Datacard I50i Card Personalization System Maintenance Manual

Datacard I50i Card Personalization System Mainte Maintenan nance ce Manua Manuall

June 2001

Part No. 539110-001 Rev. B

Liability Statement This product has been built to the high standards of Datacard Group. Please do not attempt to operate or repair this equipment without adequate training. Any use, operation, or repair in contravention of this document is at your own risk. By acceptance of this system you hereby assume all liability consequent to your use or misuse of this equipment. Datacard assumes no liability for incidental, special, or consequential damage of any kind. Equipment specifications, applications, and options are subject to change at the sole discretion of Datacard without notice.

Proprietary Notice All drawings and information herein are the property of Datacard Corporation. All unauthorized unauthorized use and reproduction is prohibited.

Trademark Acknowledgments Datacard is a registered trademark and LaserGrafix is a trademark of Datacard Corporation. Torx is a registered trademark of Textron, Inc. Windows is a registered trademark of Microsoft Corporation. All other product names are the property of their respective owners.

Datacard Group 11111 Bren Road West Minnetonka, MN 55343-9015 952.933.1223 Fax: 952.933.7971 www.datacard.com

© 2001 Datacard Corporation. All rights reserved. Printed in the United States of America.

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Contents Chapterr 1: System Description Chapte Description ____ _________ __________ __________ __________ __________ _________ _________ __________ __________ ________ ___ 1-1

Audience________________________________________________________________________ ____ 1-2 Audience____________________________________________________________________________ Repair Ability ________________________________________________________________________ 1-2 Serial Numbers ___________________________________________ _______________________________________________________________________ ____________________________ 1-2 Use of this Document__________________________________________________ Document _________________________________________________________________ _______________ 1-3 Product Specifications _______________________________________________________________ ____________________________________________ ___________________ 1-4 Electrical _______________________________________ ________________________________________________________________________ _________________________________ 1-4 Environmental __________________________________________ ___________________________________________________________________ _________________________ 1-4 Communications _______________________________________________ ________________________________________________________________ _________________ 1-4 Card Capacities_________________________________________________________________1-4 Input Hopper Capacity ________________________________________ ______________________________________________________ ______________ 1-4 Reject Hopper Capacity __________________________________________ _____________________________________________________ ___________ 1-4 Output Hopper Capacity Capacity ____________________________________________________ 1-4 Topper Cassette Capacity _______________________________________________________1-4 Protocols _______________________________________ ________________________________________________________________________ _________________________________ 1-4 Physical Specifications ________________________________________________ ___________________________________________________________ ___________ 1-5 Card Specifications ____________________________________________ ______________________________________________________________ __________________ 1-5 Magnetic Stripe Encoding Specifications ______________________________________________ 1-6 Standard Financial Emboss Line Locations _____________________________________________1-6 Standard Emboss Character Height ___________________________________________________1-7 Standard Emboss Character Spacing _________________________________________________1-7 Chapterr 2: Instal Chapte Installation lation _____ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ _________ ____ 2-1

Preparing the Site _________________________________________ ____________________________________________________________________ ___________________________ 2-2 Unpacking/Packing ___________________________________________ ____________________________________________________________________ _________________________ 2-3 Functional Tests ______________________________________________________________________2-6 Administrator Setup ______________________________________________ ______________________________________________________________ ________________ 2-6 Standard CPX Used______________________________________________ Used __________________________________________________________ ____________ 2-6 Baud Rate _______________________________________ __________________________________________________________________ ___________________________ 2-9 Parity Bits____________________________________________________________________2-9 Bits Size ____________________________________ _____________________________________________________________________ _________________________________ 2-9 Monitor _____________________________________ _____________________________________________________________________ ________________________________ 2-9 Test Card ___________________________________________________________________ 2-9 Stripe Retrys ______________________________________ ________________________________________________________________ __________________________ 2-10 Write Only Once____________________________________________________________2-10 Door Password _____________________________________________________________2-10 Save Changes _____________________________________________________________2-10 Financial Card Password ____________________________________________________________2-10 Chapter 3: Preventive Maintenance ____________________ _________________________________________ __________________________ _____ 3-1

Preventive Maintenance __________________________________________ _____________________________________________________________ ___________________ 3-2 Tools and Material ________________________________________________________ ___________ ________________________________________________________ ___________ 3-3 Preventive Maintenance Procedures__________________________________________________3-3

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Cleaning the 150i _______________________________________________________________ _________________________________________________________________ 3-4 Cleaning the O-Rings/Drive O-Rings/Drive Rollers ________________________________________________ 3-4 Cleaning the Sensors_______________ Sensors_____________________________________________________________ ______________________________________________ 3-5 Cleaning the Magnetic Stripe Head ______________________________________________3-6 Verifying Embossing Line Locations and Margins _______________________________________3-7 Verify Start Sentinel and Track Locations for Magnetic Stripe ____________________________ 3-9 Verify Even and Uniform Topping_____________________________________________________3-11 Verify Throat Gap Adjustment________________________________________________________3-12 Chapter 4: Theory of Operation______________________ Operation__________________________________________ _____________________________ _________ 4-1

150i Overview________________________________________________________________________4-2 Component Identification __________________________________________ ____________________________________________________________ __________________ 4-2 Inside View of the 150i________________________________________________________________4-3 Rear View of the 150i _________________________________________________________________ 4-4 Sequence of Operation ______________________________________________________________ ____________________________________________________________ __ 4-5 Memory Map _______________________________________ ________________________________________________________________________ _________________________________ 4-7 Electrical Block Diagram_______________________ Diagram______________________________________________________________ _______________________________________ 4-8 Microprocessor __________________________________________________________________4-9 CPLD____________________________________________________________________________ CPLD___________________________________________________ _________________________ 4-9 Flash ____________________________________________________________________________4-9 DRAM___________________________________________________________________________4-9 FPGA Controller_________________________________________________________________4-10 ROM _____________________________________ ___________________________________________________________________________ ______________________________________ 4-10 EEPROM________________________________________________________________________4-10 Power Inlet Module _____________________________________________________________4-10 36 Volt Power Supply____________________________________________________________4-10 5 Volt Regulator ________________________________________________________________4-10 12 Volt Regulator _______________________________________________________________4-11 System Interlock ________________________________________________________________4-11 RS232 Transceiver _______________________________________________________________ 4-11 LCD Display/Keypad and LEDs___________________________________________________4-11 Main Control Board Schematics______________________________________________________4-12 Chapterr 5: Troubl Chapte Troubleshoo eshooting ting _____ _________ _________ __________ __________ __________ __________ __________ __________ _________ _________ ______ _ 5-1

Troubleshooting Tips _______________________________________________ __________________________________________________________________ ___________________ 5-3 Prerequisite Skills _____________________________________________________________________ 5-4 Diagnostic Routines __________________________________________________________________5-4 Diagnostic Routines Menu ____________________________________________ ________________________________________________________ ____________ 5-5 Sensors ___________________________________________ _____________________________________________________________________ __________________________ 5-6 MS Start Sentinel Sentinel (NTT)_______________________ (NTT)________________________________________________________ _________________________________ 5-7 MS Start Sentinel (Standard) _________________________________________ __________________________________________________ _________ 5-7 Transport____________________________________________________________________5-7 Pick & Stack_________________________________________________________________ Stack______________ ___________________________________________________ 5-7 Pick & Reject _________________________________________________ ________________________________________________________________ _______________ 5-7 Calibration Menu _____________________________________________ ________________________________________________________________ ___________________ 5-8

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Test Cards Menu ________________________________________ _________________________________________________________________ _________________________ 5-9 Standard Test Card _______________________________________________ _________________________________________________________ __________ 5-10 Mag Stripe Test Card _______________________________________________________5-10 Indent Test Card____________________________________________________________5-10 MagStripe/Emboss Test Card ________________________________________________5-10 MagStripe/Emboss/Top Test Card____________________________________________5-10 Smart Card Test Card _____________________________________ _______________________________________________________ __________________ 5-11 Wheel Test Card____________________________________________________________5-11 Topper Test Card ___________________________________________________________5-12 Run Without Cards__________________________________________________________5-12 Preembossed Test Card_____________________________________________________5-12 Character Height Test Card _________________________________________________5-12 Position Offsets Menu ___________________________________________________________5-13 Wheel Parameters Menu ________________________________________________________5-15 Topper Parameters Menu _______________________________________________________5-16 Configuration Menu ____________________________________________________________5-16 Status Request Menu____________________________________________________________5-17 Restore MCB Defaults ___________________________________________________________5-17 Restore Mfg Settings ____________________________________________________________5-17 Save Changes__________________________________________________________________5-17 150i Interconnect Diagrams _________________________________________________________5-18 Main Control Board Connections ________________________________________________5-19 Main Control Board Cable Connections__________________________________________5-20 AC Wiring Diagram _____________________________________________________________5-21 Pin-Out Tables ______________________________________________________________________5-22 Motor Pin-Outs__________________________________________________________________5-22 Sensor Pin-Outs _________________________________________________________________5-24 Serial Communications Pin-Outs _________________________________________________5-26 Identifying Errors Using Error Codes ___________________________________________________5-27 Group xx _______________________________________________________________________5-27 Group yy _______________________________________ _______________________________________________________________________ ________________________________ 5-28 Group zz _______________________________________________________________________5-28 Error Codes_____________________________________________________________________5-32 Main Control Board LEDs ________________________________________________________5-38 Chapter 6: Adjustments ____________________ _______________________________________ ______________________________________ ___________________ 6-1

Introduction _________________________________________________________________________6-2 Mechanical Adjustments ____________________________________________________ _____________________________________________________________ _________ 6-2 Magnetic Stripe Head Height Adjustment _________________________________________ 6-2 Rear Indent Drive Belt Adjustment_________________________________________________ 6-4 Interlock Switch Adjustment ______________________________________________________6-6 Electrical Adjustment_________________________________________________________________6-8 Display Contrast Adjustment______________________________________________________ Adjustment________ ______________________________________________ 6-8 Software Offsets ____________________________________________________________________6-10 Start Diagnostic Routines ________________________________________________________6-10 Position Offsets Menu ___________________________________________________________6-11 Pick Offset _________________________________________________________________6-13

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Smart Card Offset __________________________________________________________6-14 MagStripe NTT Offset________________________________________________________6-15 MagStripe Standard Offset ______________________________________________ __________________________________________________ ____6-17 6-17 MagStripe Variables Offset _______________________________________ __________________________________________________ ___________ 6-19 Emboss Location Offset _____________________________________________________6-20 Topper Offset ______________________________________________________________6-21 Topper Noise Offset_________________________________________________________6-22 Exit Offset __________________________________________________________________6-23 Emboss Height Offset _______________________________________________________6-24 Indent Depth Offset ________________________________________________________6-25 Throat Gap Offset __________________________________________________________6-26 Wheel Home Offset_________________________________________________________6-27 Card Bow Offset____________________________________________________________6-28 Chapterr 7: Removal and Repla Chapte Replacement cement _____ __________ __________ __________ __________ __________ __________ __________ ________ ___ 7-1

Introduction _________________________________________________________________________7-3 Servicing Guidelines ___________________________________________________________ __________________________________________________________________ _______ 7-3 Opening the Top Cover Cover ______________________________________________________________ _______________________________________________ _______________ 7-4 Changing the Password ___________________________________________ ______________________________________________________________ ___________________ 7-5 Top Cover __________________________________________ ___________________________________________________________________________ _________________________________ 7-6 Front Access Panel__________________________________________________________ Panel_______________ ________________________________________________ _____ 7-8 Single Card Access Door ________________________________________________________7-10 Output Hopper Door __________________________________________ ____________________________________________________________ __________________ 7-12 Key Lock _______________________________________________________________________7-14 Input/Output Hopper________________________________________________________________7-16 Output Hopper Drive Belt________________________________________________________7-20 Output Hopper Drive O-Ring_____________________________________________________7-22 Card Registration Sensor ________________________________________________________7-24 Input Hopper Empty Sensor______________________________________________________7-26 Input Home Sensor______________________________________________________________7-28 Output Full Sensor_______________________________________________________________7-30 Card Picked Sensor _____________________________________________________________7-32 Throat Gap Motor ______________________________________________________________7-34 Throat Gap Motor Belt __________________________________________________________7-36 Throat Gap Sensor ______________________________________________________________7-38 Card Transport ______________________________________ ______________________________________________________________________ ________________________________ 7-40 X-Transport Drive Belt____________________________________________________________7-42 X-Home Sensor _________________________________________________________________7-44 Y-Home Sensor _________________________________________________________________7-46 Card Transport Flex Cable ____________________________________ _______________________________________________________ ___________________ 7-48 Carriage Transport Motor________________________________________________________7-50 Magnetic Stripe Assembly ___________________________________________________________7-52 Embosser Assembly__________________________________________________________________7-54 Wheel Home Sensor_____________________________________________________________7-56 Punch Home Sensor_____________________________________________________________7-58 Punch Cam Motor ______________________________________________________________7-60 Punch Cam Belt ________________________________________________________________7-62

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Die Home Sensor _______________________________________________________________7-64 Die Cam Motor _________________________________________________________________ 7-66 Die Cam Belt ___________________________________________________________________7-68 Punch and Die _________________________________________________________________7-70 Topper Assembly____________________________________________________________________7-72 Topper Foil Motion Sensor _______________________________________________________7-74 Topper Platen Sensor____________________________________________________________7-76 Topper Motor___________________________________________________________________7-78 Main Control Board _________________________________________________________________7-80 Power Supply Board_________________________________________________________________7-82 Line Filter ___________________________________________________________________________7-84 Fuse ___________________________________________________________________________7-86 Fan ________________________________________________________________________________7-88 Display/Keypad_____________________________________________________________________7-90 Solenoid Lock Assembly _____________________________________________________________7-92 Reject Full Sensor____________________________________________________________________7-94 Front Smart Card Module (Option) __________________________________________________7-96 Front Indent Printer Module (Option) _________________________________________________7-98 Replacing the Front Indent Ribbon______________________________________________7-100 Rear Indent Printer Module (Option) ________________________________________________7-102 Replacing the Rear Indent Ribbon ______________________________________________7-104 Rear Indent Motor _________________________________________________________________7-106 Rear Indent Drive Belt ______________________________________________________________7-108 Rear Indent Solenoid _______________________________________________________________7-110 Chapter 8: Illustrated Parts Breakdown____________________________________________ 8-1

Introduction _________________________________________________________________________8-2 General _____________________________________________________________________________ 8-2 Cabinet Parts____________________________________________________________________ 8-3 Input/Output Hopper Assembly___________________________________________________ 8-4 Card Transport Assembly _________________________________________________________ 8-6 Magnetic Stripe Assembly ________________________________________________________ 8-7 Embosser Assembly ______________________________________________________________ 8-8 Lower Emboss Housing Assembly_________________________________________________8-10 Upper Emboss Housing Assembly_________________________________________________8-11 Topper Assembly________________________________________________________________8-12 Topper Foil _____________________________________________________________________8-13 Main Control Board _____________________________________________________________8-14 Power Supply___________________________________________________________________8-15 Fan ____________________________________________________________________________8-16 Sensor Cable Harness ___________________________________________________________8-17 Power Cable Harness ___________________________________________________________8-18 Communications Cable_________________________________________________________8-19 Cable/Development Cable _____________________________________________________8-20

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Display/Keyboard_______________________________________________________________8-21 Miscellaneous Spare Parts _______________________________________________________8-22 Solenoid Lock Assembly _________________________________________________________8-23 Reject Full Photocell ____________________________________________________________8-24 Smart Card Assembly ___________________________________________________________8-25 Front Indent Print Assembly ______________________________________________________8-26 Rear Indent Printer Assembly_____________________________________________________8-27 Indent Ribbon __________________________________________________________________8-28 Appendix A: Glossary ___________________________________________________________ A-1

Glossary of Terms____________________________________________________________________ A-1 Appendix B: Wheel Table Configurations__________________________________________ B-1

Standard ____________________________________________________________________________B-3 Tilde N (Ñ) ___________________________________________________________________________B-4 Visa 'V' ______________________________________________________________________________B-5 Diners Club __________________________________________________________________________B-6 Barcelona ___________________________________________________________________________B-7 Barcelona OCR B1 Special____________________________________________________________B-8 Large Gothic K_______________________________________________________________________B-9 Indent-Rear OCR-A1 ________________________________________________________________B-10 Indent-Rear OCR-B1_________________________________________________________________B-11 Indent-Rear MasterCard_____________________________________________________________B-12 Common European _________________________________________________________________B-13 Portugal ____________________________________________________________________________ B-14 Japanese Financial _________________________________________________________________B-15 Japanese Financial Special__________________________________________________________B-16 Japanese Healthcare _______________________________________________________________B-17 Japan Credit (Amex/Diners and Others) ___________________________________________B-18 Visa/Master/JCB and Co-Branded ___________________________________________________B-19 Indent-Rear Inverted MasterCard ____________________________________________________B-20 Czech______________________________________________________________________________B-21 Greece ____________________________________________________________________________B-22 Hungary ____________________________________________________________________________ B-23 Iceland_____________________________________________________________________________B-24 Latvian _____________________________________________________________________________ B-25 Poland _____________________________________________________________________________B-26 Cyrillic ______________________________________________________________________________ B-27 Turkey ______________________________________________________________________________B-28 Yugoslavia__________________________________________________________________________B-29 Ukraine_____________________________________________________________________________B-30 Korea ______________________________________________________________________________B-31

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Front Visa Electron Indent____________________________________________________________B-32 Poland-OCR B1 Indent ______________________________________________________________B-33 Latvian-OCR B1 Indent ______________________________________________________________B-34 Barcelona-OCR B1 Indent ___________________________________________________________B-35 Common European -OCR B1 Indent__________________________________________________B-36 Portugal-OCR B1 Indent _____________________________________________________________B-37 Greece-OCR B1 Indent______________________________________________________________B-38 Hungary-OCR B1 Indent _____________________________________________________________B-39 Iceland-OCR B1 Indent ______________________________________________________________B-40 Turkey-OCR B1 Indent _______________________________________________________________B-41 Yugoslavia-OCR B1 Indent ___________________________________________________________B-42 Ukraine-OCR B1 Indent ______________________________________________________________B-43 Cyrillic-OCR B1 Indent _______________________________________________________________B-44 Korea Visa Electron _________________________________________________________________B-45 Czech Visa Electron _________________________________________________________________ B-46 Common European w/MasterCard Indent____________________________________________B-47 Portugal w/MasterCard Indent_______________________________________________________B-48 Greece w/MasterCard Indent _______________________________________________________B-49 Hungary w/MasterCard Indent_______________________________________________________B-50 Iceland w/MasterCard Indent _______________________________________________________B-51 Latvian w/MasterCard Indent________________________________________________________B-52 Poland w/MasterCard Indent ________________________________________________________B-53 Turkey w/MasterCard Indent_________________________________________________________B-54 Yugoslavia w/MasterCard Indent ____________________________________________________B-55

