RIO Pro Maintenance Manual Iss.1d

Colour ID Card Printer MAGICARD Rio Pro Maintenance Manual
Issue 2 10/12/2010
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 Standard Standard Standard Standard Standard Option Option Option Option
Ultra Electronics Card Systems
www.magicard.com
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 -
Rio Pro Maintenance Manual
-2-
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 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 -

-3-
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.

-4-
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 Anschlu des Druckers an die Stromversorgung mu sichergestellt werden, da die Gebudeinstallation mit einem
16 A-berstromschalter 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.

-5-
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
ID Card with Overcoat Layer used as a Security Watermark
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, its also reassuring to
know that because dyes sublimate instead of just being painted onto its surface,
Dye Sublimation prints resist fading and are colourfast.

-6-
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, televisions, 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.

-7-
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).

-8-
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.

-9-
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.

- 10 -
SECTION 3 COMPONENT LAYOUT

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

Connection

- 11 -
Top Cover
HoloKote/Flex
Interlock Sensor
Key Slot
Automatic Card
Adjustment
Thermal Print Card rotation

Head Unused Dye-Film Unit
Spool Holder
Top Cover Holding Latches
Print Head Cooling Fan
Print Head Assembly
Dye Film Sensor Bracket (top)
Rear Card Hopper
LCD Display
Function Buttons
Hand Feed Entry / Exit Slot
Front Card Stacker

Rio Pro component layout
(viewed from front of Printer)

- 12 -
Rio Pro component layout (viewed from top of Printer)
Print Head Roller
Rear Idle Roller
Cleaning Roller
Flipper Unit
Card Drive Roller
Dye-Film Sensor Magnetic
Bracket (Lower) Encoder Roller
Rio Pro Motors (viewed from underside of Printer)
Flipper Mechanism
Rotation Motor
Cam Motor
Flipper Mechanism
Card Feed Motor Main Stpper Direction Motor
Motor Dye Film Drive Motor

- 13 -
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.
Cards Ribbon
Full color Cards
Per Panel Part Number
or monochrome
ribbon layout
Full 300 one side only or 150

YMCKO MA300YMCKO
Colour both sides
Monochrome:
Black
Red
Blue
1000 one side only or MA1000K n
Green K
500 both sides (n = colour)
Gold
Silver
White
Scratch
Black & 600 one side only or 300

KO MA600KO
Overcoat both sides
Colour front &

250 front & back YMCKOK MA250YMCKOK
Black back
Colour front &

150 Front & Back YMCKO MA300YMCKO
colour back
Yellow (Y) Magenta (M) Cyan (C) Resin (K) Overcoat (O)
Ribbon Layout Colour Key
Included with each Dye-Film is a Cleaning Roller.

- 14 -
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.

- 15 -
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
CR80 1016 Pixels

CR79 990 Pixels
Recommended
page size for
edge to edge
CR80
printing
53.98mm or 2.125
CR79
51mm or 2.051 CR80 642 Pixels ISO Standard Cards
CR79 601 Pixels Sizes
Printable Area of Cards
CR80
85.6mm or 3.375
CR79
83.9mm or 3.303
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).

- 16 -
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.

- 17 -
SECTION 5 SINGLE / DOUBLE-SIDED UPGRADE.

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.
3. Close the Lid and

connect power to
the machine.
2. Fit the upgrade Film into

the Printer.
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.

- 18 -
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: +44 (0) 1305 762115

Fax: +44 (0) 1305 777904
E-Mail: support@magicard.com
USA: Tel: +1 425 556 9708

Fax: +1 425 556 3962
E-Mail: ussupport@ultraMagicard.com

- 19 -
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.

- 20 -
Applicability
The warranty and remedy provided above are exclusive and in lieu of all other warrants, either expresses or implied,
including but not limited to, implied warranties of merchantability and fitness for a particular purpose. Any statements or
representations made by any other person or Firm are void.
Neither Ultra Electronics Ltd. nor its affiliates shall be liable for any loss, inconvenience, or damage, including direct,
special, incidental, or consequential damages, resulting from the use or inability to use the Ultra product, whether
resulting from breach of warranty or other legal theory even if Ultra has been advised of the possibility of such damage or
loss.
This warranty is governed by the laws of England. Any dispute arising out of or relating to this warranty shall be
submitted for arbitration of this dispute or disputes pursuant to the rules and regulations of the UK Arbitration Act.
This warranty gives you specific legal rights, and you may also have other legal rights that vary from country to country so
the above limitations and exclusions may not apply to all Customers.
For warranty enquiries please call or fax our Customer Support Manager: -
Ultra Electronics Limited

MAGICARD Service Centre
Waverley House
Hampshire Road
Granby Estate
WEYMOUTH
Dorset, DT4 9XD, U.K.
Tel: +44 (0) 1305 784738
Fax: +44 (0) 1305 777904
SECTION 6.3 INTERNET SUPPORT

To further enhance the support already available to Magicard Customers, the Magicard Web site contains useful
information on both problem solving and operation of the Rio Pro Printer. The web site is available 24 hours per day at
www.magicard.com
SECTION 6.4 RECOMMENDED TOOLS

The following tools are recommended to support the Magicard Rio Pro in the field:
IBM PC or IBM Compatible Clone:
Pentium 600 MHz or faster (with USB support)
128 MBytes memory or higher
10 Gigabyte Hard Drive
8 speed CD ROM or faster
SVGA monitor with greater than 800 x 600 screen resolution.
Recommended PC Software:
Microsoft Windows software (Win 2000 onwards).
Rio Pro Windows Driver (preferably version 1.6.5.0 or later).
Magicard Support Utility SIN1926 (loaded separately via the Driver CD).
Graphics program such as Corel Draw, Photopaint or Paint Shop Pro.
Microsoft Office.
Badge Printing Application.
Engineers Tool Kit:
Anti-static wrist strap
Pozi blade screwdriver, preferably 150mm long or greater.
Torx Driver Size 10.
Long nosed pliers.
Multimeter or DVM.

- 21 -
SECTION 7 CLEANING THE PRINTER.

SECTION 7.1 CLEANING IS IMPORTANT
The most important procedure you can do to ensure Card print quality and the ongoing reliable operation of your Printer is
to perform regular cleaning cycles to remove dust and debris from the print rollers.
Plastic Cards attract dust. Dust then gets printed into the Card surface causing unsightly blemishes and possible
damage to the Print Head.
Your Magicard printer has built-in cleaning rollers to remove dust from the Card stock. These rollers need to be cleaned
periodically to remove the dust and debris accumulation.
Cleaning is Easy and Inexpensive
If you have not already done so, order a Cleaning Kit see the Cleaning Supplies Section 7.2.
A clean Printer produces better quality Cards, as dust and dirt are not present when the Card is being printed.
A clean Printer is far less likely to require factory maintenance, and the Print Head in your Printer will last for many years
of normal use. Remember, large particles of dirt can damage the Print Head.
Magnetic Encoding degrades when rollers are not clean as the Card does not move smoothly.
The Magicard Cleaning System
There are three main steps to your Printers cleaning system - a Cleaning Card, a Cleaning Roller and a Cleaning Pen:
1. A Cleaning Card is used to remove dirt from the print path. This should be used after
every 350 prints (every time you replace your ribbon). If you print only a few Cards a
day, we recommend that you clean the Printer more often.
2. There is a disposable Cleaning Roller in the Printer, which should be replaced after
every 1000 prints (approx. after using 3 rolls of ribbon). One cleaning roller is provided
with a new roll of Dye Film
3. There is also a Cleaning Pen, which is used to clean the Print Head. We recommend
you use this if any lines or discolorations are seen on printed Cards.
Follow the instruction on page 23 for how to clean the Printer.
SECTION 7.2 CLEANING SUPPLIES

Three Cleaning Cards and a cleaning roller are included with each new Rio Pro and Rio Pro Duo Printer. You can
purchase additional Cleaning Kits, which include cleaning Cards, rollers and pens.
Cleaning Kits
Part Number 3633-0053 (10 cleaning Cards, 5 rollers and a cleaning pen).
Part Number 3633-0054 (Cleaning Roller Kit 5 sleeves and 1 Roller Bar).

- 22 -
SECTION 7.3 CLEANING THE PRINTER ROLLERS

Step 1: Using the Cleaning Card.
We recommend that you clean your Printer using a cleaning Card after every 300 prints or each time you replace the
Dye-Film. You should do this more often if you print only a few Cards a day.
Please note: the Cleaning Card is soaked in Alcohol. Do not open the packet containing the Cleaning Card until ready to
use.
1. Select Menu option [1. Clean rollers], press [Ok] and follow the on-screen instructions:-
2. [Remove the Cards !] lift out the (rear) feed Hopper and then press [Next].
And [Remove film] open the lid and lift out the Dye-Film.
Leave the Lid open and press [Next].
3. [Ready to clean ?] - Take a new Cleaning Card from its packaging and then press [Yes].
4. [Insert Cleaning Card into slot] when prompted, place the narrow end of the Cleaning Card into the front Card
feeder slot.
The Card will automatically enter the Printer and the rollers will be cleaned.
When the cleaning cycle is finished, the Cleaning Card will be ejected.
[Clean again ?] for maximum cleaning effect it is recommended that you turn the Cleaning Card over and select [yes],
then repeat Step 4.

- 23 -
SECTION 7.4 REPLACING THE CLEANING ROLLER

Step 2 Fitting a new Cleaning Roller.
The Cleaning Roller is integral to the Media Preventer We recommend that this Cleaning Roller is replaced at least every
700 prints or sooner when a new Film is fitted.
1. Open the Printer lid and remove the used Dye-Film. Pull out the used cleaning spool.
2. Remove the central roller bar
3. Slide the central roller bar through the middle of the new cleaning roller.
4. Carefully remove the protective layer to reveal the sticky surface.
5. Place the new cleaning roller into the Printer.
1
5
4
2
3
Please Note: If the steel shaft from the cleaning Roller becomes lost, a replacement can be obtained by ordering a
Cleaning Roller Kit (Pt. 3633-0054) See Section 7.2

- 24 -
SECTION 7.5 CLEANING THE PRINT HEAD.

Step 3 Cleaning the Print Head.
The Print Head should be cleaned if any lines or discolorations are seen on printed Cards.
It is also a good idea to clean the Print Head when you replace the ribbon.
1. Use the special Print Head cleaning Pen from your

Magicard printer cleaning kit. See Section 6.1
Cleaning Supplies.
2. Open the Printer and draw the Pen several

times across the complete length of the
Print Head.
Please Note: The Print Head becomes hot during printing so the Cleaning Pen may need to be drawn along the face of
the Print Head several times.

- 25 -
SECTION 8 MAGICARD RIO PRO DRIVER.

Rio Pro and Rio Pro Duo use the new UltraDriver+. This Driver is for use on the following Operating Systems only:
Windows 2000 & Windows XP

Windows 2003 Server.
Windows Vista (32 and 64 bit).
Windows 7 (32 and 64 bit).
Please Note: Windows 3.11, 95, 98, ME, and NT are not supported.
SECTION 8.1 INSTALLATION INSTRUCTIONS FOR WINDOWS 2000/XP/2003 SERVER & VISTA
Ensure the Printer is powered off.
Load the Driver CD ROM into the PC you have connected to the
Printer.
If the CD does not run automatically, click the Start Button, then
click on run. Type D:\autorun (where D is the drive letter for
your CD drive), then press the Return key.
Choose the language you wish to use.

- 26 -

- 27 -
SECTION 8.1 INSTALLATION INSTRUCTIONS FOR WINDOWS 2000/XP/2003 SERVER & VISTA
AND WINDOWS 7 CONTINUED
Ensure the Printer is switched on and showing Ready on the front LCD display. The Printer can now be connected to
the PC.
Windows 2000 / XP /
2003 Server view
Windows Vista
Windows 7
NOTE
If the computer you are configuring for a USB connection to the Magicard Printer has
at some time run another manufacturers Printer (e.g. Eltron C-Series printer), a
Windows file necessary for the Magicard installation could be missing.
(The symptoms of this are that the computer does not seem to detect the Printers USB connection, and the
Test Page fails to print).
Recover the file as follows:-

Navigate to c:\windows\inf (Windows XP) or c:\winnt\inf (Windows 2000).
Find the file named usbprint.in, and then rename it to usbprint.inf.
Reconnect the USB cable.

- 28 -
SECTION 8.2 UN-INSTALLING THE DRIVER FOR WINDOWS 2000 / XP / 2003 SERVER.
Ensure the Printer is disconnected.
Then select Add or Remove
Programs
On the PC, go to Start >>
Control Panel

Classic view
or

Category
view
Select the Magicard RIO Pro entry,

and click on Change/Remove
Choose the Magicard RIO Pro you wish

to remove (there may be more than one),
and click Next
Lastly - follow the on-screen prompts !

- 29 -
SECTION 8.3 UN-INSTALLING THE DRIVER FOR WINDOWS VISTA / WINDOWS 7.
Ensure the Printer is disconnected.

.

or Classic view

Choose the Windows Logo Category View choose

Button followed by Control Uninstall a program......
Panel
Category
view
Classic View choose

Program and Features......
Select the Magicard Rio Pro

Printer and the choose the
Uninstall / Change Button
Follow the instructions on the

screen

- 30 -
SECTION 8.4 DRIVER DESCRIPTION
Understanding each individual Printer Driver setting:
The Printer Driver contains a built-in help file (in HTML format)
this file gives an excellent, clear explanation of each Driver setting.
To view the Drivers help file, go to the Printer Preferences

(as described above), and click on the Help Button
in any of the Tabs.

