................................................................- 37 -
section 9.2.3 previous menu .............................................................................................................................................................................- 38 -
section 10 PRINT HEAD REPLACEMENT ................................................................................................................. - 39 -
section 10.1 print head damage......................................................................................................................................................................- 39 -
section 10.2 print head Electronic failure..........................................................................................................................................................- 40 -
section 10.3 replacing the print head................................................................................................................................................................- 41 -
section 10.4 Setting the print head density calibration......................................................................................................................................- 42 -
Section 10.5 Print head setup and adjustment..................................................................................................................................................- 43 -
Section 11 DISMANTLING AND ASSEMBLING THE PRINTER ................................................................................ - 44 -
section 11.1 removing & refitting the printer casing. .........................................................................................................................................- 44 -
Section 11.2 Removing & Refitting the front fascia cover..................................................................................................................................- 44 -
section 11.3 removal & refitting of the top dye film sensor................................................................................................................................- 45 -
section 11.3 removing & Refitting of the lower dye film sensor.........................................................................................................................- 45 -
section 11.4 removal and refitting of the Card thickness adjuster .....................................................................................................................- 46 -
section 11.5 removing & Refitting the controller pcb.........................................................................................................................................- 46 -
section 11.6 removing & refitting of the front & rear Card sensor......................................................................................................................- 47 -
section 11.7 removing & refitting the Lcd display..............................................................................................................................................- 47 -
section 11.8 removal & refitting of left side components...................................................................................................................................- 48 -
section 11.9 removal and refitting of right side components .............................................................................................................................- 49 -
section 11.10 removal & refitting of the Drive motors & front Card sensor..........................................................................................................- 50 -
Section 11.11 removal of the chassis cover....................................................................................................................................................- 51 -
section 11.12 removal of the rotation unit...........................................................................................................................................................- 52 -

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section 11.13 removal of the idle rollers.............................................................................................................................................................- 52 -
section 11.14 removal and refitting of the large bearing plate.............................................................................................................................- 53 -
section 11.15 removal and refitting of steel Circlips............................................................................................................................................- 53 -
section 11.16 Removal and refitting of rollers.....................................................................................................................................................- 54 -
section 11.17 removal & refitting of the Card guide & middle Card sensor..........................................................................................................- 54 -
section 12 TOUBLESHOOTING.................................................................................................................................. - 55 -
Section 12.1 initialisation sequence..................................................................................................................................................................- 55 -
Section 12.2 hardware problems ......................................................................................................................................................................- 56 -
Section 12.3 image problems ...........................................................................................................................................................................- 57 -
Section 12.3 image problems COnt. .................................................................................................................................................................- 58 -
Section 12.4 printer driver problems.................................................................................................................................................................- 59 -
Section 12.5 Magnetic encoding problems........................................................................................................................................................- 61 -
Section 13 ERROR CODE LIST .................................................................................................................................. - 62 -
Section 13 Error code list cont............................................................................................................................................................................- 63 -
Section 13 Error code list cont............................................................................................................................................................................- 64 -
Section 13 Error code list cont............................................................................................................................................................................- 65 -
Section 14 MAGICARD PRINTER SUPPORT UTILITY.............................................................................................. - 79 -
section 15 MAGNETIC ENCODING............................................................................................................................ - 88 -
section 15.1 magnetic encoding standards.......................................................................................................................................................- 88 -
SECTION 15.2 BASIC MAGNETIC ENCODING..............................................................................................................................................- 90 -
SECTION 15.3 ENCODING USING BADGE PRINTING SOFTWARE.............................................................................................................- 91 -
section 15.4 ASCII Character Set supported by the Rio Pro.............................................................................................................................- 92 -
section 15.5 iso standards................................................................................................................................................................................- 92 -
section 15.6 error checking..............................................................................................................................................................................- 93 -
section 15.7 FITMENTS to the printer..............................................................................................................................................................- 94 -
section 16 PARTS & PART NUMBERS ...................................................................................................................... - 95 -
section 16.1 external components....................................................................................................................................................................- 95 -
section 16.2 Top cover assembly (3633-0150).................................................................................................................................................- 95 -
section 16.3 print head assembly (FG/3633-0160)...........................................................................................................................................- 96 -
section 16.4 Rotation unit assembly (3633-0140).............................................................................................................................................- 96 -
section 16.5 Roller Layout................................................................................................................................................................................- 97 -
section 16.6 Drive mechanism right hand side. ................................................................................................................................................- 98 -
section 16.7 Drive mechanism left hand side. ..................................................................................................................................................- 99 -
section 16.8 Motor layout and part numbers...................................................................................................................................................- 100 -
section 16.9 Internal wiring & sensor part numbers........................................................................................................................................- 101 -
section 16.10 Magnetic encoding option ..........................................................................................................................................................- 102 -
section 17 PRODUCT UPDATES ............................................................................................................................. - 103 -