List of Figures Figure 2-1: Unpacking/Packing ____________________________________________________________ 2-3 Figure 2-2: Included Packed Materials _____________________________________________________ 2-4 Figure 2-3: Packing Material Removal______________________________________________________2-5 Figure 3-1: Preventive Maintenance Schedule______________________________________________ 3-4 Figure 3-2: Sensor Locations _______________________________________________________________3-5 Figure 3-3: Cleaning the Magnetic Stripe Head_____________________________________________ 3-6 Figure 3-4: Embossing Line Locations and Margins Card _____________________________________ 3-8 Figure 3-5: Start Sentinel and Track Locations for Magnetic Stripe ___________________________3-10 Figure 3-6: Wheel Test Card ______________________________________________________________3-12 Figure 4-1: Component Identification ______________________________________________________ 4-3 Figure 4-2: Inside View of the 150i__________________________________________________________ 4-4 Figure 4-3: Rear View of the 150i ___________________________________________________________ 4-5 Figure 4-4: Sequence of Operation ________________________________________________________ 4-7 Figure 4-5: 150i Embedded System Memory Layout _________________________________________ 4-8 Figure 4-6: 150i Main Control Board Block Diagram _________________________________________ 4-9 Figure 4-7: 150i Main Control Board Schematic (1 of 20) ____________________________________4-13 Figure 4-8: 150i Main Control Board Schematic (2 of 20) ____________________________________4-14

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Figure 4-9: 150i Main Control Board Schematic (3 of 20) ____________________________________4-15 Figure 4-10: 150i Main Control Board Schematic (4 of 20)___________________________________4-16 Figure 4-11: 150i Main Control Board Schematic (5 of 20)___________________________________4-17 Figure 4-12: 150i Main Control Board Schematic (6 of 20)___________________________________4-18 Figure 4-13: 150i Main Control Board Schematic (7 of 20)___________________________________4-19 Figure 4-14: 150i Main Control Board Schematic (8 of 20)___________________________________4-20 Figure 4-15: 150i Main Control Board Schematic (9 of 20)___________________________________4-21 Figure 4-16: 150i Main Control Board Schematic (10 of 20)__________________________________4-22 Figure 4-17: 150i Main Control Board Schematic (11 of 20)__________________________________4-23 Figure 4-18: 150i Main Control Board Schematic (12 of 20)__________________________________4-24 Figure 4-19: 150i Main Control Board Schematic (13 of 20)__________________________________4-25 Figure 4-20: 150i Main Control Board Schematic (14 of 20)__________________________________4-26 Figure 4-21: 150i Main Control Board Schematic (15 of 20)__________________________________4-27 Figure 4-22: 150i Main Control Board Schematic (16 of 20)__________________________________4-28 Figure 4-23: 150i Main Control Board Schematic (17 of 20)__________________________________4-29 Figure 4-24: 150i Main Control Board Schematic (18 of 20)__________________________________4-30 Figure 4-25: 150i Main Control Board Schematic (19 of 20)__________________________________4-31 Figure 4-26: 150i Main Control Board Schematic (20 of 20)__________________________________4-32 Figure 5-1 : Standard Test Card ___________________________________________________________5-10 Figure 5-2: Wheel Test Card ______________________________________________________________5-11 Figure 5-3: Topper Test Card______________________________________________________________5-12 Figure 4: Main Control Input/Output Block Diagram________________________________________5-18 Figure 5-5: Main Control Board Connections ______________________________________________5-19 Figure 5-6: Main Control Board Cable Connections ________________________________________ 5-20 Figure 5-7: AC Wiring Diagram____________________________________________________________5-21 Figure 5-8: Main Control Board LEDs_______________________________________________________5-39 Figure 5-9: Sensor Locations ______________________________________________________________5-40 Figure 6-1: Magnetic Stripe Head Height Adjustment________________________________________ 6-3 Figure 6-2: Rear Indent Drive Belt Adjustment _______________________________________________ 6-5 Figure 6-3: Interlock Switch Adjustment_____________________________________________________ 6-7 Figure 6-4: Display Contrast Adjustment ____________________________________________________ 6-9 Figure 7-1: Top Cover _____________________________________________________________________ 7-7 Figure 7-2: Front Access Panel _____________________________________________________________ 7-9 Figure 7-3: Single Card Access Door ______________________________________________________7-11 Figure 7-4: Output Hopper Door __________________________________________________________7-13 Figure 7-5: Key Lock _____________________________________________________________________7-15 Figure 7-6: Input/Output Hopper__________________________________________________________7-17 Figure 7-7: Output Hopper Drive Belt ______________________________________________________7-21 Figure 7-8: Output Hopper Drive O-Ring ___________________________________________________ 7-23 Figure 7-9: Card Registration Sensor_______________________________________________________7-25 Figure 7-10: Input Hopper Empty Sensor ___________________________________________________7-27 Figure 7-11: Input Home Sensor ___________________________________________________________7-29 Figure 7-12: Output Full Sensor ____________________________________________________________ 7-31 Figure 7-13: Card Picked Sensor __________________________________________________________7-33 Figure 7-14: Throat Gap Motor____________________________________________________________7-35 Figure 7-15: Throat Gap Motor Belt________________________________________________________7-37 Figure 7-16: Throat Gap Sensor ___________________________________________________________7-39 Figure 7-17: Card Transport_______________________________________________________________7-41 Figure 7-18: X-Transport Drive Belt _________________________________________________________7-43 Figure 7-19: X-Home Sensor_______________________________________________________________7-45 Figure 7-20: Y-Home Sensor_______________________________________________________________7-47 Figure 7-21: Card Transport Flex Cable ____________________________________________________7-49 Figure 7-22: Carriage Transport Motor _____________________________________________________ 7-51 Figure 7-23: Magnetic Stripe Assembly ____________________________________________________7-53

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Figure 7-24: Embosser ____________________________________________________________________ 7-55 Figure 7-25: Wheel Home Sensor __________________________________________________________7-57 Figure 7-26: Punch Home Sensor __________________________________________________________7-59 Figure 7-27: Punch Cam Motor ___________________________________________________________7-61 Figure 7-28: Punch Cam Belt _____________________________________________________________7-63 Figure 7-29: Die Home Sensor_____________________________________________________________7-65 Figure 7-30: Die Cam Motor ______________________________________________________________7-67 Figure 7-31: Die Cam Belt ________________________________________________________________7-69 Figure 7-32: Punch and Die_______________________________________________________________7-71 Figure 7-33: Topper Assembly_____________________________________________________________7-73 Figure 7-34: Topper Foil Motion Sensor_____________________________________________________7-75 Figure 7-35: Topper Platen Sensor _________________________________________________________ 7-77 Figure 7-36: Topper Motor ________________________________________________________________ 7-79 Figure 7-37: Main Control Board __________________________________________________________7-81 Figure 7-38: Power Supply ________________________________________________________________7-83 Figure 7-39: Line Filter ____________________________________________________________________7-85 Figure 7-40: Fuse_________________________________________________________________________7-87 Figure 7-41: Fan _________________________________________________________________________7-89 Figure 7-42: Display/Keypad______________________________________________________________7-91 Figure 7-43: Solenoid Lock Assembly ______________________________________________________7-93 Figure 7-44: Reject Full Sensor_____________________________________________________________7-95 Figure 7-45: Front Smart Card Module_____________________________________________________7-97 Figure 7-46: Front Indent Printer Module ___________________________________________________7-99 Figure 7-47: Replacing the Front Indent Ribbon ___________________________________________7-101 Figure 7-48: Rear Indent Printer Module __________________________________________________7-103 Figure 7-49: Replacing the Rear Indent Ribbon ___________________________________________7-105 Figure 7-50: Rear Indent Motor __________________________________________________________7-107 Figure 7-51: Rear Indent Drive Belt _______________________________________________________7-109 Figure 7-52: Rear Indent Solenoid ________________________________________________________7-111

List of Tables Table 1-1: Magnetic Stripe Encoding Specifications_________________________________________ 1-6 Table 2-1: Installation Materials and Special Tools___________________________________________ 2-2 Table 3-1: Preventive Maintenance Schedule ______________________________________________3-2 Table 3-2: Line Location and Margins Checklist _____________________________________________ 3-8 Table 3-3: Even and Uniform Topping Checklist ____________________________________________3-11 Table 5-1: Keypad Navigation _____________________________________________________________ 5-5 Table 5-2: Sensor Bit Locations _____________________________________________________________ 5-6 Table 5-3: Test Card Menu ________________________________________________________________ 5-9 Table 5-4 : Smart Card Test Messages _____________________________________________________5-11 Table 5-5: Position Offsets Menu __________________________________________________________5-14 Table 5-6: Wheel Parameters Menu _______________________________________________________5-15 Table 5-7: Spacing and Character Type___________________________________________________5-15 Table 5-8: Topper Parameters Menu ______________________________________________________5-16 Table 5-9: Configuration Menu ___________________________________________________________5-16 Table 5-10: Status Request Menu _________________________________________________________5-17 Table 5-11: Motor Pin-Outs for Connector J10______________________________________________5-22 Table 5-12: Motor Pin-Outs for Connector J11______________________________________________5-23 Table 5-13: Sensor Pin-Outs for Connector J12 _____________________________________________5-24 Table 5-14: Sensor Pin-Outs for Connector J13 _____________________________________________5-25

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Table 5-15: Serial Communications Pin-Outs (J16) __________________________________________5-26 Table 5-16: Error Code Troubleshooting Chart______________________________________________5-32 Table 5-17: Main Control Board LEDs ______________________________________________________5-38 Table 6-1: Keypad Navigation____________________________________________________________6-10 Table 6-2: Position Offsets Menu __________________________________________________________6-11 Table 6-3: Pick Offset ____________________________________________________________________6-13 Table 6-4: Smart Card Offset _____________________________________________________________6-14 Table 6-5: MagStripe NTT Offset___________________________________________________________6-15 Table 6-6: MagStripe Standard Offset _____________________________________________________6-17 Table 6-7: MagStripe Variables Offset _____________________________________________________6-19 Table 6-8: Emboss Location Offset ________________________________________________________6-20 Table 6-9: Topper Offset__________________________________________________________________6-21 Table 6-10: Topper Noise Offset___________________________________________________________6-22 Table 6-11: Exit Offset ____________________________________________________________________6-23 Table 6-12: Emboss Height Offset _________________________________________________________6-24 Table 6-13: Indent Depth Offset __________________________________________________________6-25 Table 6-14: Throat Gap Offset ____________________________________________________________6-26 Table 6-15: Wheel Home Offset___________________________________________________________6-27 Table 6-16: Card Bow Offset______________________________________________________________6-28

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Revision Log 150i Card Personalization System Maintenance Manual Revision

Date

Affected Pages

A

May 2001

All

B

June 2001

Chapter 8

Description of Changes First release of this document. Inf ormation was originally delivered as an online help file. Added Chapter 8, Illustrated Parts Breakdown to his manual.

Regulatory Compliance Notice for USA (FCC Notice) This equipment generates, uses, and can radiate radio frequency energy. If it is not installed and used in accordance with this instruction manual, it may interfere with radio communications. This equipment has been tested and found to be within the limits for Class A computing devices, pursuant to Title 47 CFR Part 15 Subpart B of FCC rules, designed to provide reasonable protection against radio interference in a commercial environment. Operation of this equipment in a residential environment may possibly cause interference. In the event of interference, the users, at their own expense, will be required to take whatever measures are necessary to correct the problem.

Notice for Canada (CUL) This digital apparatus does not exceed the Class A limits for radio noise for digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications. Le présent appareil numérique n'émet pas de bruits radioélectriques dépassant les limites applicables aux appareils numériques de la classe A prescrites dans le Règlement sur le brouillage radioélectrique édicté par le ministère des Communications du Canada.

Notice for Europe See the Declaration of Conformity on the following page.

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Safety All Datacard products are built to strict safety and reliability specifications in accordance with UL1950 and EN60950, therefore, safety issues pertaining to operation and repair of Datacard equipment are primarily environmental and human interface. The following basic safety tips are given to ensure safe installation, operation and maintenance of Datacard equipment and are not to be considered as comprehensive on all matters of safety.

Safe Environment •

•

•

•

•

•

•

Connect equipment to a grounded facility power source. Do not defeat or bypass the ground lead. Place the equipment on a stable surface (table), and ensure floors in work area are dry and non-slip. Insulated rubber floor mats are preferred. Know the location of equipment branch circuit interrupters or circuit breakers and how to turn them on and off in case of emergency. Know the location of fire extinguishers and how to use them. Use only ABC type extinguishers on electrical fires. Know local procedures for first aid and emergency assistance at the customer facility. Use adequate lighting at the equipment. Maintain the recommended range of temperature and humidity in equipment area.

Safe Human Interface •

•

•

Use proper lifting techniques when moving or installing the equipment. Use standard electrostatic discharge (ESD) precautions when working on or near electrical circuits. Do not defeat or disconnect safety interlocks on covers.

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Chapter 1: System Description The 150i Card Personalization System operates as a standalone card embosser. This chapter provides a system description of the 150i embosser.

1

Audience 1-2 Repair Ability 1-2 Serial Numbers 1-2 Use of this Document 1-3 Product Specifications 1-4 Electrical 1-4 Environmental 1-4 Communications 1-4 Card Capacities 1-4 Input Hopper Capacity 1-4 Reject Hopper Capacity 1-4 Output Hopper Capacity 1-4 Topper Cassette Capacity 1-4 Protocols 1-4 Physical Specifications 1-5 Card Specifications 1-5

Magnetic Stripe Encoding Specifications 1-6 Standard Financial Emboss Line Locations 1-6 Standard Emboss Character Height 1-7 Standard Emboss Character Spacing 1-7

150i Card Personalization System Maintenance Manual

1-1

Audience This document is intended for use by authorized representatives of Datacard Corporation who are responsible for the maintenance, service, and repair of the Datacard® 150i Card Personalization System, which is also referred to in this document as the 150i.

Repair Ability The authorized Datacard representative must possess the following ability: • •

• • •

Ability to set up the 150i communication parameters. Ability to check 150i configuration against purchase order agreement and, if necessary, change configuration. Ability to run and interpret software diagnostics. Ability to remove and replace all FRUs (Field Replaceable Units). Ability to diagnose mechanical and electrical failures and correctly adjust all mechanical components including software adjustments.

Serial Numbers Information in this document applies to all 150i Card Personalization Systems beginning with serial number 0350 and higher.

1-2

System Description

Use of this Document This document contains the following chapters to assist the service representative in the maintenance, service, and repair of the 150i: Chapter 1: System Description Provides general information about this document and service data for the 150i. Chapter 2: Installation Provides information for site preparation, unpacking, inspection, setup, configuration, and initial checkout of a 150i. Chapter 3: Preventive Maintenance Provides a preventive maintenance schedule with procedures and tool requirements for periodic maintenance of the 150i. Chapter 4: Theory of Operation Provides basic electrical theory for the 150i. Chapter 5: Troubleshooting Provides a troubleshooting guide to determine which FRU needs to be replaced or what adjustment needs to be performed for proper operation of the 150i. Chapter 6: Adjustments Provides detailed procedures for mechanical, electrical, and software adjustments. Chapter 7: Removal and Replacement Provides removal and replacement procedures for field replaceable items in the 150i. Appendix A- Glossary Provides definitions of terms used throughout the this maintenance manual. Appendix B – Wheel Table Configurations Provided wheel table information and configurations of all available character wheels for the 150i.


1-3

Product Specifications Electrical •

90-264V AC at 4A, 50/60Hz (Single phase, 3 wire grounded receptacle only)

Environmental • • • • •

Noise level: Relative humidity: Maximum heat dissipation: Operating temperature range: ESD susceptibility:

Less than 60dB 20% to 85% non-condensing 1,195 BTU/Hour 60° F to 90° F (15° C to 32° C) The 150i can withstand an ESD discharge of 15kV, 330pF storage and 1.5K ohm series resistance in test simulating a human discharge to the machine’s outer surfaces.

Communications • • • • • •

RS-232 service port RS-232 host port Smart card 1 port Smart card 2 port Diagnostic port Development port

Card Capacities Input Hopper Capacity •

100 cards (automatic card feed)

Reject Hopper Capacity •

Up to 10 cards

Output Hopper Capacity •

Up to 15 cards

Topper Cassette Capacity •

1,600 cards (minimum)

Protocols •

1-4

Supports CPX

System Description

Physical Specifications • • • •

Width: Depth: Height: Weight:

24 inches (61.0 cm) 15.5 inches (35.6 cm) 11 inches (25.4 cm) 70 pounds. (31.8 kg)

Card Specifications The 150i supports only CR80 plastic cards. Dimensions:

Finish: Color: Bow: Material: IC (Smart Card): Magnetic Stripe:

Length: 3.375 inches (85.7 mm) Height: 2.125 inches (54.0 mm) Thickness: 0.030 ±0.010 inches (0.76 mm) Any gloss or matte finish Any color except clear 0.060 inches maximum from flat PVC laminated or unlamented Optional Standard coercivity: 300 to 600 Oe. ± 1.0% High coercivity, reference ISO/IEC 7811 Part 6


1-5

Magnetic Stripe Encoding Specifications The following table gives encoding specifications for magnetic stripe encoding used on the 150i. Table 1-1: Magnetic Stripe Encoding Specifications Track Number

Start Bit

Position*

(inches)

(millimeters)

Skew Angle

Track 1 (IATA)***

0.293 ±0.020

(7.44 ±0.51)

Track 2 (ABA)***

0.293 ±0.020

Track 3 (TTS)***

Track

Location**

BPI

(Max Top in inches)

(Min Bottom in inches)

0° ±20'

0.223

0.333

210 ±8%

(7.44 ±0.51)

0° ±20'

0.353

0.463

75 ±5%

0.293 ±0.40

(7.44 ±1.02)

0° ±20'

0.493

0.603

210 ±8%

NTT-J1

0.296 ±0.020

(6.00 ±0.51)

0° ±10'

0.236

0.472

210 ±8%

NTT-J2

0.296 ±0.020

(6.00 ±0.51)

0° ±10'

0.236

0.472

210 ±8%

* Start Bit Position is referenced from the right edge of the card as viewed from the magnetic stripe side. ** Track Location is referenced from the top edge of the card. *** Track 1 (IATA) = 76 maximum data characters. *** Track 2 (ABA) = 37 maximum data characters. *** Track 3 (TTS) = 104 maximum data characters. Maximum data characters do not include start, end sentinels, and LCR characters. All magnetic stripe specifications are per ISO 7811-2, 7811-4, and 7811-5.