- 31 -
SECTION 9 PRINTER DISPLAY

The front display panel has a text display and 4 push buttons. These buttons act as soft buttons i.e. their function
varies depending on the text displayed immediately above each button.
Text Display
Menu select
Buttons
Off Button
Switches the Printer off.
To switch the Printer ON
again press any Button
SECTION 9.1 MENU OPTIONS
Press the Menu button

The first menu option will be displayed.
Press the > button (where indicated) to

step through each option in the menu
The following menu options will be displayed:
1 of 6 Clean rollers
2 of 6 Test card
3 of 6 Info
4 of 6 Hand feed
5 of 6 Mag self test
6 of 6 Reset printer
Options 1-6 are explained on Page 32

- 32 -
SECTION 9.1.1 1. CLEAN ROLLERS
IMPORTANT: To prevent the Cards slipping on the Rollers during Printing, we recommend that you clean the Printer
using a Cleaning Card each time the Dye-Film roll is replaced.
SECTION 9.1.2 2. TEST CARD
Follow the procedure below to clean the Card transport rollers in the Printer.
Having selected this option, you will be asked to confirm that you wish to
print a Test Card.
If you select Yes the Printer will feed a Card from the Hopper and print
an internally generated Test image on it.

- 33 -
SECTION 9.1.3 3. INFO
This option provides you with information about the Printer.
Step into each option

using the right-most
arrow button.
SECTION 9.1.4 4. HAND FEED
Use this section to switch the Printer between Automatic Card Feed (Card feeder at the rear) or Hand Feed (front slot).
OFF This is the default setting. Cards will be fed automatically from the
Card Hopper.
ON At the start of each print, the Printer will request you to feed a Card V
through the Card Feed slot in the front of the Printer.
NOTE: Cards will NOT feed from the Card Hopper.
Once the desired mode is selected press the SAVE Button.
Use the arrow keys to toggle

the mode between ON and
OFF

- 34 -
SECTION 9.1.5 5. MAG SELF TEST
Select YES on this option, if you wish to test the magnetic encoding
option of the Printer.
You will be asked to confirm that you wish to encode and print a Test
Card.
If you select the YES option (arrowed), the Printer will feed a Card
from the Hopper, encode the magnetic stripe and print an internally
generated test image on it.
NOTE: If your Printer does NOT have a magnetic encoder fitted, it will be unable to perform this test and will instead
display the message:- Mag not fitted!
SECTION 9.1.6 6. RESET PRINTER
Selecting this option (Yes) will force the Printer to re-initialise (the same effect would be seen if the Printers DC Power
cable were removed and refitted).

- 35 -
SECTION 9.2 MAINTENANCE MODE
The Maintenance Mode allows the User to check the functionality of the Printer. Each electronic Sensor can be checked
individually. Image Start/End positions and the Dye-Film sensing system can be calibrated.
It is accessed by opening the Lid and holding down the Menu Button for 3 seconds.
Press and hold for

three seconds
SECTION 9.2.1 SOAK TEST MODE
The Soak Test mode moves every mechanical part of the machine, including the Print Head cooling Fan. A blank Card
will be needed and inserted from the back. Remove the front and rear Card Hoppers.
CAUTION Do not fit Dye-Film into the Printer during the Soak Test mode. The Dye-Film motor is advanced
during the cycle. The Dye-Film drive Gear will be damaged when the Dye-Film has been fully used
and Dye-Film will be wasted.

- 36 -
SECTION 9.2.2 SENSOR TEST MODE
C = Print head Up/Down

T = Tacho Sensor (film movement)
k = Dye Film Sensor
L = Top Cover Sensor
f = Front Card Sensor
m = Middle Card Sensor
r = Rear Card Sensor
P = Left Hand Function Button
p = Right Hand Function Button
s = Chip Contact Position Up/Down
Each of the above letters represents a

Sensor or Button within the Printer.
The state of each Sensor or Button will
toggle btween X and 0 according to the
current status of the Printer.
The colour of the Printers Display will
change to purple.
During the Cam Sensor test, the

value above will toggle between
X and 0.
The colour of the Printers
Display will change to purple.
The values shown above are

those measured by the Dye-Film
Sensor for each Film Panel.
The colour of the Printers
Display will change to purple.
The Sensor Test mode is a useful diagnostic Tool when Sensors in the Printer may be suspect.

- 37 -
SECTION 9.2.3 PREVIOUS MENU
Exit out of the Maintenance Menu

- 38 -
SECTION 10 PRINT HEAD REPLACEMENT

This section describes what action to take if you have to replace the Print Head in the Rio Pro/Rio Pro Duo Printer.
SECTION 10.1 PRINT HEAD DAMAGE.

Dust or contamination on the Card or Dye-Film is dragged below the Print Head. This causes scratches and permanently
damages the printing surface.
Print Head
Dye-Film
contaminant
such as sand.
Card
The contaminant imbeds

Print into the PVC surface and
direction is dragged into the print
head.

- 39 -
SECTION 10.2 PRINT HEAD ELECTRONIC FAILURE.
If an internal electronic component has failed inside the Print Head, this causes the printing elements to switch on or off
continuously. The Cards below show examples of electronic failure.
The Cards below show examples of electronic failure.

- 40 -
SECTION 10.3 REPLACING THE PRINT HEAD.
CAUTION The following procedures involve contact with Electrostatic Sensitive Devices. All precautions for
handling Electrostatic Sensitive Devices should be followed at all times, including the use of a grounded
wrist strap.
Start
Switch the 2
Printer Off !
Press any Button to

switch the
Printer On !
Remove
Connector
Re-connect
the new Print
Head
Push backwards
then tilt upward
1
Fit the new

2 Print Head
1
2

- 41 -
SECTION 10.4 SETTING THE PRINT HEAD DENSITY CALIBRATION.

CAUTION The Print Head Density Programmer (PDP) is calibrated to suit the Print Head that it is supplied with. It
will not be suitable for any other Print Heads and therefore should only be used for a specific Print
Head Assembly.
Finished

Open the
Printer Lid
Press any Button to

switch the
Printer On !
Close the
Printer Lid
Print Head Density

Programmer (PDP)

- 42 -
Section 10.5 Print head setup and adjustment

Before leaving the factory, all Thermal Print Head assemblies are set to give optimum performance and uniform colour
output.
Occasionally, due to differences in tolerances between Printers, adjustments may be required.
The Print Head angle can be varied by a few degrees either side of vertical. This adjustment is necessary because the
heater elements vary slightly on each Print Head. The position of each Print Head must be optimised to ensure the correct
thermal transfer through the Dye-Film onto the PVC Card. Once the Print Head angle is correct, the density may need to be
adjusted.
NOTE Failure to have the Print Head angle setup at the optimum position may cause the Dye-Film to wrinkle
and break. Cards may also look washed out with unsightly marks across them.
The best type of image for ensuring the Print Head angle is setup at its
R=128
optimum position is a mid grey Card (R=128, G=128 and B=128) design. It G=128
should be a constant colour with no texturing or gradients. A Card of this B=128
design can be created in any graphical design package or even MS Word.
NOTE It is advisable to start the Print Head setup procedure with the Print Head angle slightly negative. It can
then be slowly adjusted more positive.
Adjusting the Print Head.

Print a test Card from your Application and analyse the result (refer to analyzing
Test Card).
Open the top cover and locate the Print Head Assembly.
Adjustment screw is located directly above the electrical connector in the centre
of the metal framework (see right, arrowed).
Should the test print be too positive, adjust the Print Head angle by
turning the adjustment screw clockwise.
Should the test print be too negative, adjust the Print Head by turning the
adjustment screw anti-clockwise.
Carry out a further test print. Adjust as necessary to achieve the optimum
setting.
Analysing the test Card
Print Head Angle too negative

Front end of the Card will show faded colour.
The image will be lighter at the front end of
Correct Print Head Angle

Image is printed with uniform colour across
the complete Card. There is little or no
variation across the Card.
Print Head Angle too positive
Rear end of the Card will show wrinkling or
Dye Film overheating. The rear of the Card
the Card. The front of the Card is the edge is the edge that ejects out of the Printer last.
that ejects out of the Printer first.

- 43 -
SECTION 11 DISMANTLING AND ASSEMBLING THE PRINTER

The Magicard Rio Pro and Rio Pro Duo Printers have been designed with a modular construction to make servicing and
repair of the Printer very easy.
The following guidelines show you how to change the middle Card Sensor which is the most difficult component to replace.
All other parts can be exchanged following this procedure.
SECTION 11.1 REMOVING & REFITTING THE PRINTER CASING.
Removing & Refitting the Printer Casing.
1. Remove the front and rear Hoppers. Remove the Dye-Film.
2. Working below the Printer, gently move the two front plastic catches outwards in the direction shown above.
3. You can now lift the front end of the Printer out of the case, tilting it backwards. This will then release the two rear plastic catches and allow the
complete print engine to be removed.
Refitting is the reverse sequence. Locate the connector panel and carefully line up the two rear plastic catches first and lower the print engine into
place.
The front catches will locate and click into place (ensure no wires are trapped).
SECTION 11.2 REMOVING & REFITTING THE FRONT FASCIA COVER
Removing & Refitting the Front Fascia
1. Remove the Printer casing as described in Section 11.1.
2. The front fascia can now be removed by pulling the front fascia away
from the main print assembly. (Take care to retain the white Button
covers).
3. The two securing plastic catches are inside the area where the
printed Card collector sits.
4. The LCD display remains attached to the main print assembly.
Refitting is the reverse sequence. Ensure the LCD Display wires are not
trapped between the fascia and print engine.
Refit the Printer casing as described in Section 11.1.

- 44 -
SECTION 11.3 REMOVAL & REFITTING OF THE TOP DYE FILM SENSOR
wrist strap.
Removal & Refitting of the Top Dye Film Sensor
1. Remove the Print Head Assembly as described in Section

10.3.
2. Disconnect the two wiring connectors attached to the

sensor PCB, one is the Sensor and the other is the
cooling Fan. Ensure they are re-connected back the
same way.
3. Unclip the sensor PCB and remove.
Refitting the new Sensor is the reverse procedure.
Top Dye Film

Sensor PCB
SECTION 11.3 REMOVING & REFITTING OF THE LOWER DYE FILM SENSOR.
wrist strap.
Removal & Refitting of the Lower Dye-Film Sensor
1. Gently pull upwards the plastic cross piece that encloses the lower Dye-Film Sensor
in place, it is clipped into the plastic Side Plates.
2. Turn the plastic cross piece over and disconnect the Sensor cable from the small
PCB.
3. Sensor PCB can now be unclipped from the plastic cross piece.
Refitting is the reverse procedure ensuring the plastic cross piece is located into the Side
Plates.

- 45 -
SECTION 11.4 REMOVAL AND REFITTING OF THE CARD THICKNESS ADJUSTER
Spring fits between

moulded plastic
parts.
Removal & Refitting of Card Thickness Adjuster
1. Remove the cleaning roller and the rubber cleaning / feed roller below it.
2. Remove the return spring from the plastic locating pin from the back of the Printer.
3. The complete plastic Assembly will be loose, unclip from the plastic Side Plates and
withdraw from the Printer.
Refitting is the reverse procedure. Locate the assembly into position and refit the return
spring into position.
SECTION 11.5 REMOVING & REFITTING THE CONTROLLER PCB.

wrist strap.
Removal & Refitting the Controller PCB
1. Disconnect all the wiring from around the outside edge

of the Controller PCB.
Take care not to damage the small PCB connctors.
2. Unclip the four plastic catches and remove the

Controller PCB downwards.
3. On Rio Pro and Rio Pro Duo Printers with the Magnetic
Encoding and OmniKey options an extra PCB will need
to be disconnected, it is mounted onto the main
Controller PCB.
4. The plastic moulding around the USB and power

connector will also fall away.
Refitting is the reverse procedure ensuring the plastic

molding is around the USB and power connector is included.

- 46 -
SECTION 11.6 REMOVING & REFITTING OF THE FRONT & REAR CARD SENSOR
Card Sensor locations in the Rio Pro

(Printer viewed from underside)
Front
Middle Card Sensor cannot be

removed at this point, refer to
Section 11.16 to remove
Rear Mid Front

Removal & Refitting of the Front & Rear Card Sensor
1. Working inside the printing compartment the front and rear Card Sensor plastic clips can be released. The plastic clips are situated adjacent to
the Card path at the front and rear of the printing area.
2. Withdraw the two plastic clips and Card Sensors from underneath the machine. The Card sensor PCBs can now be disconnected from the
wiring.
Refitting is the reverse procedure.
SECTION 11.7 REMOVING & REFITTING THE LCD DISPLAY

wrist strap.
Removing & Refitting the LCD Display.
1. Disconnect the electrical connections to the printers front LCD (Liquid Crystal Display).
2. LCD is held in position by the plastic catch (arrowed above, right) in the centre of its top edge. Gently push upwards and remove the
LCD from the main print engine.
Refitting is the reverse procedure.