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CONVENTIONS
WARNINGS, CAUTIONS AND NOTES.
Throughout this guide, the following conventions are used to identify important information.
WARNING Warning messages indicate where personal injury could result from not following the correct procedures.
CAUTION Caution messages indicate where damage to equipment could result from not following the correct
procedures.
NOTE Notes convey important information that is identified within the text.
The information contained in this document is subject to change without notice.
Ultra Electronics Limited shall not be liable for errors contained herein or for incidental consequential damages in
connection with the furnishing, performance or use of this material.
This document contains proprietary information belonging to Ultra Electronics Limited and may not be wholly or partially
copied, stored in a data retrieval system, disclosed to third parties or used for any purpose other than that for which it was
supplied, without the express written authority of Ultra Electronics Limited. All rights are reserved.
MAGICARD®, Rio, Tango, UltraCoverplus, Alto, Opera, Prima, Prima 2E, Prima 3, Holokote, Rio 2, Tango 2, Rio 2E,
Tango 2E, Rio Pro, Rio Pro, Ultra Shield MAGICARD®is registered as a Trademark with the United States Patent and
Trademark Office, Reg. No. 2,197,276
The Ultra Secure feature of Magicard® Printers is protected by US PATENT No: 5,990,918 and by EUROPEAN PATENT
SPECIFICATION EP 0 817 726 B1.
Microsoft and Windows 2000, XP and Vista are trademarks of Microsoft Corporation.
Copyright © 2004 Ultra Electronics Limited.

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SAFETY INSTRUCTIONS
Only use the Power Source supplied by Magicard with the Printer.
Do not to spill any liquid on the Printer.
If using this printer in Germany:
To provide adequate short-circuit protection and over-current protection for this Printer, the building installation must be
protected by a 16 Amp Circuit Breaker.
Bei Anschluß des Druckers an die Stromversorgung muß sichergestellt werden, daß die Gebäudeinstallation mit einem
16 A-Überstromschalter abgesichert ist.
When Handling the Printer:
Avoid touching the thermal printing edge of the Print Head. Any grease and contamination will shorten its life.
Before transporting the Printer, remove the dye film and Card Hoppers and pack the Printer in its original packaging.
Location Requirements for your Printer:
A clean, dry level surface.
Cable access at the rear.
Allowance for air circulation.
An adequately ventilated room.
The correct Power Supply Unit provided by Magicard.
Ambient temperature +10 to +30 degrees Centigrade.
Relative Humidity 20/70% RH.
Protection from direct sunlight and chemicals.
Protection from abrupt temperature changes.

