Fargo HDP800 Series Card Printer/Encoder Service Manual – PDF Download

Description

Fargo HDP800 Series Card Printer/Encoder Service Manual – PDF Download

DESCRIPTION

This Fargo HDP® 800 Series Card Printer/Encoders Service Manual (Rev. 3.0) provides complete technical guidance for technicians, service centers, and support engineers working on Fargo HDP800 printers and optional lamination modules.
It includes step-by-step procedures, wiring references, error code diagnostics, mechanical adjustments, and image quality correction methods.

Models Covered

• Fargo HDP800 Series Printers

• HDP800 Series with Lamination Module (HDP800-LC)

• Magnetic, Smart-Card & Contactless Encoder Variants

• Section 1: Specifications
• Regulatory Compliances
• Agency Listings
• Technical Specifications
• Functional Specifications

• Printer Components: Access Card Slot to Parallel Interface Port
• Printer Components: LCD and Softkey Control Pad
• Printer Components: Centronics-Type Parallel Interface
• Printer Components: Print Ribbons
• Printer Components: Blank Cards
• Printer Components: Card Input Hopper
• Printer Components: Card Output Hopper
• Printer Components: Lamination Roller

• Reviewing the Card Lamination Module
• Reviewing the Lamination Top Cover and Station
• Reviewing the Securing Latches and Lamination LED Light
• Reviewing the Cancel button
• Reviewing the Resume (pause) button
• Reviewing the Rejection Card Hopper and Card Output Hopper
• Reviewing the Module and Printer interaction
• Reviewing the Module and LCD Display interaction
• Reviewing the Module’s Programmed Default Temperature
• Reviewing the Laminator Temperature Adjustment

• Reviewing the Overlaminates
• Reviewing the Thermal Transfer Film and PolyGuard Overlaminates
• Reviewing the CR90 or CR100 Patch Size
• Reviewing the Overlaminate Design

• Section 2: General Troubleshooting
• LCD/SmartGuard Messages
• Reviewing LCD Messages
• Reviewing SmartGuard™ Error and Status Messages

• Communications Errors
• Resolving the Communication Errors

• Firmware Errors
• Resolving the Upgrade Failed error

• Card Feeding Errors
• Resolving the Card Feeding problem
• Resolving the stalled Cards on or at the Feed Rollers
• Resolving the jammed Cards on the Flipper Table
• Resolving the Flipper Alignment Error Message
• Resolving the Cards being fed improperly off the Flipper Table
• Resolving the Card Jam Error Message
• Resolving the Card Jam: Lam Error Message

• Magnetic Encoding Errors
• Resolving the No ENC Response Error Message
• Resolving the No Magnetic Encoder Error Message
• Resolving the Failed Magnetic Encode Error Message
• Removing the Card jam in the Printer’s Magnetic Encoding Area
• Resolving the Printer being unable to read Encoded Magnetic track Data problem
• Resolving the magnetic stripe Data being printed on a Card problem

• E-card Encoding Errors
• Resolving the Job Mismatch error
• Removing the Card jam in the Printer’s Smart Card Encoding Area
• Resolving the No Prox Encoder Error Message
• Resolving the No Smart Encoder Error Message
• Resolving the Failed Smart Encode Error Message

• Printing Process Errors
• Resolving the Ribbon Alignment Error Message
• Resolving the Print Ribbon Jam
• Resolving the Print Ribbon Error Message
• Resolving the Print Ribbon Out Error Message
• Resolving the Wrong Print Ribbon Error Message
• Resolving the Unknown Ribbon Type Error Message
• Resolving the Headlift Error Message
• Resolving the Printer pausing between Panels problem
• Resolving the Printhead Temp Error Message
• Resolving the Printer Open Error Message

• Transfer Process Errors
• Resolving the Upper and Lower Film errors
• Resolving the Film Sensor errors
• Resolving the Transfer Cooling error
• Resolving the Card Jam Error Message
• Resolving the Temperature Timeout Error Message
• Resolving the Transfer Lift Error Message
• Resolving the Output Stacker errors