- 47 -
SECTION 11.8 REMOVAL & REFITTING OF LEFT SIDE COMPONENTS

CAUTION The Plastic Drive Pulleys attached to any of the Motors are designed to be push-fit and used only once.
Magicard highly recommend new Pulleys are fitted if they are disturbed. Once pushed onto the motor
shaft, the plastic deforms to produce a tight fit.
Tacho and Sensor System
1. Carefully withdraw the Tacho Wheel plastic cover from the side of the Printer. There Ensure long groove
is a spring behind so ensure it is removed slowly (not shown here). on pulley aligns with
2. The Tacho wheel can now be removed but it will also have to be tilted away from the plastic pin (arrowed)
Tacho Sensor.
3. Tacho Sensor can be removed by unclipping the outer plastic housing and sliding
the Sensor outwards.
Refitting is the reverse procedure but ensure the Tacho wheel passes through the
Tacho Sensor before fitting the plastic cover
Print Head Cam System Flipper Rotation System.
1. Cam Position Sensor can be removed by unclipping the 1. Flipper Position Sensor can be removed by unclipping the
outer plastic housing and sliding the Sensor outwards outer plastic housing and sliding the Sensor outwards
(ensure the Pulley is rotated to the correct position). (ensure the Pulley is rotated to the correct position).
Refitting is the reverse procedure. Refitting is the reverse procedure.
2. Drive Belt can be removed by sliding it off the outside of the 2. Drive Belt can be removed by sliding it off the inside of the
Cam Shaft Pulley. bottom Pulley. It can then be removed from the top Pulley.
3. Small Pulley can pulled from the DC Cam Motor shaft. 3. Large Pulley can be removed by carefully removing the
Refitting is the reverse procedure but a new Pulley is small silver Star Washer. Refitting is the reverse
essential unless glued into position. procedure.
4. Small Pulley can pulled from the Stepper motor shaft.

Remove the spring washer by bending the release Tabs
outwards. The spring washer cannot be re-used after this.
Refitting is the reverse procedure but a new pulley is
essential unless glued into position.

- 48 -
SECTION 11.9 REMOVAL AND REFITTING OF RIGHT SIDE COMPONENTS

CAUTION The Plastic Drive Pulleys attached to any of the Motors are designed to be push-fit and used only once.
Magicard highly recommend new Pulleys are fitted if they are disturbed. Once pushed onto the motor
shaft the plastic deforms to produce a tight fit.
The following procedures involve contact with Electrostatic Sensitive Devices. All precautions for
wrist strap.
Flipper Drive System.

RFID PCB & Top Cover Sensor
1. Drive Belt can be removed by sliding it off the inside of the bottom Pulley. It can then be removed
from the top Pulley. 1. Cam Position Sensor can be
Refitting is the reverse procedure. removed by unclipping the outer
plastic housing and sliding the Sensor
2. Large pulley can be removed by first removing the small silver Star Washer. outwards.
3. Small Pulley can removed from the Stepper motor shaft. Remove the spring washer by bending 2. Remove the RFID PCB plastic cover
the release tabs outwards. The spring washer cannot be re-used after this. and slide PCB outwards
Refitting is the reverse procedure but a new pulley is essential unless glued into position. Refitting is the reverse procedure.
Card Drive System. Card Feed System.
1. Remove the spring washer holding the large pulley in place then 1. Slide the drive Belt off the top Pulley the remove completely from
slide the Pulley off the roller shaft. Drive Belt can also be the bottom Pulley.
removed. Refitting is the reverse procedure.
Refitting is the reverse procedure ensuring a new spring washer
is used. 2. Top Pulley is removed by depressing the locking Tabs in the
centre of the roller shaft. Slide the pulley outwards and remove.
2. Remove the spring washer holding the small Pulley in place then Refitting is the reverse procedure.
slide the small Pulley from the main Stepper motor shaft.
Refitting is the reverse procedure ensuring a new spring washer 3. Bottom pulley can be removed by sliding it outwards off the DC
is used. motor.
Refitting is the reverse procedure but it is essential a new Pulley
3. Idle tension roller pressure can be released then the large drive is used unless it is glued into position.
Belt removed. Note how the belt is fitted and which Pulleys it fits
around.
Refitting is the reverse procedure then release the idle roller to
tension the Belt.
4. The individual roller drive Pulleys can now be removed by either

depressing the retaining tabs on the shafts or releasing the
spring washers. Slide the Pulleys outwards.
Refitting is the reverse procedure ensuring new spring washers
are used.

- 49 -
SECTION 11.10 REMOVAL & REFITTING OF THE DRIVE MOTORS & FRONT CARD SENSOR.
Card Feed Motor.
1. Disconnect the motor connections.
2. The motor is held in place by two screws,

remove these screws.
3. Remove the motor out through the bottom of

the print engine.
Refitting is the reverse procedure ensuring the

motor aligns with the screw holes.
Card Drive Flipper Motor. Card Drive Motor.
1. Disconnect the motor connector. 1. Disconnect the motor connector.
2. The motor is held in place by two screws, remove these screws. 2. The motor is held in place by two screws through elongated
holes. The elongated holes provide movement for Belt tension.
3. Remove the motor out through the bottom of the print engine. Remove these screws.
Refitting is the reverse procedure. Record where the Motor screws are 3. Remove the motor out through the bottom of the print engine.
fitted. Replace these screws in the same holes.
Refitting is the reverse procedure but leave the screws loose until the
main drive Belt is fitted and tensioned.
Cam Motor. Card Rotation Motor.
1. Disconnect the motor connections. 1. Disconnect the motor connector
1. The motor is held in place by two screws, remove these screws. 2. The motor is held in place by two screws, remove these
screws.
2. Remove the motor out through the bottom of the print engine.
3. Remove the motor out through the bottom of the print engine.
Refitting is the reverse procedure ensuring the motor aligns with the
screw holes. Refitting is the reverse procedure.

- 50 -
SECTION 11.11 REMOVAL OF THE CHASSIS COVER
The Chassis cover can be removed from the main print engine however there are no user replaceable parts inside.
Chassis Cover Removal
1. Release the front lid catch so the lid is partially open.
2. Release the plastic locking Tabs arrowed directly above.
3. Lift the complete chassis cover upwards away from the print engine.
4. Remove the wire loom from the left hand side of the Printer (note its route
through the chassis).
Refitting is the reverse procedure ensuring no wires are trapped and the Lid opens
and closes freely.

- 51 -
SECTION 11.12 REMOVAL OF THE ROTATION UNIT
Rotation Unit Removal
1. With the Pulleys removed as outlined in Sections 11.7 and 11.8.
2. Remove the white plastic Bushes (holding the Flipper Shaft) from each side .
3. Complete Rotation Unit can now be lifted out the front end of the Printer.
Refitting is the reverse procedure, drop the rotation unit into position ensuring the correct orientation and then fit
the Bearing Plates.
SECTION 11.13 REMOVAL OF THE IDLE ROLLERS
Removing the Idle Rollers
1. Remove the Idle Link Plate springs located centrally above the Idle Link Plate from each side
of the print engine.
2. Lift and withdraw the left and right Idle Link Plate from each side of the Printer.
3. Remove the Idle Rollers from inside the Printer.
Refitting is the reverse procedure; lay the Idle Rollers inside the print engine. Locate one of the Idle
Link Plates, align the Idle Rollers and then locate the opposite Link Plate. Springs can be located
and fitted into place.

- 52 -
SECTION 11.14 REMOVAL AND REFITTING OF THE LARGE BEARING PLATE
Removing the Large Bearing Plates
1. Ensure all remaining Spring Washers are removed for the metal roller shafts.
2. Working underneath the printer release the four left and right plastic catches
holding the bearing plates in position.
Refitting is the reverse procedure ensuring Cam and roller shafts are located in the
correct holes. Ensure the bearing plate with the idle roller fitted is located on the right
side of the Printer.
SECTION 11.15 REMOVAL AND REFITTING OF STEEL CIRCLIPS
Steel Circlips are used throughout the Rio Pro (including the mounting of the
Large Bearing Plate).
When Removing and refitting these, always wear approved eye protection.
WARNING Personal injury could result if the appropriate safety measures are not followed.

- 53 -
section 11.16 Removal and refitting of rollers

Removal & Refitting of Rollers
1. Once the bearing plates have been removed the

rollers can be removed out the bottom of the Printer.
Roller layout is shown below including the attached
drive Pulleys.
2. Cam linkage can also be removed but ensure both

corresponding parts are kept together to avoid
confusion when refitting.
Refitting is the reverse procedure ensuring the Cam

linkage is correctly orientated.
SECTION 11.17 REMOVAL & REFITTING OF THE CARD GUIDE & MIDDLE CARD SENSOR
Removal & Refitting of the Card Guide
1. Remove the two return springs from either end of the Card guide. Parts of the
springs are inside the Card guide plastic assembly
2. The guide will be loose, push it against the internal side wall and lift up out of the
machine.
Refitting is the reverse procedure, located the Card guide and then fit the springs.

- 54 -
SECTION 12 TROUBLESHOOTING
Introduction
This Section is intended as a quick Reference Guide to assist Magicard Rio Pro and Rio Pro Duo user and Dealers when
experiencing difficulties with their Printer. The information below covers most common problems that will be encountered;
compiled from the Magicard Technical Support Helpline records.
Technical Support Web Pages
If having tried all the solutions suggested in this guide, you are still having problems with your Printer, please visit the
Technical Support pages of the Magicard Website at www.Magicard.com you will find lots of technical information and
FAQ help.
Problem Analysis
Follow the Tables and select the problem and the path that most resembles the issue that you are experiencing.
SECTION 12.1 INITIALISATION SEQUENCE
The following section describes the sequence of events that occur when the Rio Pro is powered on. It also describes any
errors that may occur and how to rectify them.
Power the Printer On
Possible Errors.
1. Nothing Happens:
Check external Power Supply connection into the back of the Printer. Is
Main Controller PCB is Initialised. the green indicator on the external PSU on ?
1. Microprocessor boots up 2. LCD is on but information corrupted:
2. Flash Memory is checked. Microprocessor has failed to start, replace controller PCB.
3. Printer Firmware copied into DRAM. 3. Lid Open Error:
4. I/O Status Checked When the lid Sensor is disconnected the Printer will still initialise.
5. Hardware Begins to initialise. However if the lid Sensor has broken or moved the error will be shown.
Print Head is cycled Up and Down. Possible Errors.

1. Cam Motor is rotated. 1. Continuous Motor Noise is heard:
2. Belt and Pulley system drives a Cam Shaft. Cam motor is rotating continuously, check Pulley and Drive Belt
3. Optical Sensor reads Cam motor position. mechanism.
4. Cam Shaft drives Cam followers. Check Cam Opto Sensor is functioning (see section 9.2.2 Sensor Test).
5. Print Head is moved Up and Down. 2. Error on display RFID PCB Missing:
Dye Film RFID controller is disconnected, check the wiring connections
Dye Film. Possible Errors.

1. Dye Film motor rotates slightly to tension the ribbon. 1. Card or Ribbon is trapped in Printer mechanism:
2. Dye Film is tensioned to prevent it being trapped if a No Sensors are used at this point of the initialisation cycle. The Tacho
Card is stuck in the Printer mechanism. wheel should rotate clockwise (viewed from left hand side) a small
3. No information about the Dye Film is read at this amount to tension the ribbon. If there is no movement then the Dye-Film
point. may have run-out or Film take-up motor has a problem/disconnected.
Flipper Unit. Possible Errors.

1. The Flipper Unit is rotated by the Flipper Stepper 1. Flipper Error 18:01:
Motor. Check the flipper mechanism is not obstructed by a Card.
2. Flipper Unit Position Optical Sensor reads the Flipper mechanism is initialised using an optical Sensor on the left side of
position the Printer at the front. Check connections and functionality using the
3. Flipper Unit should now be horizontal Sensor test (see section 9.2.2).
Flipper mechanism Drive Belts can be checked.
Card Eject. Possible Errors.

1. Any jammed Cards are moved forward to the front 2. Flipper Card Jam 04:07:
optical Card Sensor. The front Sensor is blocked or not working, check the Sensor
2. Flipper is rotated so it is aligned with the Card feed functionality or wiring using the Sensor test (see section 9.2.2).
mechanism. 3. Flipper Card Jam 04:11:
3. Trapped Card is ejected out the front of the Printer. A trapped Card has not passed through the front Sensor, into the Flipper
mechanism before ejecting out the front. Check the Flipper mechanism
Card drive motor and Drive Belt. This can be found on the right hand
side of the Printer at the front.
Printer Ready 4. Card Inside is not ejected, no errors are seen.
Use the cleaning cycle to check if the internal rollers are rotating. If not
then the main Drive Belt may have fallen off (right hand side of Printer).

- 55 -
SECTION 12.2 HARDWARE PROBLEMS
Problem Probable Causes Possible Solutions Reference Section
1. Separate the Cards to remove the

static
1. Cards are stuck together with static. 2. Clean the Printer using the
1. Section 4.2
Cards are not being taken from the 2. Card feed roller may be dirty and not recommended Magicard Cleaning
2. Section 7
Card holder at the back. gripping the Cards. Cards.
3. Section 16.8
3. Card feed roller is not rotating 3. Remove the base and check the
integrity of the Roller, Drive Belt
and motor.
1. Replace Controller PCB or PSU if

1. Loose PSU connection on the back of necessary, call Magicard Technical
Printer switches off automatically
the Printer. Support. 1. Section 6.1
after a period of time.
2. Faulty external PSU. 2. Replace PSU, call Magicard
Technical Support.
1. Ensure the Flipper Unit

1. Drive pulley or Belt has become components are fitted correctly.
1. Section 11.8
detached. 2. Ensure the rotation position Sensor
Cards are jamming in the Flipper 2. Section 9.2.2 &
2. Sensor is not positioning the Rotation is connected and functioning
Unit. 11.8.
Unit correctly.
3. Section 18
3. Early Firmware version. 3. Ensure the Printer has the latest
Firmware installed.
1. Ensure the Cam components are

all fitted correctly on the left side of
the Printer.
Error Cannot lift Head when the 1. Print Head is not being cycled Up/Down 1. Section 11.8
2. Check the operation of the Cam
Printer is switched on. when the Printer is switched on. 2. Section 9.2.2
Position Sensor.
3. Check the correct Power Supply is
used.
1. Ensure the Cam components are

all fitted correctly on the left side of
the Printer.
Error Cannot Drop Head during 1. Print Head is not being moved Up/Down 2. Check the operation of the Cam 1. Section 11.8
printing. during the printing process Position Sensor. 2. Section 9.2.2
3. Check the correct Power Supply is
used.
4.