Standard Financial Emboss Line Locations L1 L2 L3 L4 L5

= 7CPI = 10CPI = 10CPI = 10CPI = 10CPI

V = 0.843 ±0.005 inches OCR V = 0.646 ±0.005 inches 1st AN V = 0.488 ±0.005 inches 2nd AN V = 0.332 ±0.005 inches 3rd AN V = 0.175 ±0.005 inches 4th AN

All lines have a left margin of 0.401 ±0.010 inch. V is the distance from the bottom of the card to the center of the character.

1-6

System Description

Standard Emboss Character Height OCR Farrington 7B AN Indent Characters Indent Punctuation

7 Characters per inch 0.016 to 0.019 inches 10 Characters per inch 0.015 to 0.018 inches 0.001 to 0.005 inches 0.001 to 0.007 inches

Standard Emboss Character Spacing OCR Farrington 7B 7 Characters per inch 0.143 ±0.006 inches AN 10 Characters per inch 0.100 ±0.006 inches Indent Characters ±0.006 inches Indent Punctuation ±0.006 inches


1-7



1-8

System Description

Chapter 2: Installation The 150i Card Personalization System operates as a standalone card embosser. This chapter provides instructions for installing the 150i at a customer’s site.

Preparing the Site 2-2 Unpacking/Packing 2-3

Functional Tests 2-6 Administrator Setups 2-6 Standard CPX Used 2-6 Baud Rates 2-6 Parity Bits 2-7 Bit Size 2-7 Format Types 2-7 Protocol 2-7 Sweden Stripe 2-7 Auto Retry 2-7 Topper Select 2-8 Monitor 2-8 Test Card 2-8 Stripe Retries 2-8 Write Only Once 2-8 Door Password 2-8 Save Changes 2-8 Baud Rate 2-9 Parity Bits 2-9 Bits Size 2-9 Monitor 2-9 Test Card 2-9 Stripe Retries 2-9 Write Only Once 2-10 Door Password 2-10 Save Changes 2-10

Financial Card Password 2-10


2-1

Preparing the Site The site requirements are as follows: •

•

The desk or table for the 150i to be placed on must be flat, level, and capable of supporting 70 pounds (31.8 kg). The 150i must have 2 inches of clearance all around the cabinet for ventilation and 18 inches of clearance for the Top Cover to open fully.

•

Unpack the delivered equipment and check for any cosmetic damage.

•

Connect the cables.

•

Power on the 150i.

The following table lists special equipment, materials and special tools required for 150i installation. Table 2-1: Installation Materials and Special Tools

Equipment/Material/Tool

2-2

Note

Required for

25 Blank White Cards with Magnetic Stripe

Shipped with the 150i

Testing general 150i operation.

Vernier Calipers

Standard tool

Measuring distances on card.

Magnetic Stripe Sight Glass

Datacard Part No. 594895-001

Checking encoding specifications.

Magnetic Tape Developer

Datacard Part No. TUL001-014

Checking encoding specifications for magnetic stripe.

Topper Foil

Shipped with the 150i

Checking Topper operation.

Laptop PC equipped with 150i Setup Utility

150i Setup Utility Part No. 555071-001

Running diagnostics, uploading Flash memory, Setting offsets.

OCR Indent Ribbon (option)

Shipped with the 150i (if so equipped)

Checking OCR Indent module operation.

Installation

Unpacking/Packing Refer to the unpacking illustration in Figure 2-1 for details.

Strapping

Cut Apart Cut Apart

150i001s

Cut Tape

Figure 2-1: Unpacking/Packing


2-3

1.

Cut the plastic strapping band and remove the top outer container and the protective plastic bag covering the 150i.

2.

Remove the following items from the container: •

Blank cards (25)

•

Input Hopper card weight

•

Power cord

•

Null modem cable (if ordered)

•

Administrator’s Guide

•

MasterCard™ Insertion tool (if ordered)

•

Topper Cassette

•

Top Cover access keys

•

Datacard 150i Operator Training Video (if ordered)

Input Hopper Card Weight

Blank Cards

Power Cord

Null Modem Cable

Insertion Tool

Administrator's Guide

Keys

150i002s

Topper Cassette (Located inside the 150i in the Topper Module)

Datacard Operator Training Video

Figure 2-2: Included Packed Materials

2-4

Installation

3.

Cut the tape from all 4 corners of the inner container for easier access in the removal of the 150i.

4.

Unlock and lift open the Top Cover on the 150i using the key provided. Remove two hold down screws. Remove the shipping cable tie that holds the Topper Cassette to the Topper module. Remove the shipping foam from the bottom of the transport module. If Rear Indent was ordered for your 150i, remove the shipping cable tie that holds it to the horizontal carriage rail. If Front Indent was ordered, remove its shipping cable tie. The shipping cable ties are removed by pressing the releasing tab located on the head of the cable tie. Retain all cable ties, shipping foam, the protective plastic bag and the original container for possible reshipment of the 150i. When reshipping, secure all loose items to prevent damage to the system. Take special precautions to remove all loose plastic cards from the Input Hopper along with the Input Hopper Card Weight. Use appropriate tape for securing the shipping container’s corners and top cover. Datacard is not responsible for shipping damage due to improperly repackaged systems.

Remove Cable Tie (Optional Module)

Remove Cable Tie

Remove Cable Tie (Optional Module)

Remove Shipping Foam

150i003s

Figure 2-3: Packing Material Removal

Inspect the 150i and accompanying items for shipping damage. If at any point the system or packaging appears to be damaged, follow your company policy for reporting damage. The 150i weighs about 70 pounds (30 kg). It is advisable to have another person help you remove the 150i from the container. Use proper lifting techniques when removing the 150i from the container.

5.

Close the Top Cover and lift the 150i from the container and place it at the preferred location.


2-5

Functional Tests The front panel keypad accesses many functional card tests. Refer to the Test Cards Menu in order to access these tests. To access these Setups, power ON the 150i. When “150i/CPX” is displayed, immediately press the # key. The # key must be pressed before the machine enters the Ready mode in order to access the Setup Menu.

Administrator Setups The following Setups can be changed from the front panel on the 150i: Baud rate Parity bits Bit size Monitor host stream Produce a Test Card on power ON

Standard CPX Used Press the 0 key to select new protocol or the # key to scroll to the next setup. If No was selected, the following menu items appear:

Baud Rates Press the 0 key to select one of the following baud rates or press the # key to scroll to the next setup: 300 1200 2400 4800 9600 (default) 19200 57600

2-6

Installation

Parity Bits Press the 0 key to select one of the following parity settings or press the # key to scroll to the next setup. None (default) Odd Even

Bit Size Press the 0 key to select either 7 bits or 8 bits (default) or press the # key to scroll to the next setup.

Format Types Press the 0 key to select one of the following format types or press the # key to scroll to the next setup. CPX-## (default) Open U5 Sweden1 Sweden2

Protocol Press the 0 key to select one of the following protocol settings or press the # key to scroll to the next setup. CPX-ENQ (default) Xon/Xoff RTS=Flow DTR-Flow Xoff-ENH UX US_EOT

Sweden Stripe Press the 0 key to select one of the following Sweden Strip settings or press the # key to scroll to the next setup. None (default) Code-00

Auto Retry Press the 0 key to select either Yes or No (default) for automatic retrying for reading a magnetic stripe or press the # key to scroll to the next setup.


2-7

Topper Select Press the 0 key to select one of the following topper settings or press the # key to scroll to the next setup. On (1) (default) On (2) On (3) On (4) Off

Monitor Press the 0 key to select one of the following monitor settings or press the # key to scroll to the next setup. Off (default) Card Comm. Stripe Stats

Test Card Press the 0 key to select either Yes to produce a sample financial test card every time the 150i is powered ON or No (default) so test cards will not be produced on power ON or press the # key to scroll to the next setup. (See Test Cards Menu in Chapter 6 of this manual for details.)

Stripe Retries Press the 0 key to select the number of magnetic stripe retries from 0 (default) to 9 times or press the # key to scroll to the next setup.

Write Only Once Press the 0 key to select either Yes or No (default) for writing to the magnetic stripe only once or press the # key to scroll to the next setup.

Door Password Press the 0 key to select to either enable (default) or disable the door password or press the # key to scroll to the next setup.

Save Changes Press the 0 key to select either Yes to save the changes made or No (default) to discard all changes. Press the # key to get out of the Setup Menu and return the 150i to the Ready mode.

2-8

Installation

Baud Rate Press the 0 key to select one of the following baud rates or press the # key to scroll to the next setup: 300 1200 2400 4800 9600 (default) 19200 57600

Parity Bits Press the 0 key to select one of the following parity settings or press the # key to scroll to the next setup. None (default) Odd Even

Bits Size Press the 0 key to select either 7 bits or 8 bits (default) or press the # key to scroll to the next setup.

Monitor Press the 0 key to select either Yes to output the host computer ‘s data stream or No (default) so the output will not present the data stream or press the # key to scroll to the next setup. A terminal emulator must be connected to the 150i Service Port to receive and display this ASCII data. The speed of the 150i will be reduced when in this mode.

Test Card Press the 0 key to select either Yes to produce a sample financial test card every time the 150i is powered ON or No (default) so test cards will not be produced on power ON or press the # key to scroll to the next setup. (See Test Cards Menu in Chapter 6 of this manual for details.)

Stripe Retries Press the 0 key to select the number of stripe retries from 0 (default) to 9 times or press the # key to scroll to the next setup.


2-9

Write Only Once Press the 0 key to select either Yes or No (default) for writing to the magnetic stripe only once or press the # key to scroll to the next setup.

Door Password Press the 0 key to select to either enable (default) or disable the door password or press the # key to scroll to the next setup.

Save Changes Press the 0 key to select either Yes to save the changes made or No (default) to discard all changes. Press the # key to get out of the Setup Menu and return the 150i to the Ready mode.

Financial Card Password To produce major brand financial cards, (i.e., Visa ®, MasterCard®, American Express®, Diners®, JCB®, and Discover ®) the 150i must be first given an initializing password to enable this feature. In the continental US or Canada, this password is obtained by calling the Datacard Corporation service help desk at: 800.328.3996. All other countries, contact your local Datacard Service Representative. They will instruct you on how to enter the initializing password so financial cards can be produced. The format is: *2 (followed by an 8-digit Financial Card Password). By entering the 8-digit Financial Card password enable, the Top Cover access will be reset to the 0000 default password.



2-10

Installation

Chapter 3: Preventive Maintenance The 150i Card Personalization System operates as a standalone card embosser. This chapter provides instructions for performing preventive maintenance on the 150i.

Preventive Maintenance 3-2 Tools and Supplies 3-3 Preventive Maintenance Procedures 3-3 Cleaning the 150i 3-4 Cleaning the O-Rings/Drive Rollers 3-4 Cleaning the Sensors 3-5 Cleaning the Magnetic Stripe Head 3-6

Verifying Embossing Line Locations and Margins 3-7 Verifying Start Sentinel and Track Locations for Magnetic St ripe 3-9 Verifying Even and Uniform Topping 3-11 Verifying Throat Gap Adjustment 3-12


3-1

Preventive Maintenance The following table lists the periodic cleaning and adjustment verification requirements for the 150i. A complete procedure for each item in the table is given in this chapter. Preventive Maintenance (PM) should be performed at 12-month intervals and after any of the following activities: •

Any adjustment to a FRU or subassembly.

•

Any replacement to a FRU or subassembly.

•

Any unscheduled maintenance is performed. Table 3-1: Preventive Maintenance Schedule

Task

FRU/Module

Procedure

Clean the 150i

150i

Vacuum out the entire inside of the 150i and clean the outside of the cabinet with desk cleaner.

Clean the 150i O-Rings/Drive Rollers

150i

Clean O-rings and rubber drive rollers with citrus solvent.

Clean the 150i Sensors

150i

Clean sensors with compressed air.

Clean Magnetic Stripe Head

Magnetic Stripe

Clean head using the Encoder Cleaning Card.

Verify Adjustment of Card Feed Throat

Input/Output Hopper

Verify throat width: 0.045 ±0.005 inch.

Verify Adjustment and Operation of the 150i

Card Transport

Verify horizontal margin, character height and vertical line locations on customer setups.

Verify Start Sentinel and Track Locations for Magnetic Stripe

Magnetic Stripe

Run a Magnetic Stripe Test Card and verify start sentinel and track locations.

Verify Even and Uniform Topping Topper

3-2

Run customer cards and verify cards are top coated evenly and uniformly.

Preventive Maintenance

Tools and Supplies The tools and supplies listed in Table 3-2 are required to perform preventive maintenance as specified in the PM schedule. Table 3-2: Tools and Supplies

Item

Datacard Part Number

Can of compressed air

TUL001-018

Desk cleaner

Any type

Encoder cleaning card

597729-001

Lint-free cloth

Any type

Magnetic stripe sight gage

594895-001

Magnetic stripe tape developer

TUL001-014

Citrus solvent

TUL003-007

Vacuum cleaner

Any type

Vernier calipers

0.00 to 1.00 inch (0.001-inch increments)

Interlock tool

805957-901

Preventive Maintenance Procedures The following procedures are performed to complete the requirements of the PM schedule: •

Cleaning the 150i

•

Cleaning the O-Rings/Drive Rollers

•

Cleaning the Sensors

•

Cleaning the Magnetic Stripe Head

•

Verifying Embossing Line Locations and Margins

•

Verifying Start Sentinel and Track Locations for Magnetic Stripe

•

Verifying Even and Uniform Topping

•

Verifying Throat Gap Adjustment


3-3

Cleaning the 150i 1.

Unlock and lift up the Top Cover.

2.

Power OFF the 150i and remove the power cord.

3.

Vacuum out the inside of the 150i.

4.

Clean the outside of the cabinet with either a damp lint-free cloth or desk cleaner.

Cleaning the O-Rings/Drive Rollers 1.

Unlock and lift up the Top Cover.

2.


3.

Clean the following O-Rings or drive rollers with citrus solvent: •

Magnetic Stripe Encoder roller

•

Output Hopper drive rollers (top and bottom)

•

Output Hopper drive belt

•

Topper Foil Motion roller

Inspect all O-rings and drive rollers for cracks or cuts. Replace if necessary. Topper

Topper Foil Motion Roller Magnetic Stripe Encoder Roller

Magnetic Stripe

Output Hopper Drive Roller

Output Hopper Drive Belt

150i004s

Motor

Figure 3-1: Preventive Maintenance for Rollers

3-4


Cleaning the Sensors 1. Unlock and lift up the Top Cover. 2. Power OFF the 150i and remove the power cord. 3. Use a can of compressed air to clean the following sensors (see Figure 3-2). •

Card Picked sensor

•

Card Registration sensor

•

Die Cam Home sensor

•

Input Home sensor

•

Input Hopper Empty sensor

•

Output Full sensor

•

Punch Cam Home sensor

•

Reject Full sensor

•

Throat Gap sensor

•

Topper Foil Motion sensor

•

Topper Platen sensor

•

Wheel Home sensor

•

X-Home sensor (located on 150i base)

•

Y-Home sensor

•

Indent Foil Motion sensor (if so equipped)

Topper Pla ten Sensor

Reject Full Sensor

Topper Foil Motion Sensor

Throat Gap Sensor

X-Home Sensor Y-Home Sensor

Wheel Home Sensor Punch Cam Home Sensor

Die Cam Home Sensor

Card Registration Sensor Card Picked Sensor

150i005s

Output Full Sensor

Rear View Input Hopper Empty Sensor

Input Home Sensor

Figure 3-2: Sensor Locations


3-5

Cleaning the Magnetic Stripe Head 1. Unlock and lift up the Top Cover. 2. Power OFF the 150i and remove the power cord. 3. Clean the following areas: •

•

•

Vacuum card dust from around the magnetic stripe head. Remove remaining dust with a damp cloth. Clean rubber roller with a cloth lightly moistened with citrus solvent. Move an Encoder Cleaning Card (see Table 3-2 for part number) back and forth over the magnetic stripe head.

4. Plug in the power cord and power ON the 150i.

Cleaning Card

150i006s

Figure 3-3: Cleaning the Magnetic Stripe Head

3-6


Verifying Embossing Line Locations and Margins The following procedure will produce a Standard Financial Test Card. The card will be picked, encoded, embossed, topped and placed in the output tray. Perform the following steps:

1. Place blank white cards in the Input Hopper. 2. From the READY mode, press *#3253. The message “SELECT EXIT MODE: (1) APP (2) DIAGNOSE” is displayed. 3. Press 2 on the 150i keypad. The message “BOOT TO SERVICE DIAGS!” is displayed followed by “150i Diags Rev. X.X Service.” 4. Press the # key. The message “Loading On Board Diags. Please Wait...” is displayed followed by: “150i On Board Diagnostics Diagnostic Routines.” 5. Press the 8 key twice (2), the message “150i Onboard Diagnostics Test Cards” is displayed. Press the # key to select. 6. Press the 8 key four (4) times, the message “Mag Stripe/Emboss/Top” is displayed. Press the # key to select. 7. “Select Encode Format IA” is displayed. Select either IA or NTT by pressing the 8 key. Press the # key to select. 8. The message “Stop At One Card? ( #) YES (1) NO (0) ESC” is displayed. Press the # key for one card. The message “MS (X10)/Emboss/Top” is displayed as the card is processed. 9. After the card is complete and delivered to the Output Tray, check line locations. (See Standard Financial Emboss Line Locations in Chapter 1 of this manual.) 10. To exit the Diagnostic Mode and restart the 150i, cycle power to the 150i. To remain in the Diagnostic Mode, press the 0 key to return to the Diagnostic Menu option.


3-7

Table 3-3: Line Location and Margins Checklist

Check

Values

Characters

All present and flawless.

Tolerances

Make sure the left margin is parallel to the card's left edge and all lines are parallel to the card's bottom edge.

OCR character height (top line)

0.016 to 0.019 inch.

AN character height (remaining lines)

0.015 to 0.018 inch.