• Card Lamination Errors
• Resolving the Overlaminate Jam
• Resolving the Card Lamination Placement errors
• Resolving the Lam Error/Out Error Message
• Resolving the Lamination (not adhering to the card surface) problem

• Diagnosing the Image Problems
• Resolving the Pixel failure problems
• Resolving the Card surface debris problems
• Resolving the incorrect Image Darkness problems
• Resolving the Ribbon wrinkle problems
• Resolving the excessive Resin Printing problems
• Resolving the incomplete Resin Printing pr

• Section 3: Card Lamination Module
• Safety Messages (review carefully)
• Opening the Card Lamination Module
• Loading the Overlaminate

• Adjusting the Card Lamination Module
• Adjusting the Card Flattener
• Adjusting the Card Guide Rail
• Adjusting the Internal Card Guide
• Attaching the Card Lamination Module

• Section 4: Printer Adjustments
• Safety Messages (review carefully)
• Adjusting the Card Size
• Adjusting the Card Input Guide
• Adjusting the Card Stacker Output Guide
• Adjusting the Internal Card Guide
• Adjusting the Card Thickness Knob

• Fine-Tuning the Card Separator Adjustment Assembly (D840995)
• Printing on Alternate Card stocks
• Selecting the Right Cards and optimize the HDP Print Process
• Selecting the Appropriate HDP Printer Driver settings
• Conducting the Tape adhesion Test

• Printer Driver Options
• Installing Printer Driver Updates
• Setting Up the Printer Driver
• Setting up Windows 95 / Windows 98 / Windows Millennium
• Setting up Windows NT / Windows 2000 / Windows XP

• Using the Device Options tab
• Adjusting the Ribbon Type
• Adjusting the Film Type
• Adjusting for the color matching
• Adjusting for the Resin Dither
• Using the Print Both Sides option
• Using the Split 1 Set of Ribbon Panels option
• Using the Print on Back Side Only option
• Using the Rotate Front 180 Degrees or Rotate Back 180 Degrees options
• Using the Print in Single Card Mode option
• Using the Link Card to Print Job option
• Using the Disable Printing option

• Using the Image color tab
• Using the Image Transfer tab
• Adjusting the Image Position controls
• Adjusting the Transfer Dwell Time and Temperature
• Adjusting the Flattener Temperature

• Using the K Panel Resin tab
• Selecting the Full Card with the K Panel Resin tab
• Selecting the Defined Area(s) with the K Panel Resin tab
• Selecting the Undefined Area(s) with the K Panel Resin tab
• Defining the Area to activate the Card Grid
• Measuring the Total Card area
• Measuring the Area to be positioned on the Card
• Selecting the Print YMC under the K and Print K Only options

• Using the Magnetic Encoding tab
• Using the Encoding Mode option
• Encoding the Mode / Coercivity / Magnetic Track Selection
• Reviewing the Magnetic Track Options
• Reviewing the Verification options
• Reviewing the Shift Data Left
• Reviewing the ISO Track Locations
• Sending the Track Information
• Reviewing the Sample String
• Reviewing the ASCII Code and Character Table

• Using the Card tab
• Selecting the Card Size from CR80, CR90, or CR100
• Selecting the Custom Card Size
• Selecting the Card Type
• Reviewing the Orientation
• Specifying the Copies
• Clicking on the About button

• Using the Lamination tab (only with Card Lamination Module)
• Selecting the Lamination Position
• Selecting the Lamination Side
• Selecting the Lamination Type
• Adjusting the Transfer Dwell Time and Transfer Temperature
• Selecting the Sensors button and Defaults button

• Section 5: Cleaning
• Using the Required Supplies
• Safety Messages (review carefully)
• Cleaning inside the Printer
• Cleaning outside the Printer
• Cleaning the Printhead
• Cleaning the Cleaning Rollers
• Cleaning the Card Feed Rollers
• Cleaning the Platen Rollers