- 56 -
SECTION 12.3 IMAGE PROBLEMS
White line along the length of the

1. The Print Head has some damaged
Card. Line is always in the same 1. Print Head will have to be replaced. 1. Section 10
heating elements.
place on every Card.
1. Clean the rubber Rollers in the

1. Card is being positioned in slightly
Mis-registration of colours, (3D Printer.
different positions for each colour pass. 1. Section 7
effect, ghosting of colours and 2. Slipping Drive Belt.
Black Text and Overcoat are not 2. Section 11.9
blurring). 3. Card Print Drive Motor belt tension
affected.
loose.
1. Ensure the Page Layout/Setup is

1. Incorrect page size set in the printing
taken from the installed Rio Pro
White margins at one or both ends Application.
Driver. 1. Section 4.2
of the Card > 5mm. 2. Image Size is not large enough to
2. Image size must be 1016 pixels
completely fill the Card.
(85.6mm) x 642 pixels (54.5mm)
1. Ensure the Page Layout/Setup is

1. Incorrect page size set in the printing
taken from the installed Rio Pro
Application as above.
Driver.
White margins at one or both ends 2. Image Size is not large enough to
2. Image size must be 1016 pixels 1. Section 4.2
of the Card < 2mm. completely fill the Card.
(85.6mm) x 642 pixels (54.5mm)
3. Start & End Positions are not at default
3. Restore the default Start & End
in the Printer Driver.
positions in the Printer Driver.
1. Ensure the Cards are flat, clean

and free from contamination or
fingerprints, replace if necessary.
1. Dust, dirt or surface contamination on
Small areas or dots of missing 2. If the ribbon has to be removed
the Card. 1. Section 4.2 &
colour, can be in any position on avoid touching it and do not place
2. Dust, dirt or contamination on the Dye 7.4.
the Card. flat on the surface (static).
Film.
3. Replace the Sticky Roller inside the
Printer, one is included with a new
roll of Dye-Film.
1. Cards must be PVC or have a PVC

Printed colours across the whole 1. Cards are not the correct type. covering layer across the surface.
1. Section 4.2
Card are too light and generally 2. Printer Head Power has been reduced 2. Check the driver settings and reset
2. Section 8.4
washed out. too low. the YMC Power to 50, increase if
necessary.
Text or Barcodes are either missing 1. Black Resin Power is set too low or too 1. Increase the Black Resin Power
1. Section 8.4
or too light, colour is acceptable. high. setting in the Driver.
1. High amount of surface abrasion 1. Cards may need extra protection

Card images are fading after a few occurring. like a lamination patch.
1. Section 8.4
weeks. 2. Overcoat has not been printed on the 2. Ensure the Overcoat is enabled
Card. with the Driver.
Front section of the Card (as its 1. Rotate the Print Head angle
ejected) is faded compared to the 1. Print Head angle is not set-up correctly. adjustment screw anti-clockwise by 1. Section 10.5
rest of the Card. one turn to make more positive.
1. Rotate the Print Head angle

Rear section of the Card (as it's
1. Print Head angle is not setup correctly. adjustment screw clockwise by one 1. Section 10.5
ejected) has faint dark wavy lines.
turn to make more negative.

- 57 -
SECTION 12.3 IMAGE PROBLEMS CONT.
1. Check the print path is clear and all

1. Card striking something during the
Rollers are turning.
printing cycle.
Vertical lines across the image 2. Reduce the magnetic encoding
2. Card striking the magnetic encoding 1. Section 11.9
(always in the same place on each Head height by tightening the rear
Head during printing. 2. Section 16.10
Card). grub-screw.
3. Card not running smoothly through the
3. Ensure the sprung-loaded Card
sprung-loaded Card guide system.
guide moves in and out smoothly.
1. Re-tension the main Stepper Drive

Belt (Belt should rotate through 90
degrees along the length of its
1. Incorrect Belt tension between the main
longest travel). 1. Section 11.9
Vertical lines across the image Stepper motor and large Drive Pulley.
2. Compare the rotational resistance 2. Section 11.9
(different place on each Card). 2. Stepper motor is not rotating smoothly.
to another Stepper motor, e.g. 3. Section 6.1
3. Damaged or faulty controller PCB.
Flipper driver/rotation motor. Swap
if necessary for testing.
3. Call Magicard Technical Support.
1. Poor Print Head colour compensation. 1. Replace Print Head.

Background colour changes at 1. Section 10
Usually a fault with either the Print Head 2. Replace Controller PCB, call
edges of dark or light objects. 2. Section 6.1
or Controller PCB. Magicard Technical Support.
1. Flip the Card over and print on the

reverse (if applicable) otherwise
rotate the Card through 180
1. Raised area or burr along the same
degrees. Does the faded edge 1. Section 4.2
Light faded edge along the length edge to the Card.
remain on the same side ? 2. Section 16.2
of the Card. 2. Poor contact between the Print Head
2. Ensure the Print Head moves up 3. Section 16.2
printing surface and the Card.
and springs back down smoothly.
3. Ensure the Print Head shield has
not slipped downwards.
1. Ensure Rio Pro Duo has been

Page 1 is printed on one Card and
purchased or Printer has been
page 2 is printed on a second Card 1. Single-sided Printer being used. 1. Section 5
upgraded to the Duo model.
when both pages should appear on 2. Incorrect Driver settings. 2. Section 8.4
2. Ensure the Duplex mode has been
the same Card automatically.
enabled in the Printer Driver.
1. Try using a higher quality PVC

Card.
1. Poor quality PVC Cards. 2. Clean the Printer using the
1. Section 4.2
2. Card is being mis-positioned slightly for recommended Magicard cleaning
Printed image is not very clear or 2. Section 7.
each colour pass. consumables.
sharp. 3. Section 1
3. Low resolution picture. 3. Ensure the original artwork is a
4. Section 8.4
4. Incorrect Driver settings. high resolution image.
4. Increase the sharpness setting in
the Printer Driver.

- 58 -
SECTION 12.4 PRINTER DRIVER PROBLEMS
1. Re-initialise the Printer ensuring

Dye-Film is fitted and it reports
1. Printer is Offline. Ready.
2. Incorrect Printer selected within the 2. Ensure the printing application is
Operating System. set to print to the Rio Pro. Perhaps
When a document is sent nothing
3. Incorrect Port selected in the Driver it should be set as the default
happens at the Printer.
settings. Printer.
4. Corrupted or deleted Driver within the 3. USB printing Port should be
Operating System. selected to USB001.
4. Remove the current Driver and re-
install the latest version.

When a document is sent to the
Printer it appears in the print queue 1. Printer is Off-Line.
Ready.
(Spooler) but nothing happens at 2. Windows Spooler is Paused.
2. Right Click on the Printer Driver
the Printer.
and choose Unpause Printer.
1. Delete the Print Job from the queue

and resend the document.
1. Corrupted Print Job sent to Printer.
Print document is jammed in the 2. Printer is Off-Line.
print queue (Spooler). 3. Incorrect Port selected in the Driver
Ready.
settings.
3. USB printing Port should be
selected to USB001.
When a document is sent to the 1. USB printing Port should be

1. Incorrect Port selected in the Driver
Printer it appears in the print queue selected to USB001.
settings.
(Spooler) and disappears 2. Remove the current Driver and re-
2. Corrupted Printer Driver.
immediately. install the latest version.
Unable to open the Printer settings 1. Remove the current Driver and re-
1. Corrupted Printer Driver.
within Printers and Faxes. install the latest version.

1. Printer is Off-Line.
Ready.
After installing the Driver and 2. Problem with the USB Port.
2. Try connecting to another spare
connecting the Rio Pro nothing 3. Problem with the USB cable.
USB Port.
happens, Printer is not seen. 4. Corrupted Printer Driver.
3. Try a known working USB cable.
5. Damaged Controller PCB.
4. Contact Magicard Technical
Support for another Controller PCB.

Ready.
After installing the Driver and 1. Printer is Off-Line.
2. Remove the current Driver and re-
connecting, Windows registers the 2. Corrupted Printer Driver.
install the latest version.
Printer but nothing appears in the 3. Conflicting Printer Driver files.
3. Remove all other Card Printer
Printer list. 4. Damaged Controller PCB.
Drivers.
Support for another Controller PCB.

Support for advice about removing
After installing the Driver and Beta Drivers.
1. Beta Driver is/has been installed.
connecting the Printer Found New 2. Install the Driver onto the partition
2. Partitioned Hard Drive.
Hardware Wizard appears. where the Operating System is
loaded. You may have to copy files
from one partition to another.

- 59 -

- 60 -
SECTION 12.5 MAGNETIC ENCODING PROBLEMS
1. Cards are not moving smoothly over the 1. Clean the Printer using the
magnetic encoder head during the recommended Magicard Cleaning
Magnetic Encoding is inconsistent, 1. Section 7
encoding cycle. Cards.
some Cards swipe and others do 2. Section 7
2. Feed Rollers are slipping or not moving 2. See number 1.
not. 3. Section 8.4
the Card efficiently. 3. Switch on Verification in the Printer
3. Magnetic Verification is not switched on. Driver.
1. Position the Card in the Hopper

with the magnetic stripe underneath
1. Blank Cards have been placed in the
and to the left side of the Printer.
Hopper the wrong way round and
Ensure Magnetic Verification is
magnetic verification is switched off.
switched on in the Printer Driver.
2. Magnetic Encoded data is in the wrong 1. User Manual
2. Clean the printer using the
place on the Magnetic Stripe. 2. Section 7
Cards are not encoded. recommended Magicard Cleaning
3. Magnetic Encoded data is not the 3. Section 8.4
Cards.
correct format for the swipe Reader to 4. Section 6.1
3. Ensure the Driver settings reflect
understand.
the type of magnetic stripe Cards
4. Magnetic Encoding Head is either mis-
being used, e.g. HICO or LOCO.
aligned or faulty.
Support.
1. Clean the Printer using the

1. Magnetic Encoding Head is dirty. recommended Magicard cleaning
Cards are not encoded (individual 1. Section 7
2. Magnetic Encoding Head is either mis- Cards.
tracks missing data). 2. Section 6.1
aligned or faulty. 2. Contact Magicard Technical
Support.

- 61 -
SECTION 13 ERROR CODE LIST
Error Number Displayed Error Error Code Description of Problem
Error is shown if the lid is opened while trying to feed a

Card from the Hopper. It will not be shown if the Printer is
01 Lid Open. Please close to continue 01:00
in Soak Test mode (in which case the lid is ignored, and
this error cannot occur).
Error is shown if it detects that there is a pending print job

01:01
and the Lid is opened during the download.
Error is shown if the Lid is opened while printing a colour

01:02
panel, either yellow, magenta or cyan.
Error is shown if the Lid is opened while printing the resin

01:03 black panel, or if the Lid is opened while printing with
continuous single colour resin Film.
Error is shown if the Lid is opened while printing the clear

01:04
Overcoat panel.
01:05
Error is shown if the Lid is opened while advancing the

01:06 ribbon on to the start of the next coloured panel. This
may be either during printing or initialisation.
Error is shown if the Lid is opened while aligning the start

01:07 of a coloured Dye panel with the edge of the Print Head
prior to printing.
Error is shown if the Lid is opened when the print job is

being validated against the parameters in the Printer
01:08
Driver. This can also happen if a print job is sent to the
Printer while the Lid is open.
Error is shown if the Lid is opened while trying to take up

the loose Dye-Film. Note that this function is carried out
01:09
after resetting the Print Head position on initialisation or
re-initialisation.
This error is raised if, at the end of a print job, we detect

that the Lid is open. This will usually mean that the
print job aborted early due to the lid being opened, but
01:12
could also mean (in extremely rare circumstances) that
the lid was opened just after the point when the job
actually _nished successfully.
Error is shown if the rear Card Sensor has not been

Out of Cards. Please refill the Hopper and
02 02:00 blocked by a Card passing through it. It will try to feed a
press retry.
Card three times from the Hopper.

- 62 -
SECTION 13 ERROR CODE LIST CONT.
Error is shown if the front Card Snsor has not been

Hand Feed error please select retry to try
03 03:00 blocked by a Card after trying to hand-feed a Card for 10
again.
seconds.
Error is shown if the front Card Sensor becomes blocked

Flipper Card Jam. Pease clear Printer when trying to hand feed a Card, but does not unblock
04 04:00
mechanism within 5 seconds. Card is trapped in between the Flipper
and front Card Sensor.
Error can be shown while trying to retrieve a Card out of

the Smart encoding module. If the front Card Sensor
04:01
remains unblocked for more than 5 seconds it will be
displayed. This is reserved for further use.
Error can be shown while trying to retrieve a Card out of

the Smart encoding module. If the front Card Sensor
04:02
remains blocked for more than 5 seconds it will be
displayed. This is reserved for future use.
Error can be shown while moving a Card from the Flipper

mechanism into the print engine module. If the front
04:03
Sensor remains unblocked for more than 3 seconds it
assumes a Card is trapped in the Flipper mechanism.
Error can occur while moving a Card from the print engine
module to the Flipper mechanism. If the front Sensor
remains blocked for more than 5 seconds it assumes a
04:04
Card is trapped in the Flipper mechanism. The Flipper
will try to intialise but the Flipper Sensor will not change
as a Card is trapped.
Error can occur while moving a Card towards the back of

the Printer to the standby position. Standby position is a
Card in the middle Card Sensor. If the front Sensor has
04:05
remained unblocked for 2 seconds the error will occur.
This sequence is performed during the magnetic
verification cycle while the Card is moving forwards.
Error can occur while trying to move a Card towards the

back of the Printer to the standby position. Standby
position is a Card in the middle Card Sensor. If the
04:06 middle Sensor has remained unblocked for 2 seconds the
error will occur. This sequence is performed after the
magnetic verification cycle while the Card is moving
forwards.
Error can be shown if the front Sensor is blocked when

trying to initialise the Flipper. If it fails to unblock by
04:07
rewinding the main Stepper motor) and block the mid
Sensor within 4 seconds the error will be shown.