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SECTION 1 INTRODUCTION TO THE PRINTING PROCESS.
Sublimation uses heating elements set in a rigid ceramic Print Head to transfer colour into or onto the PVC plastic surface
from the Dye Film ribbon. The colours Yellow, Magenta & Cyan are absorbed into the PVC and the Black (K) & Clear
Overcoat are heated onto the Card surface.
Dye Sublimation
Dye Sublimation, or Dye-Sub, is known for its high quality photographic output. Dye Sublimation is also known as “Dye
Diffusion” or “Thermal Transfer”.
Inside the Dye Sublimation Printer is a roll of transparent film that resembles sheets of red, blue, yellow, and black
coloured cellophane bonded together end to end. On one surface of this film are solid Dyes corresponding to the four
basic colours used in printing: cyan, magenta, yellow and black. Between the solid Dye and the film, is a layer of release
agent, which controls the amount of dye released at each temperature. The Print Head is heated up as it passes over the
film, causing the dye to vaporise and permeate the glossy surface of the PVC Card before returning to solid form on
cooling. This is sublimation.
The Clear Overcoat Layer
The Overcoat layer acts as a protective film against wear and fading and can also carry a secure image, which cannot be
photocopied –e.g. the Magicard Holokote security watermark.
Dye Sublimation / Inkjet Printing.
There are two factors that contribute to the quality of Dye Sublimation Printers. The first is continuous tone, and the other
is un-dithered colour. In Dye Sublimation printing, colours are not laid down as individual dots, as is done in inkjet
Printers.
The colour produced by a dye-sub is the result of the mixing of pigments to get
the actual colour. This is in contrast to most other printing methods which use a
tight group of coloured dots which, when seen by the human eye from a
distance, appear to be a colour (a process known as “dithering”). Under
magnification, the dots are clearly different colours, and when seen close up with
the naked eye the picture appears grainy. Because only one colour needs to be
printed (instead of up to four), a Dye Sub can place more dots on a Card. It can
take a 1200 dpi printer to get the same resolution a 300 dpi Dye Sub Printer is
capable of.
Another difference that helps is that because the colour sublimates on the Card
instead of being laid down as little dots, the edges of each pixel are blurred. This
gives the impression of blending for a more natural appearance. Dots from an
inkjet leave large white gaps in between pixels, giving the impression of grain.
Since longevity is something we all want from our prints, it‟s also reassuring to
know that because dyes sublimate instead of just being painted onto it‟s surface,
Dye Sublimation prints resist fading and are colourfast.
ID Card with Overcoat Layer used as a Security Watermark

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Subtractive Colour.
This section contains some background material on the colour process used in printing. The colours (Yellow, Magenta,
and Cyan) used in dye sublimation use a subtractive colour process. Subtractive colour starts with an object (often a
substrate such as paper or plastic) that reflects light and uses colourants (such as pigments or dyes) to subtract portions
of the white light illuminating an object to produce other colours.
If an object reflects all the white light back to the viewer, it appears white. If an object absorbs (subtracts) all the light
illuminating it, no light is reflected back to the viewer, it appears black. It is the subtractive process that allows everyday
objects around us to show colour. Colour paintings, colour photography and all colour printing processes use the
subtractive process to reproduce colour. In these cases, the reflective substrate is canvas (paintings) or paper/plastic
(photographs, prints), which is usually white. Colour monitors, television‟s, projectors etc. use the additive process.
Subtractive colour process (YMC) Additive colour process (RGB)
In theory, overprinting all three colours produces black. In reality, a dark grey is produced, so black is used as a fourth
printing ink, hence the „K‟ (for monochrome) in YMCK.
The K Resin layer allows very sharp defined black text, barcodes etc. to be added.
Printing.
Due to the ceramic print head being rigid the quality of the Card surface is extremely important if high quality images are
to be produced. Cards should be selected which are cut cleanly at the edges and have perfectly flat surfaces.
There are various Card manufacturers and several different types of PVC Card. Each of these will accept colour in
differing amounts using the same Print Head temperature. This is due to the PVC being used and the manufacturing
process.
When printing a full colour Card, the print head will get progressively hotter as it operates. This is compensated for in the
printer Firmware but it may affect how evenly some Card designs print.
Dust and debris on the Card surface will cause small white blemishes to appear in the image so keeping the Cards and
tacky rollers clean is imperative.
The Printer creates the Card by placing layers of dye onto the Card in the following sequence:
Yellow: (Y)
Magenta: (M)
Cyan: (C)
Black: (K) or Resin black
Clear: (O) or Overcoat.
The Overcoat layer acts as a protective film against wear and fading and can also carry a secure image, which cannot be
photocopied (Ultra Secure).
Colours appearing on the monitor will not always be exactly the same as those printed by a Printer; this can be due to
various issues such as in transmitted light from the monitor colours can look different than viewing reflected light from the
Card. All monitors will show the same image slightly differently. Different plastic surfaces will give differing results and
the Dye-Film could vary slightly from batch to batch. For these reasons, the Printer Driver has been designed to allow the
user to adjust various aspects of the colour output.