150i009s

Figure 3-4: Embossing Line Locations and Margins Card

3-8


Verifying Start Sentinel and Track Locations for Magnetic Stripe The following procedure will cause the 150i to pick a card and transport it to the Magnetic Stripe module. The card will be written to and read by the module and then transported to the output tray. No topping or embossing will occur. Perform the following steps:

1. Place blank white cards (with magnetic stripe) in the Input Hopper. 2. From the READY mode, press *#3253. The message “SELECT EXIT MODE: (1) APP (2) DIAGNOSE” is displayed. 3. Press 2 on the 150i keypad. The message “BOOT TO SERVICE DIAGS!” is displayed followed by “150i Diags Rev. X.X Service.” 4. Press the # key. The message “Loading On Board Diags. Please Wait...” is displayed followed by: “150i On Board Diagnostics Diagnostic Routines.” 5. Press the 8 key twice (2); the message “150i Onboard Diagnostics Test Cards” is displayed. Press the # key to select. The message “150i Test Cards Standard” is displayed. 6. Press the 8 key once (1); the message “150i Test Cards Mag Stripe” is displayed. Press the # key to select. 7. The display should read “Select Encode Format.” Select either IA or NTT by pressing the 8 key. Press the # key to select. 8. The message “Stop At One Card?” ( #) YES (1) NO (0) ESC” is displayed. Press the # key for one card. 9. The 150i encodes a test pattern on the magnetic stripe. 10. Develop the magnetic stripe using magnetic tape developer (Datacard PN TUL001-014). 11. Use the magnetic stripe sight gage to ensure proper alignment of the stripe data. Check the card against Figure 3-5. Also see, Magnetic Stripe Encoding Specifications in Chapter 1 of this manual. 12. To exit the Diagnostic Mode and restart the 150i, cycle power to the 150i. To remain in the Diagnostic Mode, press the 0 key to return to the Diagnostic Menu option.


3-9

Magnetic Stripe Sight Gage IATA Track 1 Loc ABA Track 2 Loc

Place card tight to this corner.

TTS Track 3 Loc

0.293 +/-0.020 Inch

First Bit IATA Track 1 ABA Track 2 TTS Track 3

IATA Track 1 ABA Track 2 TTS Track 3 Card (Rear)

150i089s

Figure 3-5: Start Sentinel and Track Locations for Magnetic Stripe

3-10


Verifying Even and Uniform Topping The following procedure will cause a Wheel Test Card with topping to be produced. The card will be picked, embossed with all the embossing wheel characters, topped, and placed in the output tray. Perform the following steps:

1.

Place blank white cards in the Input Hopper.

2.

From the READY mode, press *#3253. The message “SELECT EXIT MODE: (1) APP (2) DIAGNOSE” is displayed.

3.

Press 2 on the 150i keypad. The message: “BOOT TO SERVICE DIAGS!” is displayed followed by “150i Diags Rev. X.X Service.”

4.

Press the # key. The message “Loading On Board Diags. Please wait...” is displayed followed by “150i On Board Diagnostics Diagnostic Routines.”

5.

Press the 8 key twice (2); the message “150i On Board Diagnostics Test Cards” is displayed. Press the # key to select.

6.

The message “150i Test Cards Standard” is displayed.

7.

Press the 8 key 7 times; the message “Topper” is displayed. Press the # key to select.

8.

The message “Stop At One Card?” ( #) YES (1) NO (0) ESC” is displayed.

9.

Press the # key for one card.

10. The card is embossed and topped at the Topper limits, then delivered to the Output Tray. 11. Inspect the card for even and uniform coating using the following table. Table 3-4: Even and Uniform Topping Checklist

Check

Values

Characters

All present and flawless.

Tolerances

Make sure the left margin is parallel to the card's left edge and all lines are parallel to the card's bottom edge.

OCR character height (top line)

0.016 to 0.019 inch.

AN character height (remaining lines)

0.014 to 0.018 inch.


3-11

12. To exit the Diagnostic Mode and restart the 150i, cycle power to the 150i. To remain in the Diagnostic Mode, press the 0 key to return to the Diagnostic Menu option.

150i013s

Figure 3-6: Wheel Test Card

Verifying Throat Gap Adjustment To verify the throat gap adjustment, perform the following steps:

1. Insert a stack of pre-embossed cards in the Input Hopper. 2. Cycle the cards through the 150i and observe that only one pre-embossed card at a time gets picked. If pre-embossed cards are not correctly picked, refer to Throat Gap Offset in Chapter 6, Adjustments.



3-12


Chapter 4: Theory of Operation The 150i Card Personalization System operates as a standalone card embosser. This chapter provides general theory of operation for the 150i.

4

150i Overview 4-2 Component Identification 4-2 Inside View of the 150i 4-3 Rear View of the 150i 4-4 Sequence of Operation 4-5 Memory Map 4-7 Electrical Block Diagram 4-8 Microprocessor 4-9 CPLD 4-9 Flash 4-9 DRAM 4-9 FPGA Controller 4-10 ROM 4-10 EEPROM 4-10 Power Inlet Module 4-10 36 Volt Power Supply 4-10 5 Volt Regulator 4-10 12 Volt Regulator 4-11 System Interlock 4-11 RS232 Transceiver 4-11 LCD Display/Keypad and LEDs 4-11

Main Control Board Schematics 4-12


4-1

150i Overview The 150i is a full featured single-pass card personalization system. The 150i embosses, encodes, and tops financial plastic cards. Depending on the options ordered, the 150i is also capable of indent printing and smart card personalization.

Component Identification The follow bulleted list identifies the major components of the 150i. See Figure 4-1 for their location. •

•

•

•

•

•

Output Hopper Door Single Card Access Door Keyhole Keypad Display Indicators and icons on display: •

Power Indicator

•

Ready Indicator

•

Error Indicator

•

Service Indicator

Optional Indicator Top Cover Power Switch •

•

•

Indicators

Display

Keypad Keyhole Output Hopper Door

Power Switch

Single Card Access Door

Figure 4-1: Component Identification

4-2

Theory of Operation

Inside View of the 150i The following bulleted list identifies the major modules inside of the 150i. See Figure 4-2 for their location. •

•

•

•

•

•

•

•

•

•

Card Transport Module Embosser Module Front Indent Printing Module Good Card Tray (Output tray) Input Hopper Magnetic Stripe Encoding Module Reject Tray Smart Card Personalization (Optional) Topper Module Front/Rear Indent (Optional)

Top Cover

Reject Tray Front Indent Printing Module Topper Module Card Transport Module

Embossing Module

Input Hopper

SmartCard Personalization Module

Magnetic Stripe Encoding Module

Good Card Tray

Figure 4-2: Inside View of the 150i


4-3

Rear View of the 150i The following bulleted list identifies the components on the rear of the 150i. See Figure 4-3 for their location. •

•

On/Off Switch Communication Ports Host Service Smart Card 1 (Option) Smart Card 2 (Option) Diagnose (Option) Development (Option) Power Receptacle Fan •

•

•

•

•

•

•

•

Communication Ports

On/Off Switch

Communication Ports

Diagnose Host

Development Service

Power Receptacle Smart Card 1

Smart Card 2

Comm uni c a ti on Ports

Di a gnos e

De v e l opme nt

Figure 4-3: Rear View of the 150i

4-4

Theory of Operation

Sequence of Operation When reading the Sequence of Operation, reference Figure 4-4. 1. After the 150i initializes on power up, cards can be produced. a. Once the system detects that a block of data has been received, the 150i acknowledges the data and signals the Topper Platen heater to turn on. 2. The 150i senses cards in the Input Hopper by checking the Input Hopper Empty sensor: a. The card pick mechanism picks a card and then the Card Picked sensor detects that a card is present. b. The card is transported to the Card Registration sensor to index the position of the card in the 150i. 3. The card is transported to the Magnetic Stripe module: a. Depending on the magnetic stripe setup, the card makes as many as three passes to read and write to the card’s magnetic stripe tracks. b. If the magnetic stripe can not be written to or read from, the card is transported to the Reject Tray. 4. The Card Transport mechanism moves the card to the Embossing Wheel: a. The embossing wheel senses the home position (Wheel Home sensor) the first time a character is requested to print. The embossing wheel will move either clockwise or counter clockwise depending on how quickly the embossing character can be moved to be embossed on the card. b. The card will move in four directions as the punch and dies emboss characters on the card. c. The Die Cam Home sensor and the Punch Cam Home sensor detect when both cams are in their home position. Both the die and the punch cams work simultaneously to emboss characters on a card. 5. After a card is embossed, it is transported to the Topper assembly where the bottom half of the card is topped: a. The Topper Platen sensor detects that the platen is in its home position and up to temperature and ready to top cards. b. As a card is moved into the Topper assembly, a solenoid is activated to apply platen pressure and heat to the topping foil. This topping foil adheres to the raised embossed characters on the card. c. After a card is topped and removed from the Topping assembly, the topping foil is advanced. Movement of the foil is detected by the Topper Foil Motion sensor and the Topper Platen heater is turned off.


4-5

6. After a card is topped, the completed card is transported to the Output Tray for delivery to the operator.

Topper Assembly

Topper Platen Sensor

Wheel Home Sensor

Card Registration Sensor Die Cam Home Sensor

Card Picked Sensor

REAR VIEW Topper Foil Motion Sensor

Input Home Sensor

Embossing Wheel

Punch Cam Home Sensor

Output Tray

Output Full Sensor

Input Hopper Empty Sensor

Figure 4-4: Sequence of Operation

4-6

Theory of Operation

Memory Map The following shows a memory map of the 150i system.

BIOS

MiniBIOS

ROM-DOS

ROM-DOS KERNEL

Drive A: COMMAND

ROM DISK

Drive B: APPLICATION

FLASH DISK

ROM AREA

DOS ROM

BIOS RAM

256K

VECTORS

Figure 4-5: 150i Embedded System Memory Layout


4-7

Electrical Block Diagram The following section provides a brief description of the 150i Main Control Board. Refer to Figure 4-6 for details. The control board provides all the electronics to control all stepper motor functions, solenoid actions, and monitors all sensor activity.

36 Volt Power Supply

Power Inlet Module

System Interlock

12 Volt Regulator

5 Volt Regulator

Microprocessor

DRAM

CPLD DRAM Controller

Flash

RS232 Transceiver

FPGA Controller

LCD Display / Keypad & LEDs

ROM

EEPROM

Figure 4-6: 150i Main Control Board Block Diagram

4-8

Theory of Operation

Microprocessor The microprocessor is the controlling element for all functions within the 150i system. It is a 32-bit microprocessor clocked at 50 MHz. The processor power is supplied by filtered 5.0 volt supply. There are 25 address lines to the processor which supports 16 MB of memory. The microprocessor supports the address bus A1 – A25. There are two addition signals Byte High Enable (BHE) and Byte Low Enable (BLE) that are decoded by the CPLD to indicate which address space is desired. The microprocessor generates six chip selects (CS0 – CS4 and UCS) that are used by the CPLD and FPGA for device enabling devices. The microprocessor supports four Interrupts (Int0 – Int3) that are driven by the CPLD, FPGA, and interlock circuitry. There is one non-maskable interrupt (NMI) that is driven by a power supervisor chip (DS1231). When voltage drops below a set voltage, a (POWER_FAIL) signal is asserted to the NMI, which initiates a power-down sequence in the firmware code.

CPLD This component performs the address decoding, DRAM control, flash control, additional chip select (CS) generation and microprocessor interface functions. The global RESETOUT is generated internally by the system RESET input. The display control signals are generated internally.

Flash The flash memory chip is 8 MB (512K X 16 ) and contains the firmware code that controls and operates the 150i system Address line A0 is tied to ground with/BYTE time high. The flash memory chip is 16-bits wide. This component incorporates a Boot Block protection jumper (J2) that enables updating of the firmware without corrupting the boot code. A jumper placed on position 1-2 enables “Protection of the Boot Block.” A jumper placed on position 2-3 enables “Programming of the Boot Block.” There are two modes of flash control. J4 enables programming via a JTAG or invokes normal operation. A jumper placed on position 1-2 enables “Normal Operation.” A jumper placed on position 2-3 enables JTAG programming of the firmware.

DRAM There are two memory DRAMs and are 256K arranged to provide 512K X 16 of main memory for the microprocessor.


4-9

FPGA Controller The FPGA (Field Programmable Gate Array) performs the controlling functions of all the mechanical devices. It receives commands from the microprocessor and either drives the required outputs or sends a block of inputs back to the microprocessor. All the sensors, stepper motors, the DC motor, solenoids, interlock, and magnetic stripe functions are controlled by this chip. It is necessary to program this device on every power cycle. LED D18 is illuminated while the device is being programmed. D18 will be disabled when programming is complete.

ROM The ROM (Read Only Memory) is configured in serial for loading of the Field Programmable Gate Array (FPGA). The device is a one-time programmable (OTP) device organized as a 262,144 X 1 bit map. The FPGA provides the Clock (CLK) and Chip Enable (CE) signals. The RESET (RST) is provided by the global reset signal.

EEPROM The EEPROM (Electrically Erasable Programmable Read Only Memory) can be written to and changed many times and is used for data storage. This device is organized as an 8192 X 8 64 K serial device. A 2-Wire communication protocol is tied to the FPGA. Configurations, offsets, and settings are stored in this chip.

Power Inlet Module The main system ON/OFF switch is contained on this module. A replaceable 250 volt 6.3 amp fuse is accessible on the rear of the module. A power line filter is embedded into the inlet module. This reduces the Electro Magnetic Interference (EMI) measured on the power cord.

36 Volt Power Supply This switching power supplies 36V DC to the 150i system with a maximum output of 300 watts. The AC input voltage can be anywhere for 90 to 264V AC at 50/60 Hz

5 Volt Regulator A switching regulator is utilized to create the 5.0-volt supply. An inductor and a barrier diode are incorporated as part of the regulation circuitry. The 5.0 volts (Vcc) is supplied to all IC’s via a discrete Vcc plane within the printed circuit board.

4-10

Theory of Operation

12 Volt Regulator A linear regulator is utilized to create a 12.0-volt regulated supply. A voltage divider network connected to the Adj Input (pin #1) which controls the output voltage. The 12.0 volts is used to supply to the magnetic stripe driver circuitry.

System Interlock The 36-volt supply is tied to the input of a safety rated SPST relay. The output creates a 36-volt interlock voltage plane within the main controller circuit board. This 36 volts supplies all the stepper motor drivers, solenoids, and the DC Topper Foil Transport motor. The coil of the relay is connected to the interlock safety switch on the 150i system.

RS232 Transceiver The RS232 Transceiver device supports a 3-driver and 5-receiver RS232 transceiver configuration. The device incorporates an Electro-Static Discharge (ESD) circuit to withstand +/- 10 K volts shocks. The 150i Host and Debug ports support the modem control signals found on RS232 Comm lines. The transceivers inputs and outputs are tied directly to the microprocessor serial Comm ports.

LCD Display/Keypad and LEDs The display incorporates a 2 X 20 LCD display. LCD control signals and 8-bit data bus are supplied to the display. Five independently controlled LED’s provide visual status and control functions. A 10 digit keypad allows user input from the front panel.


4-11

Main Control Board Schematics The following Main Control Board schematics show the electronic circuitry for controlling the 150i system.

Figure 4-7: 150i Main Control Board Schematic (1 of 20) 4-12

Theory of Operation

Figure 4-8: 150i Main Control Board Schematic (2 of 20)


4-13


Theory of Operation

Figure 4-10: 150i Main Control Board Schematic (4 of 20) 150i Card Personalization System Maintenance Manual

4-15


4-16

Theory of Operation


4-17


4-18

Theory of Operation


4-19


Theory of Operation


4-21


Theory of Operation


4-23


Theory of Operation


4-25


Theory of Operation



4-27


Theory of Operation


4-29


Theory of Operation



4-31



4-32

Theory of Operation

Chapter 5: Troubleshooting The 150i Card Personalization System operates as a standalone card embosser. This chapter of the manual provides information and procedures to isolate a fault to the part, and/or component level. It includes symptoms, fault isolation procedures, use of diagnostic tools, and error codes.

5

Troubleshooting Tips 5-3 Prerequisite Skills 5-4 Diagnostic Routines 5-4 Diagnostic Routines Menu 5-5 Sensors 5-6 MS Start Sentinel (NTT) 5-7 MS Start Sentinel (Standard) 5-7 Transport 5-7 Pick & Stack 5-7 Pick & Reject 5-7 Calibration Menu 5-8 Test Cards Menu 5-9 Standard Test Card 5-10 Mag Stripe Test Card 5-10 Indent Test Card 5-10 MagStripe/Emboss Test Card 5-10 MagStripe/Emboss/Top Test Card 5-10 Smart Card Test Card 5-11 Wheel Test Card 5-11 Topper Test Card 5-12 Run Without Cards 5-12 Preembossed Test Card 5-12 Character Height Test Card 5-12 Position Offsets Menu 5-13 Wheel Parameters Menu 5-15 Topper Parameters Menu 5-16 Configuration Menu 5-16 Status Request Menu 5-17


5-1

Restore MCB Defaults 5-17 Restore Mfg Settings 5-17 Save Changes 5-17

150i Interconnect Diagrams 5-18 Main Control Board Connections 5-19 Main Control Board Cable Connections 5-20 AC Wiring Diagram 5-21

Pin-Out Tables 5-22 Motor Pin-Outs 5-22 Sensor Pin-Outs 5-24 Serial Communications Pin-Outs 5-26

Identifying Errors Using Error Codes 5-27 Group xx 5-27 Group yy 5-28 Group zz 5-28 Error Codes 5-32 Main Control Board LEDs 5-38

5-2

Troubleshooting

Troubleshooting Tips When correcting errors, it is a good idea to perform the following: •

•

•

•

•

•

•

Always power OFF the 150i. Load the Input Hopper if the card stock is low. Clear any rejected cards from the Reject Tray. Replace the foil in the Topper Module if it is getting low. Replace the Indent Ribbon if it is getting low. Make sure the Top Cover is closed and locked. Output Hopper door is fully closed.

Use these tips to correct the following general problems. If A Card Is Loose In The 150i •

•

Check the inside of the 150i for cards that may have fallen from the Card Transport module. Remove the cards and attempt to resume printing.

If A Card Is Jammed In The Input Hopper •

•

Remove any jammed cards from the Input Hopper module by pulling cards from the back of the Input Hopper through the card throat. Attempt to resume printing.

If A Card Is Jammed In The Embosser Module •

•

Remove any jammed cards from the Embosser module. Attempt to resume printing.

If A Card Is Jammed In The Topper Module •

•

Remove any jammed cards from the Topper module. Attempt to resume printing.

If A Card Is Jammed In The Front Or Rear Indent Module •

•

Remove any jammed cards from the front or rear Indent module. Attempt to resume printing.

If A Card Is Jammed In The Smart Card Module •

•

Remove any jammed cards from the Smart Card module. Attempt to resume printing. When removing jammed cards from the 150i, care must be taken not to damage components.


5-3

Prerequisite Skills Anyone troubleshooting the 150i system should possess the following skills: •

Proficiency in CE communications setup as covered in the Datacard Network Connectivity Handbook.

Diagnostic Routines The 150i software offers a number of diagnostic routines that test and exercise various components in the 150i. These diagnostics can be used to verify proper operation or to detect a point of failure. Start Diagnostic Routines To select the diagnostic programs on the 150i front panel, do the following: 1. Press *#3253 on the front keypad. 2. Press 2 (Diagnose) to select the diagnostic control application. 3. The system will reboot and go into the diagnostics mode.