• Section 6: Parts Replacement
• Safety Messages (review carefully)
• Reviewing the Printer Components

• Reviewing the Input Hopper Components
• Reviewing the Print Module Components
• Reviewing the Transfer Station Components
• Reviewing the Base Module Components
• HDP Main Board Cable Connections Reference
• HDP Lamination Board Cable Connections Reference
• HDP Lamination Module Board Cable Connections Reference

• Cover Removal Procedures
• Removing the Print Station cover (840361)
• Removing the Front Transfer Cover (840362)
• Removing the Mid Pulley Cover (D840166)
• Removing the Base Module cover (840363)
• Removing the Card Input Hopper cover (840167)
• Removing the Card Output Hopper cover (840167)
• Removing the Back cover

• Control Panel Assembly Components
• Replacing the Control Panel Assembly Components

• Printhead Assembly Components
• Replacing the Printhead (D840854)
• Replacing the Fan Assembly (D840986)
• Replacing the Head Force Spring – 2 (840272)
• Replacing the Ribbon Deflector (D840638)

• Print Station Components replacement
• Replacing the Headlift Drive O-Rings (140212)
• Replacing the Ribbon Drive O-Ring behind the Encoder Wheel (810492)
• Replacing the Ribbon Sensor Board Assembly (140407)
• Replacing the Encoder Wheel (810492)
• Replacing the Ribbon Sensor Array Assembly (840108)
• Replacing the Ribbon Supply Motor Assembly (D840980)
• Replacing the Ribbon Take-Up Motor Assembly (D840980)
• Replacing the Headlift Motor Assembly (D840980)
• Replacing the Ribbon Supply Encoder Sensor Assembly (D840982)
• Replacing the Headlift Sensor Assembly (D840983)

• Transfer Station Components Replacements
• Replacing the Film Drive O-Rings (140212)
• Replacing the Encoder Wheel – 2 (810492)
• Replacing the Stepper Motor Assembly (840123)
• Replacing the Supply Encoder Sensor Assembly (840135)
• Replacing the Lamination Take-Up Encoder Sensor Assembly (840136)
• Replacing the Lower Film Sensor Assembly (840199)
• Replacing the Upper Film Sensor Assembly (D841023)
• Replacing the Print Platen Roller (D840811)
• Replacing the Transfer Peel Off Bar Assembly (D840698)
• Replacing the Ribbon Drive Hub – 2 (840324)
• Replacing the Transfer Station Assembly (D841083)
• Replacing the Lamination Assembly (D841085)
• Replacing the Transfer Lift Sensor (A000126)
• Replacing the Transfer Lift Motor (D840173)

• Base Module Components Replacements
• Replacing the Drive Belt – Platen Roller to Card Feed Roller (220071)
• Replacing the Drive Belt – Card Feed Roller to Card Feed Roller (220082)
• Replacing the Stepper Motor Assembly (D841045)
• Replacing the Pinch Roller Spring Plate-Front Input Side (D840865)
• Replacing the Pinch Roller Spring Plate-Front Output Side (D840865)
• Replacing the Pinch Roller Spring Plate-Back Input Side (D840865)
• Replacing the Pinch Roller Spring Plate-Back Output Side (D840865)
• Replacing the Drive Pulley – Back – 2 (D850190)
• Replacing the Gear – Card Transport -2 (760330)
• Replacing the Compound Gear (D841032)
• Replacing the Base Module (D841082)

• Card Input Hopper Components Replacements
• Replacing the Input Hopper (D841087)
• Replacing the Separator Adjustment Assembly (D840995)
• Replacing the Flipper Table Sensor Board Assembly (140407)
• Replacing the Card Low Sensor Board Assembly (140407)
• Replacing the Cleaning Roller Drive Idler Gear – 2 (760401)
• Replacing the Card Feed Gear – 3 (810271)
• Replacing the Card Feed Gear on the Card Feed Motor Assembly (850223)
• Replacing the Card Feed Shaft Gear on the Cleaning Roller Assembly (810271)
• Replacing the Feed / Encoding Motor Assembly (E000062)
• Replacing the Cleaning Roller Assembly (840102)
• Replacing the Flipper Table Position Motor (840124)
• Replacing the Card Feed Motor Assembly (D841105)
• Replacing the Flipper Table Card Sensor Assembly (D840625)
• Replacing the Card Feed Sensor (D840624)
• Replacing the Magnetic Encoder Head (840104)
• Replacing the Encoder Card Sensor (140407)