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SECTION 1.1 CARD DESIGN LIMITATIONS
It is important to remember that no Printer of this type will give the same quality / quantity of output as can be achieved
with a mass production Offset Printer. These Printers use a completely different process, print the same image hundreds
of times on large sheets of material, punch the finished Card out of the sheet and cost 10 times as much to purchase.
As long as badge designs are created to suit the dye sublimation process and the type of Card being printed, the results
will look as good to the naked eye as the far more expensive machines and can be personalised from Card to Card.
SECTION 1.2 BADGE DESIGN
It is important to realise that it is better to design a badge that will print successfully than attempt to print to the limits of
this type of Printer and cause waste and frustration.
The main issues to be considered are as follows:
The heat in the Print Head accumulates faster if dark colours are printed. The darker the colour the more heat is used to
print the layers onto the Card.
The Printer will automatically reduce the Print Head temperature to stop the colours getting darker along the length of the
Card.
This is set up in the mid range of the print density and will be slightly different on dark or light colours. Plain colour areas
are the most likely to show any variation so it is better to use textured colours where possible. If a coloured band runs
along the Card and into a picture, it will affect the area of the picture where it has increased the print head temperature.
Pictures will sometimes print better at the start of the Card or the end of the Card depending on the layout. Always try
reversing the whole image to select the best result. When printing on electronic Cards ensure that the design of the
badge allows for any unevenness in the surface due to the chip or aerial, these can cause white or faded patches to
appear in the text or image.
Ensure that any captured image such as an ID photograph is lit correctly for colour and brightness and is properly focused
as the Printer cannot improve poor quality input. If you add a logo or bitmap to the design, ensure that the size of the
original does not cause distortion and pixelation if it has to be enlarged or reduced to fit into the design. It is more
important to ensure the colour of any picture element is correct when printed (even if the colour looks incorrect on the
screen).

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SECTION 2 KEY FEATURES OF THE MAGICARD RIO PRO
Future Upgradable
Field upgraded from single to double sided ID Card printing, with a simple drop-in upgrade.
Rio Pro Duo is pre-programmed as Double Sided, from new.
Flexible
100 Card capacity Card Feeder at the rear of the Printer / 70 Card capacity at the front Stacker.
Hand Feed slot at the front of the Printer.
Drop in Dye-Film loading with automatic detection and set up for Dye-Film type.
Simple no mess cleaning operation.
Full Bleed Edge to Edge printing as standard option.
Advanced fault diagnosis using on screen fault display.
Print Head cooling Fan (allowing the printer to Print continuously).
Automatic adjustment for different Card thicknesses.
Smart
Attractive, compact design.
Intuitive LCD with simple button menu selections.
USB and Ethernet Interface.
Microsoft Certified “plug and play”Driver make the Rio Pro easy to install and use.
Secure
Magicard Rio Pro features the patented “Holokote”watermark technology.
Holokote watermark is printed on the Card during the normal print cycle at no extra cost.
Four Holokote design patterns offered as standard with every Rio Pro.
Can be upgraded to print a custom logo Holokote and Holoflex design
Holopatch is available using special Card stock to produce a highly visible logo on a gold seal stamp.
Optional ISO 7811 Magnetic Stripe Encoder.
Optional OmniKey 5321 Combi Contact/Contactless Encoder.