- 63 -
Error is shown while trying to return the Card to the print

Flipper Card Jam. Please clear Printer
04 04:08 engine after rotating the Flipper unit. If the front Sensor is
mechanism
not obscured within 5 seconds the error is seen.
Error is shown while trying to return the Card to the print

engine after rotating the Flipper unit. If the front Card
04:09 sensor fails to clear within 5 seconds then the error is
seen. Note that the front Card Sensor has already been
obscured by the Card at this stage.
Error is shown while trying to feed a Card into the Flipper

mechanism for rotation. If the front Card Sensor is not
04:10 unblocked within 5 seconds the error is seen. By this
point the Card has already moved forwards to block the
front Card Sensor.
Error is shown while trying to eject the Card out of the

Printer. If the front Sensor remains blocked for more than
04:11 3 seconds the error is seen. At this stage the Card has
already moved towards the Flipper mechanism and has
blocked the front Sensor.
This error is raised if the Flip Sensor is always blocked

after smart encoding. The printer is attempting to rotate
04:12
the card to the horizontal position.
Error is shown while trying to move the Card from the

Smart encoding position to the standby position. If the
05 Encoder Jam. Please clear Printer mechanism 05:00 Card present Sensor does not register the Card leaving
within 3 seconds the error is displayed. Reserved for
future use.
Error is shown while trying to place the Card into the

Smart encoding position. If the Card present Sensor does
05:01
not register the arrival of the Card within 2 seconds the
error is displayed. Reserved for future use.

- 64 -
06 Card Jam. Please clear Printer mechanism 06:00
06:01
Error is shown while trying to feed a Card into the Flipper

mechanism for rotation. If the front Card Sensor is not
06:02 unblocked within 5 seconds the error is seen. By this
point the Card has already moved forwards to block the
front Card Sensor.
06:03
06:04
Error can be shown while trying to feed a Card from the

Hopper and the middle Card Sensor remains unblocked
06:05 for more than 6 seconds. Note that by this point in the
cycle the rear Sensor has already been obscured by a
Card.
Error is shown while attempting to return the Card to the

standby position (over the middle Card Sensor) from in
06:06
the rear Card Sensor. It occurs if the rear Sensor is not
unblocked within 3 seconds.
This error can occur while trying to hand-feed a Card to

the standby position (over the middle Card Sensor). If we
06:07 fail to see the mid Sensor block within 5 seconds the error
will be seen. Note, by this point a Card has already been
seen in the front Sensor (block and then unblock).
Error can be seen while trying to move a Card from the

Smart encoding position to the standby position (over the
middle Sensor). Normally occurs if the middle Sensor is
not blocked within 5 seconds. At this point the Card has
06:08
already successfully moved out of the encoder and
Flipper. At this point in the cycle the Card has been seen
by the front Sensor (suggesting that the Card is between
the front and middle Sensors).
Error is shown while trying to move the Card from over the
front Sensor to the standby position (over the middle
06:09
Sensor) if the front Sensor does not unblock within 3
seconds.

- 65 -
Error can be shown while trying to move the Card from

within the front Sensor to the standby position (over the
middle Sensor). If the middle Sensor is not blocked within
06 Card Jam. Please clear Printer mechanism 06:10
3 seconds by a Card the error will be displayed. Note that
by this point the front Sensor has become unblocked by a
Card.

Flipper to the standby position (over the middle Card
Sensor). If the middle Sensor is not blocked within 3
06:11
seconds the error will be displayed. Note by this point a
Card has passed through the front (suggesting that the
Card is between the front and mid Sensors).

main print area into the rotation mechanism. If the front
06:12
Card Sensor is not obscured within 5 seconds the error is
displayed.
Error is shown while trying to move the Card into the

magnetic encoding standby position (this is where the rear
06:13 edge of the Card just blocks the rear Card Sensor). If the
rear Sensor is not obscured within 4 seconds the error is
displayed.
Error can be shown during the magnetic encoding cycle.

If a Card fails to unblock the rear Card Sensor within 4
seconds the error is displayed. At this point the Card is
06:14
already in the magnetic encoding standby position and
has begun to move the Card forwards towards the
magnetic encoding Head.
Error is shown while moving the Card forward towards the

front Sensor during the soak test routine. If the front Card
06:15
Sensor is not blocked within 6 seconds the error will be
displayed.
Error is shown while moving the Card backward towards

the rear Sensor during the soak test routine. If the rear
06:16
Card Sensor is not blocked within 6 seconds the error will
be displayed.
Error is shown while moving the Card towards the Flipper

06:17 ready for rotation. If the front Card Sensor does not block
within 5 seconds the error is displayed.
Error is shown while trying to position the Card so that its

rear edge just covers the rear Card Sensor (ready for
06:18
printing). If the rear Sensor does not block within 3
seconds the error is displayed.
Error is shown while trying to position the Card so that its

rear edge just covers the rear Card Sensor (ready for
printing). If the rear Sensor is not unblocked within 3
06:19 seconds the error will be displayed. At this point the rear
Sensor has already been blocked by the Card moving
backwards and the Printer is moving the Card forward
again until the rear Sensor unblocks.

- 66 -
Error is shown while feeding a Card from the Hopper into

the standby position (covering the middle Card Sensor). If
the front Sensor fails to block within 6 seconds the error is
06 Card Jam. Please clear Printer mechanism 06:22 displayed. By this point the Card has been successfully
taken from the rear Card Hopper and the Rio Pro is trying
to move it to the front Card Sensor, before returning it to
the standby position.
Error is displayed while initialising the Dye Film. If the Rio

Pro cannot validate the electronic RFID Tag on the Dye
Film the error is displayed. Note that this RFID validation
No Film detected. Please load a new roll of
07 07:00 process is not performed when no Tag is present the
Film to continue.
printer assumes that a roll without a Tag is monochrome
(single colour ribbon). This error is only displayed when
the Tag is detected but invalid.
Error is shown while trying to advance the Film to the start

Out of Dye Film. Please load a new roll of of the next panel. If no Tacho Sensor pulses or Dye
08 08:00
Film to continue. Sensor transitions are seen for at least 5 seconds the
error is displayed.
Error is shown while trying to advance the Dye Film by a

certain fixed offset (for example, to line up the start of the
08:01 panel with the printing position). If no Tacho Sensor
pulses or Dye Sensor transitions are seen for at least 5
seconds the error will be displayed.
08:02
Error can be shown while running a Tacho Sensor test

(via the TAC quick command). If no Tacho Sensor
08:03
pulses are seen for at least 4 seconds an error will be
displayed.
Error can be seen while printing a colour panel. If no

Tacho Sensor pulses or Dye Sensor transitions are seen
08:04
for at least 150 printed lines (this equates to roughly
150ms) an error will be displayed.
Error can be seen during printing of the black panel. If no

Tacho Sensor pulses or Dye Sensor transitions are seen
08:05
for at least 150 printed lines (this equates to roughly
75ms) an error will be displayed.

- 67 -
Error can be seen during printing of the Overcoat panel. If

no Tacho Sensor pulses or Dye Sensor transitions are
08:06
seen for at least 150 printed lines (this equates to roughly
150 ms) an error will be displayed.
Error can be shown during Dye-Film initialization. If the

08:07 print counter on the Dye-Film RFID Tag has reached its
limit the error will be displayed.
Error can be shown while carrying out the validation

checks that are done prior to printing a Card. If the print
counter on the Dye-Film RFID Tag has reached its limit
the error will be displayed. Note the printer has already
08:08
determined that the fitted Film is capable of being used for
the downloaded print job (for example, it has the required
colour format). Also note that this error can never occur
during magnetic encoding only jobs.
Error is shown while trying to advance the Dye Film to the

start of the next panel. If Tacho pulse are seen, but no
08:09
Dye Film sensor transitions occur for at least 5 seconds
the error will be displayed.
Error is shown while trying to advance the Dye Film to the

start of the next colour panel. If Dye Film Sensor
08:10
transitions are seen, but no Tacho pulses occur for at
least 5 seconds the error will be displayed.
Error can be shown while trying to advance the Film to the

start of the next colour panel. If Tacho and Dye Film
sensor transitions are seen, but the Dye Film Sensor
08:11 change does not stabilize within 5 seconds the error is
displayed. This could be due to counterfeit ribbon, or an
uncalibrated Dye Film Sensor (in which case the Dye Film
Sensor should be calibrated using the Printer menu).
Error can be shown while initialising the Dye Film. If the

fitted Dye Film has an unsupported configuration of colour
panels an error will be shown. A list of supported Dye
Films are:
Colour, Resin and Overcoat for full-colour prints

MA300YMCKO
Continuous single-colour Resin or scratch Film

MA1000K
Unsupported Film, please load different Film to
09 09:00
continue. Resin and Overcoat for monochrome prints, for example
MA600KO
Colour, Resin and Overcoat for colour/monochrome

duplex printing
MA250YMCKOK.
Note, this error means that the Dye-Film's RFID Tag was
successfully validated. The most likely scenario for this
error is the introduction of a new Film type which is
unknown to older Printer Firmware versions.

- 68 -
Error is shown while advancing the Dye-Film to a specific

position within a certain colour panel (for example, moving
the Film into a position where it can be used for printing).
Wrong Film type. Please load different Film to If the panel requested is not present in the loaded Film
10 10:00
continue or press cancel to clear print job. type (for example, a colour panel was requested when
black only Film was loaded the error will be displayed.
This error should never arise in practice, as print jobs are
rejected if they are not compatible with the loaded Film.
Error can be shown while determining the print cycle

sequence for the current print job using a colour type Film.
In other words, Film having a YMCKO configuration, if the
image cannot be printed using the loaded Film this
10:01
particular error will be displayed. It may not arise in
practice unless short panel colour Film is supported in the
future, and the user attempts to print an image which
contains too many lines of data in a particular colour.

sequence for the current print job using single colour type
Film. In other words, continuous resin only type Film, if
the image cannot be printed using the loaded Film this
10:02
particular error will be displayed. This particular error may
arise if the user manages to send a print job file requiring
either colour or Overcoat to a machine which has single
colour only Film fitted.

sequence for the current print job using black and
Overcoat type Film. In other words, Film with a KO
configuration, if the image cannot be printed using the
10:03
loaded Dye Film this error will be displayed. This
particular error may arise if the user somehow manages
to send a print job file requiring colour to a machine which
has MA600KO Dye Film fitted.

sequence for the current print job using colour film with
the extra black resin panel type film. In other words, film
with a YMCKOK configuration. If the image cannot be
10:04 printed using the loaded Dye Film, this error will be
shown. This particular error may not arise in practice
unless short-panel colour Dye Film is supported in the
future, and the user attempts to print an image which
contains too many lines of data in a particular colour.
Error is shown while validating the downloaded print job

against the capabilities of the Dye-Film. If colour data is
sent while monochrome fFlm (K or KO) is fitted an error
10:05
will be displayed. The Printer Driver should normally
prevent this from happening, but it is possible to by pass
the Driver by sending PRNs directly to the Printer.
10:06

- 69 -
Error is shown while trying to align the Dye-Film to a

chosen offset within a chosen panel (for example, prior to
printing) if the Printer can not find the requested panel
within 8 panels of its starting point. This error often
indicates that either the Dye-Film LED is poorly
Cant find panel. Please check Dye Film and
positioned, or that the Dye-Film LED needs to be
11 Printer mechanism, or press cancel to clear 11:00
calibrated using the FCL command. This error is similar
print job.
to 11:01, but the surrounding context is slightly different.
11:00 can occur whenever the Dye Film position is being
set, whereas 11:01 can only occur when the Film position
is being set and the Printer has had to recover from a Dye
Film panel misalignment by skipping an entire panel set.
Error is shown while trying to align the Dye-Film to a

chosen offset within a specific panel (for example, prior to
printing) if the Printer cannot find the requested panel
within 8 panels of its starting point. This error often
indicates that either the Dye Film LED is poorly
positioned, or that the Dye-Film LED needs to be
11:01
calibrated using the FCL command. This error is similar
to 11:00, but the surrounding context is slightly different.
11:00 can occur whenever the Film position is being set,
whereas 11:01 can only occur when the Film position is
being set and the Printer has had to recover from a Dye
Film panel misalignment by skipping an entire panel set.
RFID PCB missing. Reconnect PCB to

12 12:00 Error is shown during Printer initialization. If the RFID
continue.
PCB cannot be detected the error is displayed.
Error is shown while checking the print head temperature

in standby. If the measured temperature is out of range
Print Head Error, switch Printer off and
13 13:00 an error is displayed. This indicates that either the print
reconnect Print Head.
Head is not connected, or that the thermistor on the Print
Head is not functioning correctly.
Error is shown while waiting for the Print Head

Overheat error, switch Printer off and allow
14 14:00 temperature to fall before printing a Card. If the measured
Print Head to cool.
temperature is out of range the error is displayed.