After a short pause, the 150i front panel will display the following message: 150i Diags Rev X.XX Service

4. To select the front panel options, press the # (pound) key.

After a short pause, the 150i front panel displays the following message: Loading Onboard Diags Please wait...

The main menu appears. When running diagnostics from the front panel, the 150i system is in the off-line mode. The keypad is used to navigate through the menus as they are displayed on the front panel of the 150i system.

5-4

Troubleshooting

Table 5-1: Keypad Navigation Key

Description

#

Selects option (Enter key).

0

Aborts menu option or backs-up 1 menu option.

2

Scrolls the menu up or will increment a setting.

3

Offset adjustments range toggle from ±1 times the increment to ±10.

4

Scrolls the menu to the left.

5

Changes offset from (-) negative to (+) positive.

6

Scrolls the menu to the right.

8

Scrolls the menu down or will decrement a setting.

Diagnostic Routines Menu The Diagnostic Routine menu is used for the selection of various options listed below: 1. From the Main menu, select Diagnostic Routines . 2. Press the # key to select a one of the menu options below: •

•

•

•

•

•

Sensors MS Start Sent. (NTT) MS Start Sent. (Standard) Transport Pick & Stack Pick & Reject


5-5

Sensors This diagnostic test is used to test all the photocells and switches on the 150i system. The test returns a status word on the front panel display. This test will indicate if a photocell or a switch is opened or closed. The test reads a hardware status port. Some of the signals for open or closed may be inverted. Check whether a photocell or switch has changed states. The example below shows the sensor value and their bit location. Sensor Value: Bit Location:

1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 1 0 0 1 1 1 1 0 0 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

Table 5-2: Sensor Bit Locations Bit Location

Description (0=open,1=closed)

1

X Home Sensor

2

Y Home Sensor

3

Wheel Home Sensor

4

Lower Emboss Motor Home Sensor

5

Upper Emboss Motor Home Sensor

6

Unused

7

Input Hopper Empty/Low Sensor

8

Unused

9

Registration Sensor

10

Unused

11

Pick Home Sensor

12

Output Hopper Full Sensor

13

Topper Solenoid Sensor

14

Indent Ribbon Motion Sensor

15


16

Card Pick Sensor

17

MCB Type 1=4.0, 0=3.5

18

Reject Full Sensor

19

Unused

20

Unused

20

Unused

22

Unused

23

Top Cover Interlock

24

Throat Gap Home Sensor

1. From the Main menu, select Diagnostic Routines . 2. Press the # key to select Sensors option.

5-6

Troubleshooting

MS Start Sentinel (NTT) Use this diagnostic to adjust the Magnetic Stripe Start Sentinel position. It will return an offset back to the display which is used for the stripe head offset. The test will return an X offset which can be saved as a reference. 1. From the Main menu, select Diagnostic Routines . 2. Press the # key to select MagStripe (NTT) option.

MS Start Sentinel (Standard) (Standard) Use this diagnostic to adjust the Magnetic Stripe Start Sentinel position. It will return an offset back to the display which is used for the stripe head offset. The test will return an X offset which can be saved as a reference. 1. From the Main menu, select Diagnostic Routines . 2. Press the # key to select MagStripe (Standard) option.

Transport This diagnostic test exercises the transport. Use this test to exercise the transport without cards. 1. From the Main menu, select Diagnostic Routines . 2. Press the # key to select the Transport option.

Pick & Stack This diagnostic test picks a card from the Input Hopper and stacks the card in the Output Hopper. 1. From the Main menu, select Diagnostic Routines . 2. Press the # key to select the Pick & Stack option.

Pick & Reject This diagnostic test picks a card from the Input Hopper and stacks the card in the Reject Tray. 1. From the Main menu, select Diagnostic Routines . 2. Press the # key to select the Pick & Reject option.


5-7

Calibration Menu The Calibration Test moves the card to a fixed stop position. The [X and Y] offsets are displayed on the front panel for the card stop location. Adjust the offset as follows: •

•

•

•

•

•

•

•

All Positions (Pick, Topper, Exit) Pick Position Topper Position Exit Position Reject Position Throat Gap Wheel Offset Smart Card XY

Adjust the offsets as follows: •

•

•

•

•

•

5-8

Select Calibration from the main menu by pressing the # key. Press the 4 key to move the card X position to the left, toward the Topper. Press the 6 key to move the card X position to the right toward the Input Hopper X home photocell. Press the 8 key to move the card Y position back to the Y home photocell. Press the 2 key to move the card Y position away from the Y home photocell. Press the # key to select the new offsets. If the 0 key is pressed, the new offset is ignored.

Troubleshooting

Test Cards Menu The Test Cards menu is used for f or the selection of various test card options. •

•

When Test Cards appears on the main menu, press # to select. Press the # key to select a menu option.

Table 5-3: Test Card Menu 150i Test Cards Standard Mag Stripe Indent Mag Stripe/Emboss Mag Stripe/Emboss/Top Smart Card Wheel Topper Run Without Cards Preembossed Character Height

To make any Test Card, do the following: •

•

•

Use the 2 key or 8 key to scroll through the Test Cards menu. Select the Test Card to be made by pressing the # key. If you are making a Mag Stripe test card or a Preembossed test card, do the following: (For other test cards, skip this step.) Press # to select encode format. Use the 2 or 8 keys to scroll through options. Press # to select an option. For “Stop at One Card?”, press # for Yes, 1 for No and 0 to Escape. •

•

•

•


5-9

Standard Test Card This option is used to setup emboss line locations and margins. The test will emboss 3 characters on the card with 7 char/inch font using the character 8. The two line locations (800, 250) are used with a fixed margin of .250 of an inch.

.250

3.000

.800

.250

Standard

Test

Card 54740-78

Figure 5-1 : Standard Test Card

Mag Stripe Test Card This option is used to encode 2 tracks of STD bank code data for f or tracks 1 and 2.

Indent Test Card This option is used to make an Indent test card if the 150i is so equipped.

MagStripe/Emboss Test Card This option is used to make a 3-line financial emboss test card with 2 tracks of encoded data.

MagStripe/Emboss/Top MagStripe/Emboss/T op Test Card This option is used to make a 3-line topped financial emboss test card with 2 tracks of encoded data.

5-10

Troubleshooting

Smart Card Test Card If the 150i is so equipped, this option is used to verify the Smart Card option for the program head location. Use this test to verify the programming of the Smart Card head in the 150i System and to adjust the Smart Card chip card head offset. •

•

•

The test will require a Smart Card placed in the Input Hopper. A card will then stop at the Smart Card head location and the program head solenoid will fire. The test will then communicate to the Smart Card board application and reset the diagnostic. One of the following status messages is returned.

Table 5-4 : Smart Card Test Messages Smart Card Messages

Description

Smart Card Comm Error

Comm failure to Smart Card board. Check cables and see if application is running in the Smart Card system.

Card OK (Answer to Reset)

No errors. Chip card is communicating to the program head.

Card Not Responding

Card time-out error.

Not an ISO 7816 reset

The Smart Card chip card is not communicating. Failure could be the card, not enough pressure on the head or the card is not aligned correctly to the program head.

This test will not test the Key Card readers. (Run an online application to test.) A Smart Card application for the 150i System needs to be loaded.

Wheel Test Card This option is used to make a card with every character on the wheel, including indent and special characters.

9/-FWJYBDMSONARELIT HCUGKPVZQX.,'&

54740d75

Wheel Test Card

Figure 5-2: Wheel Test Card


5-11

Topper Test Card This option is used to verify the topper platen squareness.

.301

3.074

.843

.172

Topper Test Card 54740-77

Figure 5-3: Topper Test Card

Run Without Cards This option is used to exercise the 150i without using cards in the system.

Preembossed Test Card This option is used to verify the throat gap adjustment for preembossed cards.

Character Height Test Card This option is used to verify character height on a standard wheel.

5-12

Troubleshooting

Position Offsets Menu This option menu is used to control the X and Y position offsets used in the 150i System. •

•

•

•

•

•

•

Select the # key to change an offset value or to view offset values. When there are more than one editable offset, press the 4 or the 6 key to move between offsets. Press the 2 key to increment the offset or the 8 key to decrement the offset. Press the 3 key to toggle the increment constant between one and ten. The [x1] is used to display the times 1 or times 10 increment range. Once an offset has been changed, the display will show a . This is a reminder that the new offset has been detected and should be saved. Press the 0 key to Exit. Increasing the offset moves the carriage away from the home position. Decreasing the offset moves the carriage towards the home position.


5-13

Table 5-5: Position Offsets Menu Position Offsets

# Key Pressed Example

Pick

Pick [x1] X or Y Offset

[

0]

Smart Card [x1] X, Y Offsets

[

0]

Magstripe Front [x1] X, Y, Coercivity Offsets [

0]

Magstripe Rear [x1] X, Y, Coercivity Offsets [

0]

Magstripe variables [x1] LTJ, BBJ Subinterval, Start Sent Var [

0]

Emboss [x1] X or Y Offsets

[

0]

Topper [x1] X or Y Offset

[

0]

Topper Noise Offset

[

0]

Exit [x1] X or Y Offset

[

0]

Reject [x1] X Offset

[

0]

Emboss Offsets [x1] Lower or Upper

[

0]

Indent Offsets [x1] Lower or Upper

[

0]

Throat Gap [x1] Offset

[

0]

Wheel Home [x1] Offset

[

0]

Card Bow [x1] Offset

[

0]

Smart Card MagStripe NTT MagStripe Standard MagStripe Variables

Emboss Location Topper Topper Noise Exit Reject Emboss Height Indent Depth Throat Gap Wheel Home Card Bow

5-14

Troubleshooting

Wheel Parameters Menu This option menu is used to change the individual wheel finger parameters on the 150i System. This option also is used to move (remap) a character on the wheel, increase or decrease emboss pressure and dwell, adjust spacing of a character, and define the character type. •

Select the 2 key or 8 key to select the finger number menu. Valid wheel finger positions are from 1 to 75.

•

Press the # key to select the correct finger to change.

•

Keys 4 and 6 are used to scroll through the wheel mapping parameters. The example below is for the 1st finger position.

Table 5-6: Wheel Parameters Menu Wheel Parameters

# Key Next Screen Example

Remap

Finger 1 [x1] Remap [

0]

Finger 1 [x1] Dwell [

0]

Lower Pos (Motor steps)

Finger 1 [x1] Lower Pos

[

460]

Upper Pos (Motor steps)

Finger 1 [x1] Upper Pos

[

460]

Spacing

Finger 1 [x1] Spacing

[

38]

Finger 1 [x1] Char Type

[

2]

Dwell

Char Type

For Spacing and Char Type, the following choices are available: Table 5-7: Spacing and Character Type Char Type

Char Type Value

Spacing Value

Characters/Inch

Std Gothic

0

27

10

Indent

1

27

10

Indent

1

19

14

OCR 7B

2

38

7


5-15

Topper Parameters Menu This option menu is used to change each Topper table parameter on the 150i System. •

•

When Topper Parameters appears on the main menu, press the # key. Select the 2 key or the 8 key to select the Topper table number menu. Valid tables are from 1 to 8.

•

Press the # key to select the specific table.

•

Keys 4 and 6 are used to scroll through the topper parameters. The example below is for table one position.

Table 5-8: Topper Parameters Menu Topper Parameters

# Key Next Screen Example

Temperature

Table 1 [x1] Temperature [

Dwell

Table 1 [x1] Dwell [

235]

850]

Configuration Menu This option is used to configure the 150i System hardware options. The configuration menu is used for selecting the options below: •

When Configuration appears on the main menu, press the # key to select it.

•

Press the 2 key or 8 key to scroll through Configuration menu selections.

•

Press the # key to select the Configuration menu option.

Table 5-9: Configuration Menu

5-16

150i Configuration

Description

Configure Indent

Press the 2 or 8 key to scroll through Indent options. Press # to select an option.

Configure Stripe

Press the 2 or 8 key to scroll through Mag Stripe options. Press # to select an option.

Configure Smart Card

Press the 2 or 8 key to scroll through Smart card options. Press # to select an option.

Configure Topper

Press the 2 or 8 key to scroll through Topper options. Press # to select an option.

Troubleshooting

Status Request Menu This option menu is used to display status information. •

When Status Request appears on the main menu, press the # key to select it.

•

Press the 2 key or 8 key to scroll through Status menu options.

•

Press the # key to select a menu option.

Table 5-10: Status Request Menu 150i Status Request

Description

Last Reported Status

Press # to display last reported status message.

Card Counts

Press # to display the card counts in the 150i System for total, good, and rejects.

Hardware Configuration

Press # to display 150i hardware options configured. Press the 2 or 8 keys to scroll.

Restore MCB Defaults This will restore all MCB offsets to pre-factory defaults. Press # when Restore MCB Defaults appears on the main menu. Press # again to confirm MCB settings.

Restore Mfg Settings This will restore all offsets to manufacturing defaults. Press # when Restore Mfg Settings appears on the main menu. Press # again to confirm manufacturing settings.

Save Changes When changes in offsets are detected, the display shows on the top line. This is a reminder to save the new offset values. Press # when Save Changes appears on the main menu.


5-17

150i Interconnect Diagrams The following diagrams show the 150i system cable connections. 36 Volt Power Supply

Interlock Switch

Interlock Circuitry

5 Volt Regulator

12 Volt Regulator

U15 L298

Stepper Driver

X Axis Motor

1.0 Amp

U14 L298

Stepper Driver

Wheel Motor

1.0 Amp

U13 L298

Stepper Driver

Punch Motor

1.0 Amp

U17 L298

Stepper Driver

Die Motor

1.0 Amp

U28 L6219

Stepper Driver

Y Axis Motor

0.56 Amp

X-Axis Home

U31 L6219

Stepper Driver

IH Motor

0.56 Amp

Y-Axis Home

U30 L6219

Stepper Driver

OCR Motor

0.56 Amp

A Encoder B Encoder

U29 LU6219

Stepper Driver

Throat Gap Motor 0.56 Amp

Wheel Home

U12 L298

Solenoid Driver

OCR Sol. Lock Sol.

U59 L6219

Mag Stripe Driver

Mag Stripe Head

Hopper Empty

Q6 FET

Heater

Heater + Output

Output Full

Q2 FET

Topper Solenoid

Topper + Solenoid

Hopper Home

Q5 Foil Transistor DC Motor

Foil + DC Motor

OCR Motion

Q4 FET

SC Solenoid

556008-000 150i Main Control

Sensors

U27 XL5210 I/O Controller

Punch Home Die Home Registration

SC Solenoid

Platten Home Foil Motion Reject Full Throat Gap Cord Picked

Figure 4: Main Control Input/Output Block Diagram

5-18

Troubleshooting

Main Control Board Connections Punch Motor Wheel Motor X axis Motor

36 Volt Supply

Die Motor Indent Input Motor Motor Throat Topper Gap Sel Motor

J9

J11

Door Lock Sel Rear Indent Sel

J10

Flash J tag

J3

Serial Comm Front Panel

J16 J7

J14 Jumper Position 1-2 Normal Op 2-3 Program J tag

J12

Display Pot Adjustment

Sensors Magnetic Stripe Interlock

J13

Sensors

Figure 5-5: Main Control Board Connections


5-19

Main Control Board Cable Connections 555961-001 Cable Assy, DC Power

556008-001 150i PWA

555037-002 Cable Assy, Comm I/O

555039-001 Cable Assy, Display

555962-001 Cable Assy, Sensor

Figure 5-6: Main Control Board Cable Connections

5-20

Troubleshooting

AC Wiring Diagram 804960-024 FUSE

594032-001 Main ON/OFF Switch

555033-001

596679-001 Cable Assy.

JP2

EMI Power Line Filter

36V Switching Power Supply

++ _ +

Chassis Ground J9

556008-001 Main Control 150i

Figure 5-7: AC Wiring Diagram


5-21

Pin-Out Tables Motor Pin-Outs Table 5-11: Motor Pin-Outs for Connector J10 Pin #

5-22

Signal Name

Signal Description

1

OCR_Sol-

Rear Indent Solenoid - Output

2

Lock_Sol+

Lock Solenoid + Output

3

PB-

Punch Motor B phase -

4

PA+

Punch Motor A phase +

5

YB-

Y Axis Motor B phase -

6

YA+

Y Axis Motor A phase +

7

WB-

Wheel Motor B phase -

8

WA+

Wheel Motor A phase +

9

XB-

X Axis Motor B phase -

10

XA+

X Axis Motor A phase +

11

N/C

12

GND

Ground

13

OCR_Sol+

Rear Indent Solenoid + Output

14

Lock_Sol-

Lock Solenoid - Output

15

PB+

Punch Motor B phase +

16

PA-

Punch Motor A phase -

17

YB+

Y Axis Motor B phase +

18

YA-

Y Axis Motor A phase -

19

WB+

Wheel Motor B phase +

20

WA-

Wheel Motor A phase -

21

XB+

X Axis Motor B phase +

22

XA-

X Axis Motor A phase -

23

N/C

24

36V_NINV

36 volt non-interlock

Troubleshooting

Table 5-12: Motor Pin-Outs for Connector J11 Pin #

Signal Name

Signal Description

1

Top_Sol-

Topper Solenoid - Output

2

SC_Sol+

Smart Card Solenoid + Output

3

SCM_B-

Smart Card Motor B phase -

4

SCM_A+

Smart Card Motor A phase +

5

OCR_B-

Rear Indent Motor B phase -

6

OCR_A+

Rear Indent Motor A phase +

7

IHB-

Input Hopper B phase -

8

IHA+

Input Hopper Motor A phase +

9

DB-

Die Motor B phase -

10

DA+

Die Motor A phase +

11

Heater+

Heater + Output

12

GND

Ground

13

Top_Sol+

Topper Solenoid + Output

14

SC_Sol-

Smart Card Solenoid - Output

15

SMC_B+

Smart Card B phase +

16

SMC_A-

Smart Card A phase -

17

OCR_B+

Rear Indent Motor B phase +

18

OCR_A-

Rear Indent Motor A phase -

19

IHB+

Input Hopper Motor B phase +

20

IHA-

Input Hopper Motor A phase -

21

DB+

Die Motor B phase +

22

DA-

Die Motor A phase -

23

FOILMTR+

Foil Motor + Output

24

GND

Ground


5-23

Sensor Pin-Outs Table 5-13: Sensor Pin-Outs for Connector J12 Pin #

Signal Name

1

Pullup

2

Sensor 15

3

Sensor 0

4

Sensor Name

Pin #

Signal Name

26

N/C

Encoder B

27

Sensor 3

X Axis Home

28

N/C

Vcc

29

GND

5

GND

30

N/C

6

Sensor 14

31

GND

7

GND

32

N/C

8

GND

33

Pullup

9

Pullup

34

Vcc

10

HD1-

35

Sensor 4

11

Sensor 1

36

GND

12

HD1+

37

GND

13

GND

38

GND

14

HD0-

39

GND

15

GND

40

Sensor 6

16

HD0+

41

Pullup

17

Pullup

42

Pullup

18

Inter-

43

Sensor 5

19

Sensor 2

44

N/C

20

Inter+

45

GND

21

GND

46

N/C

22

N/C

47

GND

23

GND

48

N/C

24

N/C

49

N/C

25

Pullup

50

N/C

5-24

Encoder A

Y Axis Home

Wheel Home

Sensor Name

Punch Home

Die Home

Registration

Hopper Empty

Troubleshooting

Table 5-14: Sensor Pin-Outs for Connector J13 Pin #

Signal Name

Sensor Name

Pin #

Signal Name

Sensor Name Foil Motion

1

GND

21

Sensor 11

2

Pullup

22

GND

3

GND

23

Pullup

4

Sensor 8

Output Full

24

GND

5

Sensor 7

Hopper Home

25

GND

6

GND

26

Pullup

7

Pullup

27

GND

8

GND

28

Sensor 13

Reject Full

9

GND

29

Sensor 16

Throat Gap

10

Pullup

30

GND

11

GND

31

Pullup

12

Sensor 10

OCR Motion

32

GND

13

Sensor 9

Platen Home

33

N/C

14

GND

34

N/C

15

Pullup

35

N/C

16

GND

6

N/C

17

GND

37

N/C

18

Pullup

38

N/C

19

GND

39

RTD2

20

Sensor 12

40

RTD1

Card Picked


5-25

Serial Communications Pin-Outs Table 5-15: Serial Communications Pin-Outs (J16)