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SECTION 2.1 SPECIFICATION OF THE MAGICARD RIO PRO
Printing Method: Direct to Card Dye Sublimation.
Feed Format: Automatic and Hand Feed.
Resolution: 300 dots per inch (11.8 Dots per mm).
Colour Reproduction: 256 graduations for each colour.
Internal Memory Size: 16 MBytes.
Printing Time: Approximately 35 seconds each side (YMCKO).
Approximately 7 seconds each side for single colour. (K).
Printer Interface: USB Rev 1.1 (USB 2.0 compatible), Ethernet.
Operating Environment: Temperature 15 –30 degrees Centigrade.
Humidity 20% - 80%
Storage Environment: Temperature 15 –55 degrees Centigrade.
Humidity 20% - 80%
Power Source: External Power Supply auto-ranging.
Input Voltage: AC Input 100 –240 V AC.
Input Current Consumption: 1.8 Amps.
Frequency: 50 –60 Hz
Output Voltage: 24 V DC
Output Current Supply: 3.75 Amps.
Output Power Rating: 90 Watts (Max).
Weight: 5.5 kilograms (12 lbs) including Hoppers and PSU.
Dimensions: 453mm (L) x 206mm (W) x 233mm (H) incl. Hopper and Stacker.
17.8” (L) x 8.1” (W) x 9.2” (H).
Dye film loading: Drop in Dye-Film design.
Dye film Set-up: Automatically detects Dye-Films.
Software: Supplied with Windows 2000, 2003 Server, XP, Vista and Win 7 Drivers.
Magstripe Encoder: Optional HICO/LOCO magnetic stripe encoder to ISO 7811 standard.
Card Size: Standard ISO CR80 & CR79 sized Cards.
Card Thickness: 0.51 –1.02mm (0.020” – 0.040”)
Card Types: PVC.
Holopatch Cards are available. They are used with the Holokote feature
to produce a highly visible “gold seal”on the Card.
Card Input Hopper Capacity: 100 Cards (0.76mm / 0.030”).
Exit Stacker Capacity: 70 Cards (0.76mm or 0.030”).
Print Length: Full Card 1016 pixels (85.6mm).
Print Width: Full Card 642 pixels (54.5mm).
Print Speed: Normal/High (Draft).
Safety: CE Certified, UL listing USA.
EMC: EN 50 081-1 and EN 50 082-1 (Europe) FCC pt 15 curve A (USA).
& CSA 08.8 curve A (Canada). CCC approved (China)
Warranty: Three years UCP (North America, EU and selected other countries only).
Elsewhere 2 year manufacturers limited warranty.

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SECTION 3 COMPONENT LAYOUT
Cleaning Roller
Blank Card
Hopper
Print Head
Assembly
Top Cover Opening Latch
Front Card
Stacker
LCD Display
Hand Feed Slot
Rear Card
Hopper
DC Power Input
Network
Connection
USB Connection

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Top Cover Holding Latches
Print Head Cooling Fan
Print Head Assembly
Rear Card Hopper
LCD Display
Hand Feed Entry / Exit Slot
Front Card Stacker
Function Buttons
Dye Film Sensor Bracket (top)
Rio Pro component layout
(viewed from front of Printer)
Card rotation
Unit
Top Cover
Interlock Sensor
Unused Dye-Film
Spool Holder
Automatic Card
Adjustment
Thermal Print
Head
HoloKote/Flex
Key Slot

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Magnetic
Encoder Roller
Dye-Film Sensor
Bracket (Lower)
Flipper Unit
Card Drive Roller
Cleaning Roller
Rear Idle Roller
Print Head Roller
Flipper Mechanism
Rotation Motor
Flipper Mechanism
Direction Motor
Dye Film Drive Motor
Card Feed Motor
Main Stpper
Motor
Cam Motor
Rio Pro Motors (viewed from underside of Printer)
Rio Pro component layout (viewed from top of Printer)

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SECTION 4 DYE FILM OPTIONS
MA300YMCKO Dye Film is the appropriate choice for colour printing with Rio Pro Printer.
MA250YMCKOK Dye Film (for the double-sided models only), is more economic when printing in colour on the front side
and black on the rear.
MA1000K & MA600KO Dye-Film –where cost is critical, monochrome printing is a fraction of the cost of colour printing.
The Table below is a guide to selecting the best Dye Film to use for any intended application.
Ribbon Layout Colour Key
Included with each Dye-Film is a Cleaning Roller.
Full color Cards
or monochrome
Cards
Per
ribbon
Ribbon
Panel
layout
Part Number
Full
Colour
300 one side only or 150
both sides
YMCKO
MA300YMCKO
Monochrome:
Black
Red
Blue
Green
Gold
Silver
White
Scratch
1000 one side only or
500 both sides
K
MA1000K n
(n = colour)
Black &
Overcoat
600 one side only or 300
both sides
KO
MA600KO
Colour front &
Black back
250 front & back
YMCKOK
MA250YMCKOK
Colour front &
colour back
150 Front & Back
YMCKO
MA300YMCKO
Yellow (Y)
Magenta (M)
Cyan (C)
Resin (K)
Overcoat (O)