- 70 -
Error can be shown during the print cycle, while waiting

for the main Stepper motor to reach the appropriate
Image too dark. Please cancel print job and position for the next printing pass. If the Printer detects
15 reduce Driver Print Head power settings to try 15:00 that the motor has already passed that position. This can
again. sometimes occur when the image being printed is very
dark, and/or the Print Head temperature is very low,
causing the Print Head strobe widths to be come too long.
Error is shown while resetting the Cam to the Head Up"

16 Cant Lift Head, check Printer Mechanism 16:00 position. If the Printer does not see the Cam Sensor
become obscured within 5 seconds the error is displayed.
Error is shown while trying to reset the Cam to the Head

Up" position. If the Printer does not see a light-to-dark
16:01 Cam Sensor transition within 5 seconds the error is
displayed. By this point the Cam Sensor is already
unblocked.
Error is shown while trying to lift the Print Head. If the

Cam Sensor does not block within 5 seconds an error is
16:02
displayed. Note, this function is only used by the HEAD
quick command and the Cleaning Routine.
Error is shown while trying to lift the Head at the end of

printing a panel. If the Cam Sensor does not clear within
16:03
5 seconds the error is shown. By this point the Sensor
has already been blocked.
Error is shown while trying to move the Cam in the Head-

Up" position. If the Cam Sensor does not block within 5
16:04
seconds the error is seen. This function only happens
during Printer Boot-up and print job cancellation.
Error is shown while trying to place the Cam in the Head

Up" position. If the Cam Sensor does not make a dark-to-
light transition within 5 seconds the error is seen. Note
16:05
that the Sensor has already been blocked by this point.
This function only happens during Printer Boot-up and
print job cancellation.
Error is shown while trying to place the Cam in the Head

Up" position. If the Cam Sensor does not make a light-to-
dark transition within 5 seconds the error is shown. Note
16:06
that by this point the Sensor has already made a dark-to-
light transition. This function only happens during Printer
Boot-up and print job cancellation.
Error is shown while lifting the Print Head and the Cam
16:07
Sensor does not block within 5 seconds.

- 71 -

- 72 -
Error is shown while trying to lift the Print Head. If the

Cam Sensor does not block within 5 seconds the error is
16 Cant Lift Head, check Printer Mechanism 16:08 displayed. By this point the Head has been lifted and the
Cam Sensor has just unblocked. The Printer is pulsing
the Cam Motor backwards to prevent overrun.
Error is raised while trying to lower the Print Head. If the

Cam Sensor does not unblock within 5 seconds the error
17 Cant Drop Head, check Printer Mechanism 17:00
is displayed. This function is called by the HEAD quick
command, the Cleaning routine and the Soak test routine.
Error is shown while lowering the Print Head and

analyzing the image data. If the Cam Sensor does not
unblock within 3 seconds this error is displayed. Note by
17:01
this point the image data has been completely analysed.
This function is used during the Printing routine before
starting to print each colour panel.
Error is shown while trying to initialise the Flipper

mechanism. If the Flipper Position Sensor is not blocked
Flipper Error, cannot initialise the Flipper. within 4 seconds the error is displayed. By this point the
18 18:00
Please clear Printer mechanism Printer has already cleared any Card jam away from the
Flipper mechanism, if the front Sensor was found to be
blocked.
Error is shown while trying to initialise the Flip

mechanism. If the Flipper Position Sensor is not
unblocked within 4 seconds the error will be displayed.
18:01 By this point the Printer has already cleared any Cards
away from the Flipper mechanism if the Front Sensor was
found to be blocked. Also the Flipper Position Sensor has
been cleared (In other words, the Sensor is in the slot).
Error is shown after carrying out the Magnetic Verification

cycle. If the data read back from the Card on the final
attempt does not match the data that was sent in the print
Mag Verify Fail. Press Retry or Cancel to
19 19:00 job the error is displayed. This error cannot occur if either
continue.
Perform Verification is switched off in the Printer
Settings or another error (e.g. Lid Open or Card Jam)
occurs during encoding/verification cycle.

- 73 -
Error is shown while processing a Magnetic Self Verify

command from the Support Utility (e.g. a pre-encoded
Mag Verify Fail. Press Retry or Cancel to Card is read back by the Printer and the results displayed
19 19:01
continue. in the Support Utilty). If the data read back from the Card
cannot be determined the error is displayed (e.g. could
be in a Non-ISO format).
Error can be shown while determining the format of the

downloaded print job. If colour printing has been
Mode Unsupported. Cannot print requested
requested for the front of the Card but the Printer does not
20 image with this printer model. Please cancel 20:00
support colour printing the error is displayed. Note that
print job and adjust Driver settings to try again.
this type of Printer does not yet exist and this feature is
reserved for future development.
Error is raised while determining the format of the

downloaded print job. If colour printing has been
requested for the back of the Card but the Printer does
20:01
not support colour printing the error is displayed. Note
that this type of Printer does not yet exist and this feature
is reserved for future development.
Error can be shown if the cleaning prompt is enabled.

This prompt is displayed when the number of Cards
CLEAN REQUIRED. Please clean the Rollers
21 21:00 printed since the last clean exceeds the user configurable
to avoid deterioration
threshold (by default 700). Note that this check is only
performed at Printer boot-up.
Error is shown after executing a Sensor Test, initiated

22 Test Results 22:00 using an SNS command. If the Printer found that the
Cam Sensor never changed then the error is displayed.
Error is shown after completing a Sensor Test, initiated

22:01 using an SNS command. If the Cam Sensor changed but
the Flip Sensor failed to unblock the error is displayed.
Error is shown after completing a Sensor test, initiated

22:02 using an SNS command. If the Cam Sensor changed but
the Flip Sensor never changed the error is displayed.
Error is raised after completing a Sensor Test, initiated

22:03 using an SNS command. If the Cam and Flip Sensors
both change the error is displayed.

- 74 -
Error is shown after completing a Sensor Test, initiated

22:04 using a SNS command. If the Flip Sensor result is
Invalid" the error is displayed.

- 75 -
Error can be shown after intialising the Cam at switch on.

If the time taken to rotate the Cam mechanism by half a
Wrong PSU. Please switch the Printer off and turn was longer than 2.5 seconds the error is displayed.
23 23:00
check the Power Supply. This is designed to indicate a low level output from the
external PSU (PSU looks very similar to other IT
equipment).
Error is shown while processing a downloadable Firmware

General Error. Please contact Magicard
24 24:00 Binary File. If the file length is greater than 1170432
Technical Support quoting code.
bytes (1143kB) the error is displayed.
Error is shown while attempting to write a downloaded

Firmware Binary File into Flash memory. If the format ID
24:01
string in the downloaded file is not the correct one for the
Rio Pro (e.g. Rio/Tango 2E) the error is displayed.
24:02
Error is shown after printing a Card. If it fails to increment

24:03 the printed Card count in the RFID Tag this error will be
displayed.
Error is shown while trying to feed a Card from the Hopper

to the printing area. If the Printer sees the middle Card
Sensor block before the rear Card Sensor does the error
24:04
is displayed. This could possibly indicate that the rear
Sensor has dropped out of position, but could also mean
that the middle Card Sensor is faulty.

to the printing area. If the Printer sees the front Card
Sensor block before the rear and middle Card Sensors
24:05 the error is displayed. This could possibly indicate that
both the rear and middle Card Sensors have dropped out
of position, but could also mean that the front Card
Sensor is faulty.

to the print engine if the Printer sees the front Card
Sensor block before the middle Card Sensor the error is
24:06
displayed. This could possibly indicate that the middle
Card Sensor has dropped out of position, or that the front
Card Sensor is faulty.
Error is shown while trying to hand feed a Card into the

printing area. If the Printer sees the middle Card Sensor
block before the front Card Sensor the error is displayed.
24:07
This could possibly indicate that the front Card Sensor
has dropped out of position, or that the middle Card
Sensor is faulty.

- 76 -
SECTION 13 ERROR CODE LIST CONT

printing area. If the Printer sees the rear Card Sensor
General Error. Please contact Magicard block before the front and middle Card Sensors the error
24 24:08
Technical Support quoting Error code. is displayed. This could possibly indicate that both the
front and middle Card Sensors have dropped out of
position, or that the rear Sensor is faulty.

printing area. If the Printer sees the middle Card Sensor
24:09 block before the front one clears the error is displayed.
This could possibly indicate that the front or middle Card
Sensor is faulty.

block before the front or middle Card Sensor the error is
24:10
displayed. This could possibly indicate that the front Card
Sensor has failed, that the middle Card Sensor has
dropped out of position or that the rear Sensor is faulty.

block before the middle Card Sensor the error is
24:11
displayed. This could possibly indicate that the middle
Card Sensor has dropped out of position, or that the rear
Card Sensor is faulty.
Error is shown while attempting to write a downloaded

Firmware file into Flash memory. If the encrypted
checksum of the file is invalid the error is displayed. This
24:12
would mean that the Firmware file has been either
corrupted during transmission, or modified by a third
party.
Error is shown while attempting to move the Card into the

standby position. If the Firmware data relating to the
24:13
current position of the Card is invalid the error is
displayed. This should never happen.
24:18
24:19
24:20

- 77 -
26
27
28
29
30
31
32
33
34
35

- 78 -
SECTION 14 MAGICARD PRINTER SUPPORT UTILITY

This Utility provides advanced diagnostic and configuration tools for use when setting up and testing Magicard Printers.
Install the Magicard Support Utility from the Driver CD. Alternatively it can be found in Program Files in a folder called
Ultra Electronics Ltd. It is also available from our website using the following link:
http://www.Magicard.com/support/technical-support/?R=&L=&id=&lang=1&printerID=39&supportOption=3
Once installed, a short cut will appear on your Desktop.
Open the Support Utility and choose the USB Port:
When it has connected to the first Magicard Printer a number of extra Tabs will appear. If the connection fails, an error
will be shown.

It is recommended that the user does not change the settings within the Magicard Support Utility
unless requested by Magicard Technical Support or trained Magicard Dealerships. Serious damage
can occur if the configuration settings are changed by inexperienced users.

- 79 -
SECTION 14.1 PRINTER IDENTITY
Information about the printer,

the serial number is unique
and set during manufacturing.
Firmware can be updated by

the user, firmware can be
downloaded from Printer configuration
settings, see below.
www.magicard.com
The Printer configuration can only be changed when the printer is in Dealer Service Mode. The mode is switched on by
sending a special command to the Printer DEALERSERVICEON (see Section 14.2).
Before adjusting any configuration settings it is important to understand the printing cycle. Both the Image Start and
Image End can be adjusted in both directions and can lead to confusion as to what is changing.
Print Sequence
Previous Image Image Outline Next Image
Y M C K O
Start Position End Position
Image Start Card is moved to this calibrated position directly over the print roller prior to lowering the Print
Head and printing the first colour pass.
(Increasing the number in the Support Utility moves the image start position further onto the
Card, thus increasing the width of the white line at the front of the Card. A numerical change of 8
digits moves the start position a distance of 1 pixel width).
Image End Rio Pro has printed the colour panel and the Print Head is lifted off the Card at this point.
(Increasing the number makes the image length longer, closer to the rear of the Card, thus
decreasing the width of the white line at the rear of the Card. A numerical change of 1 moves the
end position a distance of 1 pixel width).
Print Head Density Every Print Head has a different resistance which means they will print at different colour depths.
To ensure each Rio Pro will print at a calibrated density the adjustment is calibrated at time of
manufacture. Once this calibration is carried out the Rio Pro can print a wide variety of image
designs. If the density is set too high the Dye-Film will be overheated and wrinkle or break.
When it is set too low the images look faded and washed out. Adjustments should be made in
increments of 25 or 50 before you see any change in the printed image.
(As a datum point, the setting should be close to the resistance that is printed on the Print Head
assembly (e.g. R = 3893)).
Print Head Position Adjustment of the image vertically across the Card (when the Card is held in landscape). The
setting changes which group of Print Head elements are used during the printing cycle.

- 80 -
SECTION 14.2 DEALER SERVICE MODE
As mentioned in Section 14.1, the configuration settings can only be adjusted in Dealer Service Mode. The mode is
switched on by sending a command to the Printer:
DEALERSERVICEON
The parameters can be adjusted (within defined limits) using the configuration settings in the Printer Identity Tab of the
Magicard Support Utility.
To activate Dealer Mode, enter DEALERSERVICEON as a quick command from the Statistics/Commands Tab. The LCD
backlight will change to yellow in response.
To deactivate Dealer mode, enter DEALERSERVICEOFF as a quick command (or re-boot the Printer). The LCD backlight
will change back to its normal colour.
Description of Dealer Mode features:
After boot-up, the Printer is not in Dealer Mode and the image parameters cannot be modified.
After entering Dealer Mode, the LCD backlight becomes yellow. The image parameters may be modified within the
permitted limits (shown in the table below).
If the entered values are outside of the permitted limits, they will be reduced to the upper or lower limit, as
appropriate.
After leaving Dealer Mode, the LCD backlight returns to its normal colour. The image parameters retain their
dealer-modified values and cannot be further modified.
After rebooting the Printer, the image parameters retain their Dealer-modified values.
If the Printer is placed into Dealer Mode and then re-booted, it will not boot up in Dealer Mode.
If the Printer receives a Reset command (from the Reset button on the Printer Identity tab), it will reload the
original factory settings.
Parameter Maximum deviation from factory setting

Print Head density calibration 500
Image start position 192 (equivalent to 1.04 mm)
Image end position 24 (equivalent to 2.08 mm)
Print Head position 12 (equivalent to 1.04 mm)

- 81 -
SECTION 14.3 STATISTIC AND COMMANDS
This tab contains three separate areas:
Statistics Shows information on Printer usage.
Quick Commands Enables the user to send special commands to the Printer (usually used for fault diagnosis).
See table below.
Print *.PRN file Enables the user to send previously saved print data to the Printer.
Quick Command Function
Function called upon receiving a CAM command. The function will cause the Printer to Reset the
CAM
Print Head Cam Mechanism Position.
Function called upon receiving a CHP command.