5-26

Pin #

IC Pin

Signal

Connector/Pin #

1

RX2 A

DCD

Host – 1

2

RX3 A

DSR

Host – 6

3

RX1 A

RXD

Host – 2

4

TX2 A

RTS

Host - 7

5

TX1 A

TXD

Host - 3

6

RX4 A

CTS

Host - 8

7

TX3 A

DTR

Host - 4

8

RX5 A

RI

Host - 9

9

GND

GND

Host - 5

10

N/C

N/C

Host - N/C

11

RX2 B

DCD

Debug - 1

12

RX3 B

DSR

Debug - 6

13

RX1 B

RXD

Debug - 2

14

TX2 B

RTS

Debug - 7

15

TX1 B

TXD

Debug - 3

16

RX4 B

CTS

Debug - 8

17

TX3 B

DTR

Debug - 4

18

RX5 B

RI

Debug - 9

19

GND

GND

Debug - 5

20

N/C

N/C

Debug - N/C

Troubleshooting

Identifying Errors Using Error Codes When the Error indicator is illuminated, an Administrator Recoverable Error has occurred. An Error Code is displayed on the 150i display. Use the following Error Code list to identify and repair the error. Errors detected by the 150i firmware f irmware are reported as 16-bit values. These values consist of three basic parts: 1. Which module reported the error. 2. When was the error reported, and 3. Which device reported the error and why.

For clarity, the error codes are grouped as xx-yy-zz. Once an error coded is displayed, it can be deciphered to give the operator and service personal a clear understanding on exactly what happened, when it happened, and the offending module. For example: the 150i displays the error PK 0826: PK (xx) tells the operator that an error occurred while the pick mechanism was being accessed.

•

•

08 (yy) tells the operator that the interlock was detected.

•

26 (zz) tells the operator that the interlock was opened unexpectedly

So, PK 0826 tells the operator that while the 150i was attempting to pick a card, the interlock was opened.

Group xx This group identifies which module reported the error, but not necessarily which module was at fault. Function

Value

Description

Picking

PK yy zz

150i is accessing the Pick mechanism.

Transport

XP yy zz

150i is accessing the Transport mechanism.

Mag Stripe

MS yy zz

150i is accessing the Mag Stripe mechanism.

Embosser

EM yy zz

150i is accessing the Emboss mechanism.

Stacker

STyy zz

150i is accessing the Stacker mechanism.

Interlock

IN yy zz

150i is accessing the Interlock.


5-27

Group yy This group identifies during which process did the error occur. Function

Value

Description

Homing

xx 01zz

150i is homing mechanisms.

Pick

xx 02 zz

150i is picking a card.

Embossing

xx 03 zz

150i is embossing (and topping) a card.

Stacking

xx 04 zz

150i is stacking a card.

Moving

xx 05 zz

150i is moving a card.

Registration

xx 06 zz

150i is defining the card origin.

Verify Reg

xx 07 zz

150i is verifying that the card/mechanism has slipped.

Interlock

xx 08 zz

150i detected interlock.

Encode

xx 09 zz

150i is encoding a card.

SCInit

xx 0A zz

150i is initializing a Smart Card.

Group zz This group identifies which device caused the error and why.

5-28

Function

Value

Description

X Sensor Hit

xx yy 01

X-Sensor was seen.

X Sensor Miss

xx yy 02

X-Sensor was not seen.

X Sensor Early

xx yy 03

X-Sensor was seen early.

X Sensor Late

xx yy 04

X-Sensor was seen late.

Y Sensor Hit

xx yy 05

Y-Sensor was seen.

Y Sensor Miss

xx yy 06

Y-Sensor was not seen.

Y Sensor Early

xx yy 07

Y-Sensor was seen early.

Y Sensor Late

xx yy 08

Y-Sensor was seen late.

Pick Sensor Hit

xx yy 09

Pick home Sensor was seen.

Pick Sensor Miss

xx yy 0A

Pick home Sensor was not seen.

Wheel Sensor Miss

xx yy 0B

Wheel home Sensor not seen.

Wheel Sensor Early

xx yy 0C

Wheel home Sensor seen unexpectedly.

Troubleshooting

Function

Value

Description

Upper Emboss Sensor Hit

xx yy 0D

Upper Emboss Home Sensor seen.

Upr Emboss Sensor Miss

xx yy 0E

Upper Emboss Home Sensor missed.

Upr Emboss Sensor Early

xx yy 0F

Upper Emboss Home Sensor seen early.

Upper Sensor Late

xx yy 10

Upper Emboss Home Sensor seen late.

Lower Emboss Sensor Hit

xx yy 11

Lower Emboss Home Sensor seen.

Lwr Emboss Sensor Miss

xx yy 12

Lower Emboss Home Sensor missed.

Lwr Emboss Sensor Early

xx yy 13

Lower Emboss Home Sensor seen early.

Lwr Emboss Sensor Late

xx yy 14

Lower Emboss Home Sensor seen late.

Coord. Err

xx yy 15

Illegal position requested (card or transport).

Cmd Seq Err

xx yy 16

150i Command out of sequence (e.g. emboss before pick).

No Cards

xx yy 17

No cards in card stack.

Card Not Picked

xx yy 18

Card was not seen a card exit Sensor.

Card Not Taken

xx yy 19

Card was not gripped.

Motor On

xx yy 1A

Requested motor is on.

User Stop

xx yy 1B

User requested motor stop.

Illegal Emb Char

xx yy 1C

Illegal wheel position requested.

Illegal Cmd

xx yy 1D

Illegal device command.

X Reg Hit

xx yy 1E

X-Registration Sensor was seen.

X Reg Miss

xx yy 1F

X-Registration Sensor was not seen.

X Reg Early

xx yy 20

X-Registration Sensor was seen early.

X Reg Late

xx yy 21

X-Registration Sensor was seen late.

Y Reg Hit

xx yy 22

Y-Registration Sensor was seen.

Y Reg Miss

xx yy 23

Y-Registration Sensor was not seen.

Y Reg Early

xx yy 24

Y-Registration Sensor was seen early.

Y Reg Late

xx yy 25

Y-Registration Sensor was seen late.

Interlock

xx yy 26

Interlock was broken.


5-29

5-30

Function

Value

Description

Interlock Missed

xx yy 27

Interlock should have been broken before continuing.

Out Door Open

xx yy 28

Output stacker door is open. Output stacker is full.

Platen Stuck Home

xx yy 29

Topper platen did not drop.

Platen Stuck Out

xx yy 2A

Topper platen did not return home.

Card Not Stacked

xx yy 2B

Card was not placed in output after verifying registration.

Topper Foil Out

xx yy 2C

Topping foil is empty.

Reject Tray Full

xx yy 2D

Reject tray is full.

Topper Temp High

xx yy 2E

Topper temperature is too high.

Topper Temp Low

xx yy 2F

Topper temperature is too low.

Topper Temp

xx yy 30

Topper temperature is not in control.

Indent Rib. Out

xx yy 31

Indent ribbon is empty.

Indent Stuck In

xx yy 32

Indent (solenoid) is stuck in.

Indent Stuck Out

xx yy 33

Indent (solenoid) is stuck out.

SC Not Present

xx yy 34

Smart Card application is not responding.

Troubleshooting

Encode errors are handled separately as follows: MS Error

Value

Description

CARD_POSITION_ERROR

MS0901

Error positioning card.

TRACK_TABLE_NOT_FOUND

MS0902

Requested track table not found. (Possible financial password violation.)

INVALID_START_CODE

MS0910

Bad start code given.

INVALID_START_SENTINEL

MS0911

Invalid start sentinel.

INVALID_END_SENTINEL

MS0912

Bad end sentinel given.

INVALID_CHARACTER

MS0913

Bad character to encode.

INVALID_DATA_LENGTH

MS0914

Data is too long.

READ_OVERRUN_ERROR

MS0915

Overrun while reading stripe data from card.

NO_TRANSITIONS_FOUND

MS0916

No transitions seen on stripe.

NO_START_FOUND

MS0917

No start sentinel found.

START_POSITION_ERROR

MS0918

Start code was in wrong position.

LTJ_ERROR

MS0919

Long term jitter.

BBJ_ERROR

MS091A

Short term jitter.

PARITY_ERROR

MS091B

Parity error.

LRC_ERROR

MS091C

Checksum error.

COMPARE_ERROR

MS091D

Data read did not match data written.


5-31

Error Codes Error codes and messages are displayed on the display located to the left of the keypad on the front of the 150i. The error codes are structured to tell the operator not only what the failure is but where the failure occurred in the system. Use the following table to identify and correct these errors: Table 5-16: Error Code Troubleshooting Chart

5-32

Error Code

Error Message

Possible Cause

Corrective Action

EM0301

Transport Error

The card carriage could not verify its position.

Open the top cover and verify no obstructions to prevent moving Transport to the right or left.

EM0305

Transport Error


Open the top cover and verify no obstructions to prevent moving transport in or out.

EM0306

Transport Error


Open the top cover and verify no obstructions preventing Transport from moving backward.

EM0307

Transport Error


Open the top cover and verify no obstructions preventing Transport from moving backward.

EM030B

Emboss Wheel Error

The embossing wheel could not verify its position.

Check Embosser Wheel Home sensor.

EM030C

Wheel Error

The embossing wheel could not verify its position.

Check Embosser Wheel Home sensor.

EM030E

Embossing Error

The emboss mechanism jammed. Two cards may have been picked.

Check Input Hopper mechanism..

EM030F

Embossing Error



EM0310

Emboss Char Err



EM0312

Embossing Error



EM0313

Embossing Error



EM0314

Embossing Error



Troubleshooting

Error Code

Error Message

Possible Cause

Corrective Action

EM0315

Coordinate Out Of Range

The 150i could not make the card due to physical limits of the card. Either too many emboss characters on the card or they are in the wrong position on the card.

Redo card layout..

EM0326

Interlock Seen

The top cover was opened during card processing.

Close the Top Cover.

EM0329

Topping Platen Error

The topper platen did not come down correctly.

Open the top cover and verify no obstructions around or in Topper or platen photocell. Check Topping foil for correct routing.

EM032A

Topping Platen Error

The topper platen did not come down correctly.

Open the top cover and verify no obstructions around or in Topper or platen photocell. Check Topping foil for correct routing.

EM032C

Foil Advance Error

The 150i did not detect topper foil motion.

Verify no obstructions around or in Topping foil. Is there foil and is it loaded correctly?

EM032E

Top Temperature Error

The 150i detected the topper temperature is out of its limits.

Topper temperature too hot. Shut down 150i and allow to cool at least 5 minutes then send card data again.

EM0330

Top Temperature Error

The 150i detected the topper temperature is not hot enough.

Allow Topper to warm up. Check heater platen.

EM0331

Indent Ribbon Error

The 150i did not detect indent ribbon motion.

Broken ribbon, out of ribbon or not installed correctly.

IN0826

Interlock Seen

The top cover was opened during card processing


MS 0902

TRACK_TABLE_NOT_FOUND

The 150i could not verify the information that it encoded on the magnetic stripe.

Reload table magnetic stripe table and send card data again (unique table). (Possible financial password violation.)

MS0910

INVALID_START_CODE


Examine data for correct start sentinel. Send card data again.

MS0911

INVALID_START_SENTINEL


Examine data for correct start sentinel. Send card data again.

MS0912

INVALID_END_SENTINEL


Examine data for correct end sentinel. Send card data again.

MS0913

INVALID_CHARACTER


Examine data for correct information. Send card data again.


5-33

5-34

Error Code

Error Message

Possible Cause

Corrective Action

MS0914

INVALID_DATA_LENGTH


Examine the data sent. Send card data again.

MS0915

READ_OVERRUN_ERROR


Check cards in the Input Hopper. Check coercivity (refer to CPX Manual). Send card data again.

MS0916

NO_TRANSITIONS_FOUND


Check coercivity (refer to CPX Manual). Verify the card has a magnetic stripe and cards are stacked in the Input Hopper correctly.

MS0917

NO_START_FOUND


Clean Magnetic Strip head.

MS0918

START_POSITIION_ERROR


Check for obstructions in the magnetic stripe encoding area. Send card data again.

MS0919

LTJ_ERROR


Check for bad card stock. Send card data again.

MS091A

BBJ_ERROR



MS091B

PARITY_ERROR



MS091C

LRC ERROR



MS091D

COMPARE_ERROR


Check for bad card stock.

MS0926

Interlock Open



PK0102

Transport Error


Verify no obstructions are between Transport and the right side of the 150i.

PK0105

Transport Error


Verify no obstructions between Card Carriage and back of the Transport.

PK0106

Transport Error


Verify no obstructions between Card Carriage and back of the Transport.

PK010A

Transport Error


Verify no obstructions between Transport and Input Hopper. Remove all cards and reload Input Hopper.

Troubleshooting

Error Code

Error Message

Possible Cause

Corrective Action

PK010B

Emboss Wheel Error


Verify no obstructions preventing the Emboss wheel from turning.

PK010E

Embossing Error


Verify no obstructions preventing the Die mechanism from returning to home.

PK0112

Embossing Error


Verify no obstructions around punch.

PK0119

Card Feed Error

150i failed to pick a card.

Open the top cover and remove all cards from the Input Hopper and reload.

PK0126

Interlock Seen


Close Top Cover and send card data again.

PK0128

Check Output Tray

Output door is opened during card processing or output tray is full.

Close Output Door or empty Output Stacker.

PK012B

Card Not Stacked

Card did not make it to the output stacker.

Open Output Supply door and remove card from rollers.

PK012D

Reject Stack Full

Reject Stacker full.

Open Top Cover and empty Reject Stacker.

PK0135

Card Feed Error

Throat home sensor not found during homing.

Reload cards and send card data again.

PK0201

Transport Error


Verify that there are no obstructions preventing Transport from moving to the left.

PK0202

Transport Error


Verify that there are no obstructions preventing Transport from moving to the right or left.

PK0205

Transport Error


Verify no obstructions preventing Transport Carriage from moving forward or backwards.

PK0206

Transport Error


Verify no obstructions preventing Transport Carriage from moving backward or forward.

PK0209

Transport Error i+


Verify no obstructions around Card Supply Stack preventing stack from moving. Two cards may have be picked, remove and reload cards.

PK020A

Transport Error i+


Verify no obstructions around Card Supply Stack preventing stack from moving. If two cards were picked, remove and reload cards.

PK0217

Card Supply Empty

No cards in the input hopper.

Place cards in card Input Hopper.

PK0218

Card Feed Error


Remove all cards, reload and retry. Verify cards are in Input Hopper.


5-35

5-36

Error Code

Error Message

Possible Cause

Corrective Action

PK0219

Card Feed Error


Remove all cards, reload and retry. Verify no obstructions around Input Hopper card throat and cards are in Input Hopper.

PK0226

Interlock Seen

The top cover was opened during card processing

Close Top Cover and send card data again.

PK0228

Check Output tray

Output door is opened during card processing or output tray is full.

Empty Output Tray and/or close door.

PK022D

Reject Stack Full

Reject Tray is full

Open the top cover and remove cards from the Reject Tray.

PK0235

Card Feed Error


Turn off 150i, remove all cards, reload cards and send card data again.

SC0A34

Smart Card Comm Error

The 150i failed to communicate with the Smart Card logic board.

Reload Smart Card application.

ST0401

Transport Error


Verify no obstructions around Transport and Output Stacker.

ST0402

Transport Error



ST0406

Transport Error



ST040A

Transport Error


Verify no obstructions around Output Stacker. Card jammed.

ST0426

Interlock Open



ST042B

Card Not Stacked

Cards not stacked properly in Input Hopper.

Remove card from Output Stack rollers. Verify no obstructions around Output Stacker that would prevent card from exiting.

XP0501

Transport Error


Verify no obstructions in X transport direction.

XP0505

Transport error


Verify no obstructions around Y- Sensor.

XP061E

Card Registration Error

The 150i could not verify the correct card position.

Verify no obstructions around Registration photocell or Transport.

XP061F




XP0622



Send card data again.

XP0623




XP0626

Interlock Open



Troubleshooting

Error Code

Error Message

Possible Cause

Corrective Action

XP071F

Verify Regist. Error

This error is due to possible card slippage during processing.

Verify that the embossing on the card is correct. Send card data again if necessary.

XP0720



Verify that the embossing on the card is correct. Send the card data again if necessary

XP0723




XP0724




XP0726

Interlock Open




5-37

Main Control Board LEDs The following describes the LED functions for the Main Control Board of the 150i. These LEDs serve as a quick visual indication that the LED, sensor and the associated wiring harness to that LED is functional. See Figure 5-8 for LED locations. See Figure 5-9 for the physical location of the sensor. Table 5-17: Main Control Board LEDs LED ID

5-38

Description

LED is ON

LED is OFF

D17

Throat Gap Sensor

Indicates the Throat Gap sensor is fully open.

Indicates the Throat Gap sensor is closed.

D18

Xilinx Done

Indicates the Xilinx processor is busy.

Indicates the Xilinx processor is not busy.

D19

Reject Full Sensor

Indicates the Reject Hopper if filled with cards.