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SECTION 4.1 LOADING THE DYE FILM.
Incorporated in colour (and black & clear) Dye Film is an
electronic RFID protective Tag. When the Printer begins
its initialisation process, the Printer reads the Tag and
looks for the following info:
Ribbon Type
Remaining number of prints.
If it fails to read any of the data from the RFID protective
Tag, the Printer assumes it has single colour Film fitted.
Operate the top cover release catch and lift the cover.
Place the cassette into the 4 cradles (right side first) and press it into place. Ensure the gear (front right)
engages with the Spool.
Gently close the top cover until it clicks into the closed position.
The Printer will automatically recognise the type of Film that has been loaded by reading the film RFID Tag
as it initialises.

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CR80
85.6mm or 3.375”
CR79
83.9mm or 3.303”
CR80
53.98mm or 2.125”
CR79
51mm or 2.051”
CR80 –1016 Pixels
CR79 –990 Pixels
CR80 –642 Pixels
CR79 –601 Pixels
Recommended
page size for
edge to edge
printing
ISO Standard Cards
Sizes
Printable Area of Cards
SECTION 4.2 CARDS
Card Material
Not all white plastic Cards are the same. For best image quality always use high quality grade PVC Cards.
Pure PVC Card stock or laminated PVC/Polyester Cards are available. The latter are more durable and better suited to
heavy use and heat lamination when required. For access control and smart Card applications, your Dealer should
provide the appropriate type for “direct to Card”printing. For good consistent results, stick to a single variety of good
quality Cards, such as those available from your Magicard Dealer.
Card Size
Card Thickness
Minimum 0.51mm 0.020”
Standard 0.76mm 0.030”
Maximum 1.02mm 0.040”
To obtain good quality prints the Cards must be:
Glossy white.
Free from dirt or grease.
Free from surface contamination (e.g. finger marks).
Free from burrs at the edge of the Card.
Free from pits or bumps in the surface.
Printable Area of the Card.
Both the Rio Pro and Rio Pro Duo Printer offer high quality edge to edge (Full Bleed) printing. Thus the surface of the
Card may be printed edge to edge.
Die cut PVC Cards typically have an edge roll off (bevel) which can result in a thin white line around the edge of full bleed
printed Cards. When setting up your Card design using your graphics software on your PC, you should use a maximum
page size of 1016 pixels (3.375”/85.6mm) x 642 pixels (2.125”/53.98mm).

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Other Card Types.
Self-Adhesive Cards.
We recommend only self-adhesive Cards supplied by Ultra Electronics via your Magicard Dealership (Pt. M9007-011)
There are many different types of self-adhesive Cards. Thorough investigation and testing has shown that poorer quality or
incorrect Card types will cause problems in the Printer. These problems range from poor image quality, failure to feed from
the Card Hopper and Dye Film being cut through to Cards getting jammed in the roller mechanism.
Contact Chip Cards.
Smart Cards must conform to the ISO 7816 specification, with the Chip contacts being below the surface of the Card. It is
unwise to print graphics or text directly adjacent to the Smart Chip as image quality may be affected.
Contactless (Proximity) Cards.
Proximity Cards must be completely flat with no sign of the electronics or antenna being visible through the surface of the
Card.

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The Magicard Rio Pro Printer can be purchased in single or double-sided printing format.
If you choose the Rio Pro single format model, you can purchase an upgrade from Magicard. This will change the
Rio Pro to a Rio Pro Duo in the convenience of your Office allowing you to print double-sided Cards.
No tools are required for this upgrade. Simply drop the Dye-Film upgrade into the machine.
1. Purchase the upgrade kit
from Magicard Sales.
2. Fit the upgrade Film into
the Printer.
3. Close the Lid and
connect power to
the machine.
4. Wait for the Printer to finish initialising (the Printer Display will change
colour and show text). You are now ready to print.
The upgrade is Printer specific, so once the Dye-Film upgrade has been
fitted into a Rio Pro it will not work in another Printer.
The Printer is now enabled for duplex printing with any type of Dye-Film,
YMCK, YMCKK etc.
SECTION 5 SINGLE / DOUBLE-SIDED UPGRADE.