The function takes a single parameter (either UP or DOWN). If the parameter is DOWN, a Card is
CHP
fed into the Smart Encoding Unit. If the parameter is UP, the Card is moved to the standby position
(over the Middle Sensor).
Function is called upon receiving a CLN command.

CLN
The function will cause the Printer to execute its Cleaning Cycle.
Function is called upon receiving a DYE command.

DYE
The function re-initialises the Dye-Film.
Function is called upon receiving an EJT command.

EJT
The function causes the Printer to eject a Card if there is one in the Print Engine.
Function is called upon receiving an ENC command.

ENC
The function initiates the Magnetic Encoding Test Cycle.
Function is called upon receiving a FEED command.

This function feeds a Card into the Standby Position (over the Middle Sensor). It takes a Single
FEED Numeric Parameter: if this is Zero or One, the Card is left in the Standby Position, but if it is greater
than one it will eject the Card and feed another in, repeating however many times the parameter
specifies.

- 82 -
Function is called upon receiving a FLIP command.

FLIP If Duplex Printing is Enabled, and there is a Card in the Print Engine, this function will Feed the
Card into the Flipper Mechanism, rotate it, and return it to the Printer.
Function is called upon receiving a FRN command.

The function enables/disables the Film Saving Feature (required for printing with Short Colour
FRN
Panels).
It takes a single parameter of either ON or OFF.
Function is called upon receiving a HEAD command.

HEAD This function takes a Single Parameter, either UP or DOWN, and raises or lowers the Print Head
accordingly.
Function is called upon receiving a RAMP command.

RAMP The function sets the Density Ramp adjustment according to the given numeric parameter
(between 0 and 100 where 50 is the Default Setting).
Function is called upon receiving a SET command.

SET
This function saves the current printer settings into the Protected Memory Area.
Function is called upon receiving a TST command.

TST
This function initiates an Internal Test Print.
Function is called upon receiving a STN command.

STN
This function causes the printer to re-initialise the Internal Holokote Images.
Function is called upon receiving a SNS command.

SNS
Operates a single Soak Cycle and checks all Sensors.
Function is called upon receiving a SHW command.

This function enables the Sensor Status to be reflected at the front panel LEDs.
It takes a single parameter, which specifies the sensor to be tested.
The possible values for the parameter are:
CAM - to test the cam sensor

TACHO - to test the tacho sensor
FLIP - to test the flip sensor
DYE - to test the dye film sensor
LID - to test the lid sensor
SHW
FRONT - to test the front Card sensor
MID - to test the mid Card sensor
REAR - to test the rear Card sensor
BUTTON1 - to test button 1 on the front panel
BUTTON2 - to test button 2 on the front panel
SMART - to test the encoder Card sensor
TEMP - to test the printhead temperature sensor
ON - to test all the optosensors at once
OFF - to terminate sensor test mode
Sending an invalid parameter is equivalent to SHWOFF.

- 83 -
Function is called upon receiving a LNG command.

The function takes a single numeric parameter, which is used to set the Boot Up Language for
Status and Error Messages.
The possible parameter values are as follows:

LNG
0 - ENGLISH
1 - PORTUGUESE
2 - FRENCH
3 - GERMAN
4 - SPANISH
5 ITALIAN
Function is called upon receiving a RUN command.

The function takes a single parameter, and enables various tests to be performed
The possible parameter values are as follows:
CAM - Runs the Cam Motor while displaying the Cam Sensor State
FEED - Runs the Feed Motor Backwards
DYE - Runs the Dye Motor while displaying the Tacho Sensor State
RUN MAIN - Runs the Main Stepper Motor
FLIPPER - Runs the Flipper Rotation Motor while displaying the Flipper Position Sensor State
FLIPROLL - Runs the Flipper Card Drive Motor
FAN - Runs the Print Head Cooling Fan
PANEL - Displays the current state of the Dye Film Sensor
POUT - Raises the P-OUT line for 5 seconds
CAL - Sets the LEDs in the Middle and Rear Card Sensors to Bright Mode for 5 seconds
LCD - Cycles the LCD backlight through its entire range of Colours
OFF - Turns Off all Motors
Function is called upon receiving a FLM command.

FLM The function takes a Single Parameter, which may be either Y,M,C,K or O, and Aligns the Ribbon at
the Corresponding Panel.
Function is called upon receiving a FCL command.

The function, with no parameter, initiates the Dye LED Calibration Routine. If a parameter is
FCL
supplied, it must be in the form of a # sign followed by a Six Digit Hexadecimal Number, which is
then used to set the dye LED Colour directly.

- 84 -
SECTION 14.4 UPGRADE FIRMWARE

Use this Tab to upgrade the Printers Firmware.
The latest Firmware can be downloaded from www.Magicard.com as an executable file.
SECTION 14.5 QUERY PRINTER
Collects advanced diagnostic data from the Printer. If you experience a problem, you may be asked to email the results of
the query to Magicard Technical Support for analysis.

- 85 -
SECTION 14.6 ETHERNET
Ethernet connection is available with Rio Pro and Rio Pro Duo Printers. The settings are visible because this Support Utility
is also used for Magicard Rio 2e, Tango 2e and Tango +L Printers which do have this capability.
SECTION 14.7 MAG ENCODE
NOTE For use with Magnetic Encoding Models only.
Self Test Magnetic Encode Button enables the user to confirm the integrity of the Printers magnetic encoding operation.
Direct Magnetic Encoding the user can encode Cards directly from this tool.
To use this tool:-

Ensure magnetic stripe Cards are correctly loaded into the Card Hopper.
Select the Track(s) that you wish to encode and enter the data to be encoded.
Click on the Encode Button.

- 86 -
SECTION 14.8 MAG READ
NOTE For use with Magnetic Encoding Models only.
Mag Read function enables you to read ISO Standard magnetic encoding using the Printer hardware.
To use this tool:-

Ensure a magnetic encoded Card is loaded into the Card Hopper.
Select the Track(s) that you wish to read using the tool.
Click on the Read button. If successful, your data will be displayed together with an accompanying green
indicator. If it fails, no data will be displayed together with an accompanying red indicator.
Choose Eject to feed the Card out the front of Printer.
PLEASE NOTE:- The Magnetic Reader function is NOT a reliable indicator of magnetic Encoding quality.
It contains no error correction functions and so is not a substitute for a Magnetic Swipe Reader.

- 87 -
SECTION 15 MAGNETIC ENCODING

SECTION 15.1 MAGNETIC ENCODING STANDARDS
MAGTEK
DIMENSIONS FINANCIAL TRANSACTION CARDS.
Hi-Co = 2750 - 4000 Oersteds.
Magnetic Stripe
ISO 7810 Properties of Card Size Document 54.5 mm
7811-1 Embossing 2.125 inches
7811-2 Magnetic Stripe
7811-3 Location of Embossed Characters
7811-4 Location of Tracks 1 and 2 EMBOSSED
7811-5 Location of Track 3 INFORMATION
7813 Financial Transaction Cards
85.6mm / 3.375 inches
0.76 mm / 0.030" Thick
For Copies of Specifications contact: AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

11W. 42nd Street
New York, New York 10036
001 (212) 642-4900.
5.66mm / 0.223 inches
Track 1 IATA 210 7 bits per character 79 alphanumeric characters
Track 2 ABA 75 5 bits per character 40 numeric characters
Track 3 THRIFT 210 5 bits per character 107 numeric characters
Track Recording Density Character Configuration Information Content

(Bits per inch) (including parity bit) (including control
characters)
ISO Range for start sentinel:
0.273 to 0.313 inches
6.93 to 7.97 mm
MAGNETIC STRIPE ENCODING FINANCIAL TRANSACTION CARD
CARD DATA FORMAT FOR TRACK ONE
76 Alphanumeric Data Characters
SS FC PAN FS NAME FS ADDITIONAL DATA DISCRETIONARY DATA ES LRC
Primary Account No. Name Expiry Date (YYMM)

PVKI 1 character
19 digits maximum 26 alphanumeric (Characters = 4) PVV or Offset 4 characters
characters Service Code
CVV or CVC 3 characters
SS Start Sentinel % maximum (Characters = 3) Some or all the above field
FS Field Separator ^ may be found in discretionary
ES End Sentinel ? data.
FC Format Code
LRC longitudinal redundancy check PVKI Pin Verification Key Indicator
character PVV Pin Verification Value
CVV Card Verification Value
CVC Card Validation Code

- 88 -
37 Numeric Data Characters
SS PAN FS ADDITIONAL DATA DISCRETIONARY DATA ES LRC
Primary Account No. Expiry Date (YYMM) PVKI 1 character

19 digits maximum (Characters = 4) PVV or Offset 4 characters
Service Code CVV or CVC 3 characters
SS Start Sentinel Hex B ; (Characters = 3) Some or all the above fields may
FS Field Separator Hex D = be found in discretionary data.
ES End Sentinel Hex F ?
PVKI Pin Verification Key Indicator
LRC longitudinal redundancy check
PVV Pin Verification Value
character
CVV Card Verification Value
CVC Card Validation Code
CARD DATA FORMAT FOR TRACK TWO
104 Numeric Data Characters
SS FC PAN FS USE & SECURITY DATA ADDITIONAL DATA ES LRC
Primary Account No. Country Code (opt.) 3 characters First Subsidery Account
19 digits maximum Currency Code 3 characters Number (opt.)
Currency Exponent 1 character
SS Start Sentinel Hex B ; Amount Authorised / Cycle 4 characters Second Subsidery Account
FS Field Separator Hex D = Amount Remaining this cycle 4 characters Number (opt.)
ES End Sentinel Hex F ? Cycle Begin (Validity Date) 4 characters
FC Format Code Two digits Cycle Length 2 characters Relay Marker 1 character
LRC longitudinal redundancy check Retry Count 2 characters
character PIN control parameters (opt.) 6 characters Cryptographic Check 6 characters
Interchange Controls 1 character Digits (opt.)
PAN Service Restriction 2 characters
SAN 1 Service Restriction 2 characters Discretionary Data
SAN 2 Service Restriction 2 characters A field separator (FS) must be used if an
Expiry Date (opt.) 4 characters optional field is not used.
Card Sequence Number 1 character
Card Security Number (opt.) 9 characters
CARD DATA FORMAT FOR TRACK THREE
The Track formats used in this document are based on ISO Standards, however, other formats may be used.
Contact your Card issuer for your exact requirements.
MAGTEK
20725 South Annalee Ave
Carson,
California 90746
USA
TEL: 001 (310) 631-8602
FAX: 001(310) 631-3956

- 89 -
SECTION 15.2 BASIC MAGNETIC ENCODING.
The Magicard Rio Pro and Rio Pro Duo may have the Magnetic stripe encoder fitted as an enhancement and for added
security. To ensure the encoding is compatible with your Card Readers, it has the ability to meet I.S.O STD 7811.
The Printer is capable of encoding, both CR80 Hi-Co and Lo-Co Cards using the standard 3 Track format. To change
between the two, there is a setting in the Printer menu.
The Printer display will tell you whether it has a magnetic encoder fitted by showing an M.
All Magnetic Encoding data must be typed using a True Type font in Black, all text must be in Upper Case
To produce a basic encoding document, follow the instructions below:
Bring the image you require to print, onto the screen.
Ensure that the Image you are printing is using a Rastagraphic Program (i.e. such as a word processing
program, DTP package, or proprietary badge making program)
Type in your magnetic code anywhere on the face of the Card using the following format.
Type your code in a black, True Type font only.
All Tracks of the code must start with a tilde ~ followed by the Track number.
Example: ~1
Type in your code.
Track 1 may be a combination of numbers and uppercase letters, Tracks 2 and 3 numbers only.
Example: To encode the data 12345XYZ on track 1 of a magnetic strip Card: ~1%12345XYZ?
Print the Card.

- 90 -
SECTION 15.3 ENCODING USING BADGE PRINTING SOFTWARE.
Magnetic Track data is sent in the form of text strings from the Application software to the Printer Driver, along with all of
the other printable objects within your Card design.
For the Printer Driver to differentiate between magnetic Track data and the rest of the printable objects, the magnetic
Track data strings must be uniquely tagged and be formatted using the System font. In other words, specific characters
must be added to the magnetic Track data for the Printer Driver to know which data is to be encoded, which Tracks to
encode, when the Track data stops and starts etc.
When using the Generic Printer Driver, you must manually add these characters to the string of magnetic Track data. If
these characters are not added to the Track data, the text intended for the magnetic Track will most likely appear as
printed text on the Card.
To avoid this, Track information must be entered as described below. When entering Track data, the ~ character is
entered first, followed by the Track number 1, 2, or 3 on which you intend to encode the data, the data to be encoded
should then follow. There must be no spaces between these encoding characters.
The first character of this data string must be the Track specific SS (Start Sentinel), and the last character must be Track
specific ES (End Sentinel). The characters or data in between the SS and the ES can include all of the valid characters
specific to each Track format.
The number of these characters, however, is limited by each Tracks maximum character capacity. When segmenting
Track data, the appropriate FS (Field Separator) must be used.
The following table shows the SS, ES, FS, and valid characters defined for each Track. TR-1, TR-2, and TR-3/NNT
format options selected in the Magnetic Encoding properties, enforce Track character limits.
NOTE Magnetic Encoding Data must always appear on Page One of your Badge Design.
The following example illustrates how Track data should be entered for tracks 1, 2, and 3 under Windows Operating
Systems:
Windows 2000 / XP / VISTA / Windows 7 / 2003 SERVER.
FIELD VALID
TRACK START SENTINEL END SENTINEL
SEPARATOR CHARACTERS
~1 % ? ^ ASCII CHAR 32-95
~2 ; ? = ASCII CHAR 48-63
~3 ; ? = ASCII CHAR 48-63
It should be noted that testing independently from an application could be carried out in WordPad.
Sample Encoding Data.
~1%MAGICARD MAGTEST^24-07-2013?
~2;0123456789?
~3;0123456789?
However, after the page set-up has been carried out, the text must fit within the Card; Carriage Returns could be
automatically inserted if the Magnetic string continues over the page edge.
The text must be of True Type Font and in capital letters.