Indicates the Reject Hopper is not completely filled with cards

D20


D21

Card Picked Sensor

Indicates that a card has been picked.

Indicates that no card is blocking the sensor.

D22

Topper Platen Home Sensor

Indicates the Topper Platen is at home position.

Indicates the Topper Platen is not at home position.

D23

OCR Motion Sensor

D24

Input Home Sensor

Indicates the Input Home Picker is at home position..

Indicates the Input Home Picker is not at home position.

D25

Output Full Sensor

Indicates the Output Input Hopper is filled with cards.

Indicates the Output Input Hopper is not completely filled with cards.

D26

Card Registration Sensor

Indicates a card is blocking the Card Registration sensor.

Indicates that nothing is blocking the Card Registration sensor.

D27


Indicates there are no cards in the Input Hopper.

Indicates there is at least one card in the Input Hopper.

D28

Upper Emboss Home Sensor

Indicates the Upper Emboss cam is in the home position.

Indicates the Upper Emboss cam is not in the home position.

D29

Lower Emboss Home Sensor

Indicates the Lower Emboss cam is in the home position.

Indicates the Lower Emboss cam is not in the home position.

D30

Wheel Home Sensor

Indicates the Embosser Wheel is in the home position.

Indicates the Embosser Wheel is not in the home position.

Indicates the Topper Foil is moving.

Indicates the OCR ribbon is moving.

Troubleshooting

D17 D18

LED ID

Description

LED is ON

LED is OFF

D31

Y-Home Sensor

Indicates the Y Carriage is in the home position.

Indicates the Y Carriage is not in the home position.

D32

ENC B

D33

X-Home Sensor

D34

ENC A

D35

+12V2

Indicates the +12 VDC V2 Power Supply is on.

Indicates the +12 VDC V2 Power Supply is off.

D36

+12V1

Indicates the +12 VDC V1 Power Supply is on.

Indicates the +12 VDC V1 Power Supply is off.

D37

+5V

Indicates the +5 VDC Power Supply is on.

Indicates the +5 VDC Power Supply is off.

D19

D21 D20

Indicates the B section of the Magnetic Stripe Encoder Wheel is moving. Indicates the X Carriage is not in the home position.

Indicates the A section of the Magnetic Stripe Encoder Wheel is moving.

D23 D22

Indicates the X Carriage is in the home position.

D25 D24

D27 D26

D29 D28

D31 D30

D33 D32

D34

D35

D37 D36

150i015s

Figure 5-8: Main Control Board LEDs


5-39

Topper Platen Sensor

Reject Full Sensor Topper Foil Motion Sensor

Throat Gap Sensor

X-Home Sensor Y-Home Sensor

Wheel Home Sensor Punch Cam Home Sensor

Die Cam Home Sensor

Card Registration Sensor

Card Picked Sensor

REAR VIEW Output Full Sensor


Input Home Sensor

Figure 5-9: Sensor Locations



5-40

Troubleshooting

Chapter 6: Adjustments The 150i Card Personalization System operates as a standalone card embosser. This chapter provides information for adjusting the 150i.

Introduction 6-2 Mechanical Adjustments 6-2 Magnetic Stripe Head Height Adjustment 6-2 Rear Indent Drive Belt Adjustment 6-4 Interlock Switch Adjustment 6-6

Electrical Adjustment 6-8 Display Contrast Adjustment 6-8

Software Offsets 6-10 Start Diagnostic Routines 6-10 Position Offsets Menu 6-11 Pick Offset 6-13 Smart Card Offset 6-14 MagStripe NTT Offset 6-15 MagStripe Standard Offset 6-16 MagStripe Variables Offset 6-18 Emboss Location Offset 6-19 Topper Offset 6-20 Topper Noise Offset 6-21 Exit Offset 6-22 Emboss Height Offset 6-23 Indent Depth Offset 6-24 Throat Gap Offset 6-25 Wheel Home Offset 6-26 Card Bow Offset 6-27


6-1

Introduction This chapter presents mechanical, electrical, and software adjustment procedures for the 150i. These procedures are not part of preventive maintenance and are performed only as unscheduled maintenance requirements identified during fault isolation.

Mechanical Adjustments The following pages describe the mechanical adjustments for the 150i. The software offset adjustments appear after the mechanical adjustments.

Magnetic Stripe Head Height Adjustment The purpose of this adjustment is to insure proper pressure and contact of the encoding head with card stripe.

Symptoms If this adjustment is not correct, the magnetic head will not come in contact with the magnetic stripe and read/write errors will occur. If the magnetic head is too high, card jamming may occur.

Tools •

Hex key set

Procedure

6-2

1.

Unlock and lift up the Top Cover (see Opening the Top Cover in Chapter 7, Removal and Replacement).

2.


3.

Loosen one Magnetic Stripe height holding screw on the side of the Magnetic Stripe module.

4.

Manually rotate the Card Transport carriage lead screw so the Card Transport carriage is in front of the Magnetic Stripe module.

5.

Manually insert a card with the magnetic stripe up in the Card Transport carriage grippers.

6.

Position the card over the Magnetic Stripe head.

Adjustments

7.

Adjust the Magnetic Stripe head height so as a card enters the nip of the roller, minimum deflection of the card occurs, while still making good contact with the Magnetic Stripe head.

8.

Tighten the Magnetic Stripe height holding screw.

Head Height Adjustment Wheel Height Holding Screw

Figure 6-1: Magnetic Stripe Head Height Adjustment


6-3

Rear Indent Drive Belt Adjustment The purpose of this adjustment is to ensure the Rear Indent Drive Belt engages with the motor and drive pulleys.

Symptoms If this adjustment is not correct, the Indent ribbon will not advance.

Tools •

#10 Torx driver

Procedure

6-4

1.

Unlock and lift up the Top Cover (see Rear Indent Drive Belt Adjustment in Chapter 7, Removal and Replacement).

2.


3.

Loosen two Rear Indent Motor adjustment screws.

4.

Adjust the bracket so the Rear Indent Drive belt has enough tension so it will not slip when driven.

5.

Tighten the two Rear Indent Motor adjustment screws.

Adjustments

Adjustment Screws

Drive Belt

Rear Indent Motor

Figure 6-2: Rear Indent Drive Belt Adjustment


6-5

Interlock Switch Adjustment This adjustment is to ensure power will be OFF to the 150i when the Top Cover is opened.

Symptoms If this adjustment is not correct, the 150i will not operate.

Tools •

#20 Torx driver

Procedure 1.


2.


3.

Loosen two bracket adjustment screws.

4.

Adjust the bracket so when the Top Cover is fully closed and seated, the Interlock switch is activated.

5.

Tighten the two bracket adjustment screws. Test the Key Lock using a key and the password control to open the Top Cover.

6-6

Adjustments

Bracket Adjustment Screws

Figure 6-3: Interlock Switch Adjustment


6-7

Electrical Adjustment The following pages describe the electrical adjustment for the 150i.

Display Contrast Adjustment This adjustment sets the viewing brightness of the 150i display for optimum viewing.

Symptoms If this adjustment is not correct, the display will be too faint or too bright to read.

Tools •

Pot adjustment tool

Procedure

6-8

1.


2.

Power ON the 150i and adjust the contrast control (R212) for the best readability for an operator.

3.

Power OFF the 150i and replace Front Access Panel.

Adjustments

Display Contrast Adjustment Pot

Figure 6-4: Display Contrast Adjustment


6-9

Software Offsets The following software adjustments are used to set up, calibrate, and define the operating parameters for the 150i.

Start Diagnostic Routines To select the diagnostic programs from the 150i front panel, perform the following steps:

1.

Press *#3253 on the front keypad.

2.

Press 2 (Diagnose) to select the diagnostic control application.

3.

The system will reboot and go into the diagnostics mode.

4.

After a short pause, the 150i front panel will display the following message: 150i Diags Rev X.XX Service

5.

To select the front panel options, the user must first press the # (pound) key.

6.

After a short pause, the 150i front panel will display the following message: Loading Onboard Diags Please wait...

The main menu appears. When running diagnostics from the front panel, the 150i System is in the off-line mode. The keypad is used to navigate through the menus as they are displayed on the front panel of the 150i System. Table 6-1: Keypad Navigation

Key

6-10

Description

#

Selects option (Enter key).

0

Aborts menu option or backs-up 1 menu option.

2

Scrolls the menu UP or will increment a setting.

3

Offset adjustments range toggle from ±1 times the increment to ±10.

4

Scrolls the menu LEFT.

5

Changes offset from (-) negative to (+) positive

6

Scrolls the menu RIGHT.

8

Scrolls the menu DOWN or will decrement a setting.

Adjustments

Position Offsets Menu This option menu is used to control the X and Y position offsets used in the 150i System.

1.

Select the # key to change an offset value or to view offset values.

2.

When there are more than one editable offset, press the 4 or the 6 key to move between offsets.

3.

Press the 2 key to increment the offset or the 8 key to decrement the offset.

4.

Increasing the offset moves the carriage away from the home position. Decreasing the offset moves the carriage towards the home position.

5.

Press the 3 key to toggle the increment constant between one and ten. The [x1] is used to display the times 1 or times 10 increment range.

6.

After changing the offset, press the # key to save the setting. Once an offset has been changed, the display will show a . This is a reminder that the new offset has been detected and should be saved.

7.

Press the 0 key and the message “Save Changes?” appears. Press the # key for Yes, the 1 key for No or the 0 key to Escape. Table 6-2: Position Offsets Menu

Position Offsets Pick Smart Card MagStripe NTT MagStripe Standard MagStripe Variables

Emboss Location Topper Topper Noise Exit

# Key Pressed Example Pick [x1] X or Y Offset

[

0]

Smart Card [x1] X, Y Offsets

[

0]

Magstripe Front [x1] X, Y, Coercivity Offsets

[

0]

Magstripe Rear [x1] X, Y, Coercivity Offsets

[

0]

Magstripe variables [x1] LTJ, BBJ Subinterval, Start Sent Var [

0]

Emboss [x1] X or Y Offsets

[

0]

Topper [x1] X or Y Offset

[

0]

Topper Noise Offset

[

0]

Exit [x1] X or Y Offset

[

0]


6-11

Position Offsets Reject Emboss Height Indent Depth Throat Gap Wheel Home Card Bow

6-12

# Key Pressed Example Reject [x1] X Offset

[

0]

Emboss Offsets [x1] Lower or Upper

[

0]

Indent Offsets [x1] Lower or Upper

[

0]

Throat Gap [x1] Offset

[

0]

Wheel Home [x1] Offset

[

0]

Card Bow [x1] Offset

[

0]

Adjustments

Pick Offset The purpose of this offset is to adjust the position of the card grips so they are flush and centered on the card being picked. Table 6-3: Pick Offset

Reference Point

Pick X-Offset

Pick Y-Offset

Default value

0

0

Increase offset

Moves the grip position to the left-hand sided of a card.

Moves the grip position closer to a card.

Decrease offset

Moves the grip position to the right-hand sided of a card.

Moves the grip position away from a card.

Symptoms If this offset is not correct, a card will not be properly gripped and may hit obstructions as it moves through the 150i.

Procedure 1.


2.

Press the 2 key to select the diagnostic control application.

3.

The system will reboot and go into the diagnostics mode. After a short pause, the 150i front panel will display the following message: 150i Diags Rev X.XX Service

4.

To select the front panel options, you must first press the # (pound) key. After a short pause, the 150i front panel will display the following message: Loading Onboard Diags Please wait...

5.

The main menu will appear. Press the 8 key until Position Offsets appears.

6.

Press the # key to enter the Position Offsets menu. Scroll down to Pick , and then press the # key. When there is more than one editable offset, press the 4 or the 6 key to move between offsets.

7.


8.


9.

After changing the offset, press the # key to store the setting.

10. Press the 0 key and the message “Save Changes?” appears. Press the # key for Yes, the 1 key for No or the 0 key to Escape. 150i Card Personalization System Maintenance Manual

6-13

Smart Card Offset The purpose of this offset is to set the Smart Card Offset position to position a smart card accurately over the programming pins. Table 6-4: Smart Card Offset

Reference Point

Smart Card X-Offset

Smart Card Y-Offset

Default value

0

0

Increase offset

Moves a card to the left-hand side of the programming pins.

Move a card closer to the programming pins.

Decrease offset

Moves a card to the right-hand side of the programming pins.

Moves a card away from the programming pins.

Symptoms If this offset is not correct, a smart card will not make proper contact with the smart card programming pins.

Procedure 1.


2.


3.


4.


5.


6.

Press the # key to enter the Position Offsets menu. Scroll down to Smart Card, and then press the # key. When there is more than one editable offset, press the 4 or the 6 key to move between offsets.

7.


8.


9.

After changing the offset, press the # key to save the setting.

10. Press the 0 key and follow the prompts to save the new setting.

6-14

Adjustments

MagStripe NTT Offset The purpose of this offset is to set the front MagStripe NTT Offset position and select the coercivity. Table 6-5: MagStripe NTT Offset

Reference Point

MagStripe NTT X-Offset

MagStripe NTT Y-Offset

MagStripe NTT Coercivity

Default value

0

0

2

Increase offset

Moves a card to the left-hand side of the Magnetic Stripe Head.

Raises the track position on the card.

Decrease offset

Move a card to the right-hand side of the Magnetic Stripe Head.

Lowers the track position on the card.

1 = 25 ma (Loco) 2 = 50 ma 3 = 75 ma 4 = 100 ma 5 = 150 ma (Hico)

Symptoms If this offset is not correct, the track data may be positioned too high or too low on the magnetic stripe. No data or data errors will occur if not positioned correctly.

Procedure 1.


2.


3.


4.


5.


6.

Press the # key to enter the Position Offsets menu. Scroll down to MagStripe NTT, and then press the # key. When there is more than one editable offset, press the 4 or the 6 key to move between offsets.

7.


8.


9.



6-15

10. Press the 0 key and the message “Save Changes?” appears. Press the # key for Yes, the 1 key for No or the 0 key to Escape.

MagStripe Standard Offset The purpose of this offset is to set the rear MagStripe Standard Offset position and select the coercivity. Table 6-6: MagStripe Standard Offset

Reference Point

MagStripe XOffset

MagStripe YOffset

MagStripe Coercivity

Default value

0

0

1

Increase offset

Moves a card to the left-hand side of the Magnetic Stripe Head.

Raises the track position on the card.

Decrease offset

Move a card to the right-hand side of the Magnetic Stripe Head.

Lowers the track position on the card.

1 = 25 ma (Loco) 2 = 50 ma 3 = 75 ma 4 = 100 ma 5 = 150 ma (Hico)

Symptoms If this offset is not correct, the track data may be positioned too high or too low on the magnetic stripe. No data or data errors will occur if not positioned correctly.

Procedure 1.


2.


3.


4.


5.


6.

Press the # key to enter the Position Offsets menu. Scroll down to MagStripe Standard, and then press the # key. When there is more than one editable offset, press the 4 or the 6 key to move between offsets.

7.

6-16


Adjustments

8.


9.

After changing the offset, press the # key to save the setting.



6-17

MagStripe Variables Offset The purpose of this offset is to set the MagStripe Variables Offset percentages. Table 6-7: MagStripe Variables Offset

Reference Point

MagStripe Variables LTJ Offset

MagStripe Variables BBJ Subinterval

MagStripe Variables Start Sent Var

Default value

12

15

0

Offset Value

10 to 20%

10 to 25%

8 to 100%

Symptoms If this offset is not correct, offset errors will occur.

Procedure 1.


2.


3.


4.


5.


6.

Press the # key to enter the Position Offsets menu. Scroll down to MagStripe Variables, and then press the # key. When there is more than one editable offset, press the 4 or the 6 key to move between offsets.

7.


8.


9.



6-18

Adjustments

Emboss Location Offset The purpose of this offset is to set the Emboss Location Offset position so characters can be embossed in the proper location on a card. Table 6-8: Emboss Location Offset

Reference Point

Emboss Location XOffset

Emboss Location YOffset

Default value

-10

-10

Increase offset

Moves embossing to the right-hand side on a card.

Raises the embossing on a card.

Decrease offset

Moves embossing to the left-hand side on a card.

Lowers the embossing on a card.

Symptoms If this offset is not correct, embossed characters may not be properly located on a card.

Procedure 1.


2.


3.


4.


5.


6.

Press the # key to enter the Position Offsets menu. Scroll down to Emboss Location, and then press the # key. When there is more than one editable offset, press the 4 or the 6 key to move between offsets.

7.


8.


9.




6-19

Topper Offset The purpose of this offset is to adjust the position of a card in the Topper. Table 6-9: Topper Offset

Reference Point

Topper X-Offset

Topper Y-Offset

Default value

0

0

Increase offset

Moves the card position to the left of the Topper.

Moves the card position closer to the Topper.

Decrease offset

Moves the card-position to the right of the Topper.

Moves the card position away from the Topper.

Symptoms If this offset is not correct, topping quality will be bad or missing on the bottom of a topped card.

Procedure 1.


2.


3.


4.


5.


6.

Press the # key to enter the Position Offsets menu. Scroll down to Topper Offset, and then press the # key. When there is more than one editable offset, press the 4 or the 6 key to move between offsets.

7.


8.


9.



6-20

Adjustments

Topper Noise Offset The purpose of this offset is to set the Topper Noise Offset attempts to lessen the noise made by the topping solenoid. Table 6-10: Topper Noise Offset

Reference Point

Topper Noise Offset

Default value

0

Increase offset

Makes the solenoid louder.

Decrease offset

Makes the solenoid quieter.

Symptoms If this offset is not correct, excessive noise may be generated by the topping solenoid.

Procedure 1.


2.


3.


4.


5.


6.

Press the # key to enter the Position Offsets menu. Scroll down to Topper Noise, and then press the # key. When there is more than one editable offset, press the 4 or the 6 key to move between offsets.

7.


8.


9.




6-21

Exit Offset The purpose of this offset is assure cards are placed accurately in the Output Hopper. Table 6-11: Exit Offset

Reference Point

Exit X-Offset

Exit Y-Offset

Default value

-100

-100

Increase offset

Moves a card to the left-hand side of the Output Hopper.

Moves a card closer to the Output Hopper.

Decrease offset

Moves a card to the right-hand side of the Output Hopper.

Moves a card away from the Output Hopper.

Symptoms If this offset is not correct, cards will not be placed in the Output Hopper and/or not released from the card pick mechanism.

Procedure 1.


2.


3.


4.


5.


6.

Press the # key to enter the Position Offsets menu. Scroll down to Exit, and then press the # key. When there is more than one editable offset, press the 4 or the 6 key to move between offsets.

7.


8.


9.