Ultra Electronics Card Systems
Rio Pro Maintenance Manual
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SECTION 6 PHILOSOPHY
SECTION 6.1 REPAIR AND MAINTENANCE
The repair and maintenance philosophy for the Magicard Rio Pro is for repairs to be carried out by the replacement of
defective modules. The Printer has been specifically designed to comprise of several major modules:
External Power Supply Unit
The Main Control PCB
The Print Engine Assembly
The Thermal Print Head
Field Repair
Every precaution has been taken in the design of the Rio Pro printer to ensure user problems are rare. We have also
tried to anticipate any possible problems in the Field due to misuse, accidental failure or straightforward component
failure. This Manual should enable the Service Agent to identify any module or component that has failed, replace it, and
carry out the appropriate setting up and testing to ensure satisfactory operation.
Feedback
Ultra Electronics Limited is committed to the manufacture of quality products and encourages feedback of any problem or
faults occurring in the field, in order that we can improve the quality of our design, manufacture and support.
We would be grateful if the Service Agent would give full details of all faults when returning the Printer to us for repair.
We also provide a Customer Support service to help customers in case they are having problems with their Printer.
You will find lots of helpful information on our web-site: www.Magicard.com
Contact Magicard Customer Support on the following numbers:
UK: Tel: [phone]
Fax: [phone]
E-Mail: [e-mail]
USA: Tel: [phone]
Fax: [phone]
E-Mail: [e-mail]

Ultra Electronics Card Systems
Rio Pro Maintenance Manual
- 20 -
SECTION 6.2 THE WARRANTY
Coverage
Ultra Electronics Ltd warrants that the MAGICARD Printer shipped with this warranty statement will conform to the
manufacturers specifications and be free from defects in materials or workmanship for a period of 24 months from the
date of original purchase by the user, but there are additional conditions on the Print Head warranty (see Para 2).
Limited Print Head Warranty
Ultra warrants that, under normal use and service, thermal Print Heads will be free from defects in material and
workmanship for a period of 12 months from the date of original purchase or for a quantity of 40,000 printed Cards
(whichever comes first), provided that Ultra-approved Card media is utilised. If a warranty claim is submitted for a
defective Print Head, Ultra will have the right to inspect the Print Head and samples of the printed and blank ID Cards
used with it for the purpose of verifying that the claimed defect has not been caused by non-Ultra approved media, or by
foreign particles or substances which have caused chemical or physical damage. Ultra's decision in any such claims
shall be final.
Warranty Claims
If the MAGICARD Printer proves defective during this period, please contact Magicard Customer Support, at the address
and telephone/Fax number given below. The Customer Support personnel may first ask you to carry out certain simple
checks to confirm the nature of the problem, and if a return is appropriate they will give you a Magicard Return
Authorisation Number (MRAN) and consignment instructions to the appropriate repair centre. Ultra will, at its discretion,
repair or replace the defective parts at no charge to the Customer.
Warranty Limitations
The warranty does not apply to MAGICARD Printers that have been:
Damaged through physical or electrical mishandling.
Damaged through operation in environments that are outside normal office conditions in terms of corrosive
atmosphere, temperature, humidity, shock or vibration.
Improperly installed or interfaced to other products which may exhibit software problems or expose the
MAGICARD to improper voltages or control signals.
Fitted with Dye-Film rolls from any source other than Ultra Electronics, or have been used to print on anything
other than Card surfaces which are approved by Ultra and which will generally be made of PVC, be completely
flat, and be free of harmful particles or substances.
Serviced or investigated by anyone other than an Ultra Authorised Service Provider.
Shipping
Insurance and shipping costs incurred in sending the MAGICARD Printer for warranty service is the responsibility of the
Customer. Whenever possible Magicard Customer Support will use the same class of shipping service selected and paid
for by the Customer to return the Printer. Return shipping costs from Ultra to the Customer will be at Ultra's expense.
After obtaining a Magicard Return Authorisation Number (MRAN) as described above, the Printer should be securely
packed in its original packaging with „proof of date of purchase‟and a note describing the problem and quoting the MRAN
number. The Printer must be sent to the Service Centre address supplied with the MRAN. This address may be different
to the address listed below, but will generally be closer to you. Please also mark the MRAN number on the outside of the
shipping carton. All Customs Duties and Taxes, if applicable, are the responsibility of the Customer.