- 91 -
SECTION 15.4 ASCII CHARACTER SET SUPPORTED BY THE RIO PRO

ASCII CHAR. DETAIL ASCII CHAR. DETAIL ASCII CHAR. DETAIL
32 space 53 5 74 J
33 ! 54 6 75 K
34 55 7 76 L
35 # 56 8 77 M
36 $ 57 9 78 N
37 % 58 : 79 O
38 & 59 ; 80 P
39 60 < 81 Q
40 ( 61 = 82 R
41 ) 62 > 83 S
42 * 63 ? 84 T
43 + 64 @ 85 U
44 , 65 A 86 V
45 - 66 B 87 W
46 . 67 C 88 X
47 / 68 D 89 Y
48 0 69 E 90 Z
49 1 70 F 91 [
50 2 71 G 92 \
51 3 72 H 93 ]
52 4 73 I 94 ^
95 _
SECTION 15.5 ISO STANDARDS

Track 1.
Recorded information can be of the alphanumeric type. (ASCII Char 32-95)
Bit density of the recorded information shall be 210 Bits per inch.
Number of data bits making up each character is 6 plus 1 parity check bit.
The total number of data characters, control characters and Longitudinal Redundancy Check (LRC) characters
together must not exceed 79, including Start and End sentinels.
Track 2.
Recorded information can only be of numeric type. (ASCII Char 48-63)
The total number of data characters, control characters and Longitudinal Redundancy Check characters together
must not exceed 40, including Start and End sentinels.
Track 3.
Recorded information can only be of numeric type. (ASCII Char 48-63)
The total number of data characters, control characters and Longitudinal Redundancy Check characters together
must not exceed 107, including Start and End sentinels.

- 92 -
SECTION 15.6 ERROR CHECKING.
The data has two checking systems to ensure accuracy. The Longitudinal Redundancy Check (LRC) and the Parity
check. They can be set to odd or even.
Even Parity makes the number of 1s in the data being checked total an even number (2,4,6)
Odd Parity makes the number of 1s in the data being checked total an odd number (1,3,5)
If 123 was encoded in 5 MPC on Track 2 with ODD Parity and EVEN LRC would look thus:
II0I0 I0000 0I000 II00I IIIII 00I0I

; 1 2 3 ? LRC
The first 4 bits of each group (except the LRC) represent the information ( 2 = 0I00 )
th
The 5 bit of each group (except the LRC) is the parity bit for its group ( 0 or I )
The LRC consist of a parity bit for all of the information groups (each bit in the LRC is the parity bit for the same coloured
bits in all the other groups).

- 93 -
SECTION 15.7 FITMENTS TO THE PRINTER.
To ensure maximum flexibility the Magnetic Controller PCB is added-on to the main Controller PCB. It connects directly
into the main PCB and is not Printer specific.
Although it is relatively straightforward to fit the magnetic encoding components into the Printer it is extremely difficult to
calibrate (to meet ISO specifications). To do this requires specialist equipment and a thorough knowledge of data
encoding techniques.
It is therefore not recommended that Printers are upgraded from Standard (STD) to Magnetic encoding (MAG) types.
Connector for the
Magnetic writing head
USB
Ethernet
DC Power

- 94 -
SECTION 16 PARTS AND PART NUMBERS

The following section lists the main assemblies and their relative part numbers.
SECTION 16.1 EXTERNAL COMPONENTS
Metallic Collar
3652-0100-002
Rear Card Hopper

3652-0100-005 Front Card Hopper
3652-0100-001
Rio Pro Base

3652-0100-001 Rio Pro Front Fascia
3652-0100-003
Feet x 4
E9070 Rio Pro Front Label
3652-0100-008
SECTION 16.2 TOP COVER ASSEMBLY (3633-0150)
Latch Button
E9319
Top Cover
3652-0150-005
Top Cover Latch

3652-0150-003
Top Cover Latch Spring

Print Head Cooling Fan (24v) E9319
E092
Chassis Top Cover

3652-0150-005
Print Head Cable

3633-0400 Dye Film Sensor (Upper)
3652-0505
Print Head Springs x 2
E9041
Print Head Assembly

FG/3652-0160

- 95 -
SECTION 16.3 PRINT HEAD ASSEMBLY (FG/3633-0160)

Guide Bar (Dye-Film) x2
3633-0160-007
Print Head Mount

3652-0160-002
Heatsink
3652-0160-003
Spring
Thermal Print Head
E9165
E9312
M3 x 20mm Torx Adjustment Screw
E9091
Support Plate x2
3652-0160-001
M3 x 6mm Torx Screw x 2
3x8mm Dowel x2 E9091
E9368
SECTION 16.4 ROTATION UNIT ASSEMBLY (3633-0140) Rotation Drive Gear

x2
Roller Spring Plate

x2
Flipper Unit Housing

(Left side)
Flipper Unit Housing

(Right side)
Card Feed Rollers

x4 Idler Pulley x2
Star Washer x2
The Rotation Unit is now assembled externally as one complete unit so individual items are not available, a complete
unit will be sent if required.
The external Pulleys on the Rotation Unit are now considered a permanent fixture and the locking pin holds the Pulley
Assembly in place. If the Rotation Unit is to be removed and replaced it should exchanged as a complete item.

- 96 -
SECTION 16.5 ROLLER LAYOUT.
30 Teeth Pulley x 3
3633-0200-005
Print Head Roller
3633-0180
110 Teeth Pulley
3633-0200-010
Card Feed Roller
3633-0204
Cam Linkage Long x 2
3633-0300-002
Cam Linkage Short x 2

3633-0300-001
Star Washer x 2
Rio/0055/R
Camshaft
3633-0300-001
Rotation Unit
3633-0140
Bearing Plate x 2 Flipper Pulley
3633-0300-004 3652-0140

- 97 -
SECTION 16.6 DRIVE MECHANISM RIGHT HAND SIDE.
Top Cover Assembly

3652-0150-005
80 Teeth Belt
E9055
144 Teeth Belt

E9058
115 Teeth Belt RFID PCB

E9056 H Frame Assembly
M9500-853/R
30 Teeth Pulley
30 Teeth Pulley 3633-0200-005
3633-0200-006

- 98 -
SECTION 16.7 DRIVE MECHANISM LEFT HAND SIDE.
Rotation Unit Position Sensor

3633-0502
115 Teeth Drive Belt

E9056
30 Teeth Pulley
Cam Sensor 3633-0200-005
3633-0502
Camshaft Pulley
3633-0200-005
Camshaft Motor Pulley

3633-0200-006 80 Teeth Cam Belt
E9055

- 99 -
SECTION 16.8 MOTOR LAYOUT AND PART NUMBERS.
Dye-Film Motor
(DC)
Flipper Unit Motor

(Stepper)
Card Feed Motor

Print Head Roller (DC)
Flipper Card Feed Motor
Motor (Stepper) (Stepper) Cam Motor
(DC)

- 100 -
SECTION 16.9 INTERNAL WIRING & SENSOR PART NUMBERS
Dye Film Motor (DC)

LCD Display
Flip Card Motor (Stepper)
Flipper Position Sensor

Cam Sensor
Dye Film Sensor (lower)
Tacho Sensor
Flip Rotation Motor (Stepper)

Cam Motor (DC)
Card Feed Motor (DC)

Card Print Motor (Stepper)
RFID Controller Card Front Sensor
Card Middle Sensor
Top Cover Sensor
Card Rear Sensor
Print Head Wiring
Main Controller PCB
Dye Film Sensor (Upper) FG/3633-0500 (S/Ns A----)
FG/3633-0511 (S/Ns C----)
Print Head Cooling Fan
Magnetic Controller PCB
3633-0501
Power Connector USB Connector
Connector Wiring Loom Part Number Connected Hardware Hardware Part Number(s)
CN1 3633-0174 LCD Display LCD Display E9038
Flipper Position Sensor Flipper Position Sensor 3633-0502

Cam Sensor Cam Sensor 3633-0502
CN2 3633-0170
Dye Film Sensor (Lower) Dye Film Sensor (Lower) 3633-0505
Tacho Sensor Tacho Sensor 3633-0502
Flip Rotation Motor Flip Rotation Motor Rio/0112/R

CN3 3633-0177
Cam Motor Cam Motor Rio/0043/R
Card Front Sensor Card Front Sensor 3633-0502

CN5 3633-0178 Card Middle Sensor Card Middle Sensor 3633-0502
Card Rear Sensor Card Rear Sensor 3633-0502
Dye Film Motor Dye Film Motor Rio/0043/R

CN12 3633-0179
Flip Card Motor Flip Card Motor Rio/0112/R
Card Feed Motor Card Feed Motor Rio/0043/R

CN15 3633-0171
Card Print Motor Card Print Motor Rio/0112/R
RFID PCB RFID PCB 3633-0300

CN16 3633-0172
Top cover Sensor Top cover Sensor 3633-0502
Print Head Print Head 3633-0160

CN17 3633-016 Top Dye Film Sensor Top Dye Film Sensor 3633-0502
Fan Fan E9092

- 101 -
SECTION 16.10 MAGNETIC ENCODING OPTION
Magnetic Encoding Head Mounting Grubscrew Tension Spring Mounting Washer

3633-0110 x1 P1-0038/R x2 E9147 x1 M1560-110/R x2
Location of mounting screws for

Magnetic Head - Rio Pro
3 x 6mm Grub Screws x 2

M1550-140/R

- 102 -
SECTION 17 PRODUCT UPDATES
Rio Pro Printhead Roller Pulley
Please Note:
The large Drive Pulley Flange is fitted here
(attached at four points).
The Large Drive Pulley is now fitted with a

3652-0145 Large Drive Pulley
black Flange to prevent Belt slippage.

- 103 -
Anti Static Brush Strip is fitted

here.
Part Numbers:
3633-0100-011 Brush Strip

E9243 Pop Rivet
3633-0403 Modified Wire Loom
Rio Pro Stepper Motor pulleys are now held in

place by Push-On Star Washer (P/N
RIO/0465), left side also.

- 104 -

- 105 -
Rio Pro Cam Pulley
Cam Pulley (Print Head Up/Down) is now glued

onto the motor shaft with Loctite 422 adhesive.

- 106 -
Fig 1
Additional Plastic Flange now fitted to all

Rio Pro printers to prevent Rotation Belt
and Rotation Drive Belt slipping off.
Fitted to both pulleys on each side.

- 107 -

- 108 -

RIO Pro Maintenance Manual Iss.1d

Diunggah oleh

Informasi Dokumen

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

RIO Pro Maintenance Manual Iss.1d

Diunggah oleh

Hak Cipta:

Format Tersedia

Colour ID Card Printer MAGICARD Rio Pro Maintenance Manual

Magicard Rio Pro single sided colour ID Card Printer - 3633-9001

Duplex Upgrade Kit - 3633-0052

Ultra Electronics Card Systems

Rio Pro Maintenance Manual

The information contained in this document is subject to change without notice.

Rio Pro Maintenance Manual

If using this printer in Germany:

When Handling the Printer:

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.

Rio Pro Maintenance Manual

SECTION 1 INTRODUCTION TO THE PRINTING PROCESS.

The Clear Overcoat Layer

ID Card with Overcoat Layer used as a Security Watermark

photocopied e.g. the Magicard Holokote security watermark.

Dye Sublimation / Inkjet Printing.

Rio Pro Maintenance Manual

Subtractive colour process (YMC) Additive colour process (RGB)

Rio Pro Maintenance Manual

SECTION 1.1 CARD DESIGN LIMITATIONS

SECTION 1.2 BADGE DESIGN

Rio Pro Maintenance Manual

SECTION 2 KEY FEATURES OF THE MAGICARD RIO PRO

Rio Pro Duo is pre-programmed as Double Sided, from new.

Hand Feed slot at the front of the Printer.

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.

Intuitive LCD with simple button menu selections.

USB and Ethernet Interface.

Can be upgraded to print a custom logo Holokote and Holoflex design

Optional ISO 7811 Magnetic Stripe Encoder.

Optional OmniKey 5321 Combi Contact/Contactless Encoder.

Rio Pro Maintenance Manual

SECTION 2.1 SPECIFICATION OF THE MAGICARD RIO PRO

Printing Method: Direct to Card Dye Sublimation.

Resolution: 300 dots per inch (11.8 Dots per mm).

Printing Time: Approximately 35 seconds each side (YMCKO).

Printer Interface: USB Rev 1.1 (USB 2.0 compatible), Ethernet.

Operating Environment: Temperature 15 30 degrees Centigrade.

Power Source: External Power Supply auto-ranging.

Weight: 5.5 kilograms (12 lbs) including Hoppers and PSU.

Dye film loading: Drop in Dye-Film design.

Card Size: Standard ISO CR80 & CR79 sized Cards.

Card Input Hopper Capacity: 100 Cards (0.76mm / 0.030).

Print Length: Full Card 1016 pixels (85.6mm).

Safety: CE Certified, UL listing USA.

Rio Pro Maintenance Manual

SECTION 3 COMPONENT LAYOUT

Hand Feed Slot

Network USB Connection

Rio Pro Maintenance Manual

Thermal Print Card rotation