• Power Assembly Components Replacements
• Replacing the Power Switch (120011)
• Replacing the Power Cord Receptacle (130067)
• Replacing the Main Print Board (A000271)
• Replacing the Lamination Board (140402)
• Replacing the Power Supply (150240)

• Output Stacker Components Replacements
• Replacing the Output Stacker (D841079)
• Replacing the Stacker Full Sensor (140407)
• Replacing the Stacker Lift Motor (840130)

• Card Lamination Module Component Replacements
• Replacing the Lamination Module Board Cover (D870151)
• Replacing the Lamination Module Main Cover (D870159)
• Replacing the Lamination Module Main Board (A000250)
• Replacing the Lamination Module Arm Assembly (D870153)
• Replacing the Lamination Module Card Flipper Table Assembly (D870091)
• Replacing the Card Position Sensor Assembly (D870186)
• Replacing the Lamination Module Flipper Position Sensor (D870188)
• Replacing the Lamination Module Overlaminate Encoder Sensor (D870189)
• Replacing the Lamination Module Ribbon ID Sensor (820593)
• Replacing the Lamination Module Overlaminate Sensor (D870241)
• Replacing the Lamination Module Hopper Sensor Assembly (D870228)
• Replacing the Lamination Module Platen Motor (D870218)
• Replacing the Lamination Module Flipper Table Motor (D870217)

• Section 7: Packing the HDP800 Series Card Printer

• Section 8: Board Level Diagnostics
• Board Errors
• Resolving the EE Memory Error
• Resolving the EE Checksum Error
• Resolving the DRAM Memory Error
• Resolving the RAM Memory Error
• Resolving the FPGA Error

• Sensor Testing
• Reviewing the Sensor Location and Voltages
• Reviewing the Sensor Layout on Ribbon Sensor array
• Reviewing the Sensor Location and Voltages for the Lamination Module

• Section 9: LCD On-Line Menu Navigation
• Entering the LCD Menu and selecting an Option
• Selecting from the HDP800 Series Menu Option Structure Tree
• Reviewing the Printer Setup
• Preparing to Adjust the Print Offset, Transfer TOF, and Transfer EOF
• Aligning the Print Offset
• Setting the Transfer TOF
• Setting the Transfer EOF
• Adjusting the Transfer Tension
• Adjusting the Film Drive
• Adjusting the Ribbon Tension
• Adjusting the Ribbon Drive
• Adjusting the Transfer Temperature
• Setting the Flattener Temperature
• Setting the Printhead Resistance
• Adjusting the Image Darkness
• Changing the Encoder Settings
• Setting the Magnetic TOF
• Adjusting the Flipper Offset
• Adjusting the Lamination Flipper Offset
• Adjusting the LAM TOF and EOF
• Adjusting the Lamination Sensor Calibration
• Adjusting the Lamination Temperature Setting
• Show the Error Count
• Using the Show Card Count option
• System Upgrade (Firmware Upgrade)

• Section 10: Firmware Updates
• Firmware Updater Application Program
• Downloading Firmware Updates
• Updating the Printer’s Firmware
• Updating the Main Firmware
• Updating the LCD Firmware

• Section 11: FARGO Technical Support
• Contacting FARGO Technical Support

• Section 12: Reviewing Spare Parts Lists
• Reviewing Spare Parts List for HDP 800 Series Card Printer
• Reviewing Spare Parts List for Card Lamination Module

• Glossary of Terms

• Index

• Appendix A: Engineering Drawings

• Appendix B: Technical Updates

• Appendix C: Miscellaneous

✅ FILE DETAILS