6-22

Adjustments

Emboss Height Offset The purpose of this offset is to set the Emboss Height Offset position. Table 6-12: Emboss Height Offset

Reference Point

Emboss Height Lower Offset

Emboss Height Upper Offset

Default value

0

0

Increase offset

Increases the distance the lower stepper drive moves.

Increases the distance the upper stepper drive moves.

Decrease offset

Decreases the distance the lower stepper drive moves.

Decreases the distance the upper stepper drive moves.

Symptoms If this offset is not correct, may become bowed. Characters may experience excessive height when the card is embossed or too little height.

Procedure 1.


2.


3.


4.


5.


6.

Press the # key to enter the Position Offsets menu. Scroll down to Emboss Height, and then press the # key. When there is more than one editable offset, press the 4 or the 6 key to move between offsets.

7.


8.


9.




6-23

Indent Depth Offset The purpose of this offset is to set the Indent Depth Offset position. Table 6-13: Indent Depth Offset

Reference Point

Indent Depth Lower Offset

Indent Depth Upper Offset

Default value

0

0

Increase offset

Increases the distance the lower stepper drive moves.

Increases the distance the upper stepper drive moves.

Decrease offset

Decreases the distance the lower stepper drive moves.

Decreases the distance the upper stepper drive moves.

Symptoms If this offset is not correct, cards may become bowed. Wheel characters may experience excessive pressure when the card is indented or not enough pressure to properly intent a card.

Procedure 1.


2.


3.


4.


5.


6.

Press the # key to enter the Position Offsets menu. Scroll down to Indent Depth, and then press the # key. When there is more than one editable offset, press the 4 or the 6 key to move between offsets.

7.


8.


9.



6-24

Adjustments

Throat Gap Offset The purpose of this offset is to set the Throat Gap Offset position in order to process preembossed cards. Table 6-14: Throat Gap Offset

Reference Point

Throat Gap Offset

Default value

0

Increase offset

Widens the throat gap.

Decrease offset

Narrows the throat gap.

Symptoms If this offset is not correct, the 150i may jam cards in the Input Hopper.

Procedure 1.


2.


3.


4.


5.


6.

Press the # key to enter the Position Offsets menu. Scroll down to Throat Gap, and then press the # key. When there is more than one editable offset, press the 4 or the 6 key to move between offsets.

7.

Press the 2 key to increment the offset or the 8 key to decrement the offset. The throat gap should be approximately 0.015 inch between the card and the pick plate.

8.


9.




6-25

Wheel Home Offset The purpose of this offset is to properly align the print wheel for embossing characters on cards. Table 6-15: Wheel Home Offset

Reference Point

Wheel Home Offset

Default value

0

Increase offset

Moves the wheel further clockwise from the home position.

Decrease offset

Moves the wheel further counter clockwise from the home position.

Symptoms If this offset is not correct, characters will be not be registered on the card correctly. Damage could also be incurred to the punches and dies on the print wheel or emboss errors from the lower emboss and upper emboss motors will occur.

Procedure 1.


2.


3.


4.


5.


6.

Press the # key to enter the Position Offsets menu. Scroll down to Wheel Home, and then press the # key. When there is more than one editable offset, press the 4 or the 6 key to move between offsets.

7.


8.


9.



6-26

Adjustments

Card Bow Offset The purpose of this offset is to set the Card Bow Offset position to minimize card bowing. Table 6-16: Card Bow Offset

Reference Point

Card Bow Offset

Default value

0

Increase offset

Affects card bowing in one direction.

Decrease offset

Affects card bowing in the opposite direction.

Symptoms If this offset is not correct, cards may be bowed when they exit the 150i.

Procedure 1.


2.


3.


4.


5.


6.

Press the # key to enter the Position Offsets menu. Scroll down to Card Bow, and then press the # key. When there is more than one editable offset, press the 4 or the 6 key to move between offsets.

7.


8.


9.




6-27



6-28

Adjustments

Chapter 7: Removal and Replacement The 150i Card Personalization System operates as a standalone card embosser. This chapter provides instructions for r emoval and replacement of assemblies and parts.

Introduction 7-3 Servicing Guidelines 7-3 Opening the Top Cover 7-4 Changing the Password 7-5 Top Cover 7-6 Front Access Panel 7-8 Single Card Access Door 7-10 Output Hopper Door 7-12 Key Lock 7-14

Input/Output Hopper 7-16 Output Hopper Drive Belt 7-20 Output Hopper Drive O-Ring 7-22 Card Registration Sensor 7-24 Input Hopper Empty Sensor 7-26 Input Home Sensor 7-28 Output Full Sensor 7-30 Card Picked Sensor 7-32 Throat Gap Motor 7-34 Throat Gap Motor Belt 7-36 Throat Gap Sensor 7-38

Card Transport 7-40 X-Transport Drive Belt 7-42 X-Home Sensor 7-44 Y-Home Sensor 7-46 Card Transport Flex Cable 7-48 Carriage Transport Motor 7-50


7-1

Magnetic Stripe Assembly 7-52 Embosser Assembly 7-54 Wheel Home Sensor 7-56 Punch Home Sensor 7-58 Punch Cam Motor 7-60 Punch Cam Belt 7-62 Die Home Sensor 7-64 Die Cam Motor 7-66 Die Cam Belt 7-68 Punch and Die 7-70

Topper Assembly 7-72 Topper Foil Motion Sensor 7-74 Topper Platen Sensor 7-76 Topper Motor 7-78

Main Control Board 7-80 Power Supply Board 7-82 Line Filter 7-84 Fuse 7-86

Fan 7-88 Display/Keypad 7-90 Solenoid Lock Assembly 7-92 Reject Full Sensor 7-94 Front Smart Card Module (Option) 7-96 Front Indent Printer Module (Option) 7-98 Replacing the Front Indent Ribbon 7-100

Rear Indent Printer Module (Option) 7-102 Replacing the Rear Indent Ribbon 7-104

Rear Indent Motor 7-106 Rear Indent Drive Belt 7-108 Rear Indent Solenoid 7-110

7-2

Removal and Replacement

Introduction This section gives procedures for the removal and replacement of the 150i Card Personalization System Field Replaceable Units (FRUs) and sub-assemblies. Some FRU replacements may require self-tapping screws to be used.

Servicing Guidelines Use the following guidelines when servicing the 150i: •

Observe warning and caution labels affixed to various areas of the equipment.

•

Use only the recommended tools as specified to perform service.

•

•

•

•

Replacement of certain assemblies and parts requires follow-up adjustments. Make sure these adjustments are performed after replacement. Always perform preventive maintenance as described in Chapter 3, Preventive Maintenance, of this manual after replacement procedures. Verify the 150i functions after replacement by performing and/or observing a limited customer production run. DO NOT defeat the safety interlock.


7-3

Opening the Top Cover The Top Cover can be opened with either a four-digit password or a key. The default password shipped from the factory for the 150i is *00000. This password should be changed upon receipt of the machine (see Changing the Password). •

•

•

To open the Top Cover using a password, using the keypad, enter *0 (unlock code) followed by your 4 digit password (XXXX). The solenoid to open the Top Cover will be energized for 5 seconds. The Message “OPEN COVER!” is displayed. If the password is entered incorrectly, “ACCESS DENIED!” is displayed. To reenter the correct password, press *0 followed by the correct password. To open the Top Cover using a key, insert the key in the keyhole and turn it clockwise ¼ turn. R

7-4

150i


Changing the Password The default password shipped from the factory for the 150i is *00000. The password can be changed by doing the following:

Change Password Code

*1[0000][5555] Old Password

New Password

Enter *1 (change password code) followed by the current password and then the new password. For example, to change the default password 0000 to 5555, enter *100005555. In this example, the keystrokes to open the Top Cover again using the new password would be *05555. If you do not remember your current password, use the key or contact your Datacard Service Representative for information on how to reset it. By entering the 8 digit Financial Card Password enable, the Top Cover access will be reset to the 0000 default password.


7-5

Top Cover The Top Cover can be locked to protect unauthorized access to the inside of the 150i. Use the following procedure to remove and replace the Top Cover.

Tools • • • •

Phillips screwdriver #10 Torx driver 11/32 inch nut driver 5/16 inch nut driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Remove four nuts (1 in Figure 7-1) holding the two ribbon cable straps (2) 4. Disconnect Display Cable connector P4 (3) and place the cable inside the 150i. 5. Remove one nut (4) holding the cover grounding strap and place inside the 150i. 6. Loosen two screws (5) retaining the cover holding pins (left-hand side of the 150i). 7. Manually rotate the Card Transport carriage lead screw to the left-hand side of the 150i. 8. Loosen one screw (6) that retain the cover holding pins. 9. Remove four Phillips screws (7)holding the right Top Cover bracket and the Input Hopper shield (8). Fold the hinge out of the way. 10. Remove three Phillips screws (9) holding the left Top Cover bracket. Fold the hinge out of the way. 11. Close the Top Cover and remove the three cover holding pins (10). 12. Remove the Top Cover. Replace 1. Transfer the Display/Keyboard, Key Lock and the Alignment Pin bracket for the old Top Cover over to the new Top Cover (see Display/Keypad and Key Lock). 2. Place the Top Cover on the 150i. Insert and center the cover holding pins so the screws align with the cover holding pin groves. Tighten all three screws to retain the cover holding pins. 3. Lift up the Top cover and place the left Top Cover bracket in place, securing it with three screws.

7-6


4. Place the right Top Cover bracket and the Input Hopper shield in place and attach with four screws. 5. Place the grounding strap in position and attach with one nut. 6. Reconnect the Display Cable to P4. 7. Replace the ribbon cable straps and attach with four screws. 8. Ensure that the Top Cover opens and closes properly with no binding. 9. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification. 4 3

2 (2x) 1 (4x)

9 (3x)

5 (2x)

6

8 10 (3x)

7 (4x)

Figure 7-1: Top Cover


7-7

Front Access Panel The Front Access Panel is used to restrict access to the Main Control Board. Use the following procedure to remove and replace the Front Access Panel.

Tools •

#20 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. The Topper Platen May Be Very Hot.

3. Lift up on the Topper Solenoid Ring and remove the Topping Foil Cassette. 4. Loosen two screws (1 in Figure 7-2) but do not remove, then remove the Front Access Panel (2). Replace 1. Place the Front Access Panel in position and tighten two screws. 2. Plug in the power cord and power ON the 150i. 3. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.

7-8


1 (2x)

2

Figure 7-2: Front Access Panel


7-9

Single Card Access Door The Single Card Access Door is used to insert one plastic card at a time for embossing. Use the following procedure to remove and replace the Single Card Access Door.

Tools •

#20 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Open the Single Card Access Door (1 in Figure 7-3) and remove two screws (2) securing the door to the base of the cabinet. 4. Lift the access door so the door arms (3) are in a vertical position. Squeeze the access door arms together to remove them from the access door guides (4). Replace 1. Place the new Single Card Access Door in position and attach with two screws. Check the door for proper movement and alignment.

2. Plug in the power cord and power ON the 150i. 3. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.

7-10


3

4

3

4

2 (2x) 1

Figure 7-3: Single Card Access Door


7-11

Output Hopper Door The Output Hopper Door holds cards that have been produced by the 150i. Use the following procedure to remove and replace the Output Hopper Door.

Tools • •

#10 Torx driver #20 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Remove two screws (1 in Figure 7-4) attaching the Output Hopper Door (2) to the base of the 150i. 4. Remove two screws (3) from the pivot arm block (4) and remove Output Hopper Door. Replace 1. Place the new pivot arm block in position and attach with two screws. 2. Position the Output Hopper Door in place and attach with two screws. Check the door for proper movement and alignment.

3. Plug in the power cord and power ON the 150i. 4. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.

7-12


Inside View Of Output Door

2

1 3 1 3 4

Figure 7-4: Output Hopper Door


7-13

Key Lock The Key Lock is designed to secure the top cover preventing unauthorized access access to the inside of the cabinet Use the following procedure to remove and replace the Key Lock.

Tools •

Adjustable crescent wrench

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Remove the Paddle Nut (1 in Figure 7-5) and 7-5) and the Paddle (2) from the Key Lock. 4. Remove the Key Lock Securing Nut (3) and remove the Key Lock (4) from the Top Cover. Replace 1. Place the new Key Lock on the Top Cover and screw on the Securing Nut. 2. Place the Paddle on the Key Lock and screw on the Paddle Nut. 3. Plug in the power cord and power ON the 150i. 4. Test the Key Lock using a key and also by using the password control to open the Top Cover. (see Opening the Top Cover.) Cover.) 5. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.

7-14


1 2 3 4

Figure 7-5: Key Lock

150i Ca Card Personalization System Maintenance Manual

7-15

Input/Output Hopper The Input/Output Hopper is a main assembly assembly used for stacking cards (or a single card) to be embossed and as an output receptacle for completed cards. Use the following procedure to remove and replace the Input/Output Hopper.

Tools • •

¼ inch box wrench #20 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually rotate the Card Transport carriage lead screw to the center of the 150i. 4. Remove the Input Hopper card weight and all cards from the 150i. 5. Remove the Single Card Access Door. 6. Remove two screws (1 in Figure 7-6) and 7-6) and remove the Input/Output Hopper holding plate (2). 7. Open the Output Hopper Door. 8. Loosen the rear mounting screw (3) and rotate the hold down plate (4) 180 degrees and partially remove the Input/Output Hopper Hopper from the base to gain access access to the cable connectors. Remove cable ties as necessary.

9. Disconnect the following cable connectors: • • • • • • • •

Motor Cable (5) Input Empty Sensor (6) Input Home Sensor (7) Card Picked Sensor (8) Card Registration Sensor (9) Output Full Sensor (10) Throat Gap Motor (11) Throat Gap Sensor (12)

10. Lift the Input/Output Hopper from the 150i.

7-16


12 11 10 5 9 8 7 1 (2x) 2

6

3

4

Figure 7-6: Input/Output Hopper


7-17

Replace 1. Partially place the new Input/Output Hopper in position. 2. Reconnect the following inline connectors: • • • • • • • •

Motor Cable (5) Input Empty Sensor (6) Input Home Sensor (7) Card Picked Sensor (8) Card Registration Sensor (9) Output Full Sensor (10) Throat Gap Motor (11) Throat Gap Sensor (12)

3. After connecting the inline connectors, place the new Input/Output Hopper in position and rotate the hold down back into place, then tighten the rear mounting screw. 4. Place the Input/Output Hopper holding plate in position and attach with two screws. 5. Replace the Single Card Access Door. 6. Replace any cable ties that were removed. Make sure wires are not pinched. Secure wires with tie wraps. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.

7. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.

7-18


12 11 10 5 9 8 7 1 (2x) 2

6

3

4


7-19

Output Hopper Drive Belt The Output Hopper Drive Belt provides movement to transport an embossed card into the Output Hopper. Use the following procedure to remove and replace the Output Hopper Drive Belt.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Open the Output Hopper Door. 4. Remove one screw (1 in Figure 7-7) holding the upper Output Guide Card Transport Drive Roller (2) and remove the roller. 5. Slip the Output Hopper Drive Belt ( 3) off the Output Hopper drive motor pulley and remove the belt from the assembly. Replace 1. Place the new Output Hopper Drive Belt in position. 2. Replace the upper output guide Card Transport drive roller in position and hold in place with one screw. 3. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.

7-20


2 1

3

Input/Output Hopper

Figure 7-7: Output Hopper Drive Belt


7-21

Output Hopper Drive O-Ring The Output Hopper Drive O-Rings provide traction for moving an embossed card into the Output Hopper. Use the following procedure to remove and replace the Output Hopper Drive O-Ring.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Open the Output Hopper Door. 4. Remove one screw (1 in Figure 7-8) holding the upper Output Guide Card Transport Drive Roller (2). This will allow better access for the removal of the Output Hopper Drive O-Rings (3). 5. Roll all four Output Hopper Drive O-Rings off from the upper and lower Output Hopper drive rollers. Replace 1. Place all new Output Hopper Drive O-Rings on the upper and lower Output Hopper drive rollers. 2. Place the upper output guide Card Transport drive roller in position and hold in place with one screw. 3. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.

7-22


2 1

3

Input/Output Hopper

Figure 7-8: Output Hopper Drive O-Ring


7-23

Card Registration Sensor The Card Registration Sensor detects when a card first enters the 150i. Use the following procedure to remove and replace the Card Registration Sensor.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Open the Output Hopper Door for better access. 4. Remove the Output Hopper Drive Belt (1 in Figure 7-9) from the drive motor pulley. 5. Disconnect the Output Full Sensor cable connector (2) and the Card Registration Sensor cable connector (3). Cut cable ties as necessary.

6. Remove four screws (4) holding the Card Transport Drive assembly. 7. Remove two screws (5) holding the Card Registration Sensor (6) and remove the sensor from the Card Transport assembly. Replace 1. Place the new Card Registration Sensor in position with emitter pointing down and attach with two screws. 2. Place the Card Transport Drive assembly in place and attach with four screws. 3. Place the Output Hopper Drive Belt back on the drive motor pulley. 4. Connect the Output Full Sensor and the Card Registration Sensor cable connectors. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


7-24


6

5 (2x)

2 3

4 (4x) 1

Figure 7-9: Card Registration Sensor


7-25

Input Hopper Empty Sensor The Input Hopper Empty Sensor detects when the Input Hopper has no more cards. Use the following procedure to remove and replace the Input Hopper Empty Sensor.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Open both input and output doors for better accessibility. 4. Disconnect the Input Hopper Empty Sensor cable connector (1 in Figure 7-10). Cut cable ties as necessary.

5. Remove one screw (2) holding the Input Hopper Empty Sensor (3) to the Input/Output Hopper assembly and remove the sensor. Replace 1. Place the new Input Hopper Empty Sensor in position and attach with one screw. 2. Reconnect the Input Hopper Empty Sensor connector. 3. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


7-26


1

3 2

Figure 7-10: Input Hopper Empty Sensor


7-27

Input Home Sensor The Input Home Sensor detects when the card picking mechanism is at its home position. Use the following procedure to remove and replace the Input Home Sensor.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually rotate the Card Transport carriage lead screw to the center of the 150i. 4. Open both input and output doors for better accessibility. 5. Disconnect the Input Home Sensor cable connector (1 in Figure 7-11). Remove cable ties as necessary.

6. Remove one screw (2) holding the Input Home Sensor (3) to the Input/Output Hopper assembly. Replace 1. Place the new Input Home Sensor in position and attach with one screw. 2. Reconnect the Input Home Sensor connector. 3. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


7-28


3 2 1

Figure 7-11: Input Home Sensor


7-29

Output Full Sensor The Output Full Sensor detects when the Output Hopper is full of embossed cards and should be emptied. Use the following procedure to remove and replace the Output Full Sensor.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Open both input and output doors for better accessibility. 4. Disconnect the Output Full Sensor cable connector (1 in Figure 7-12). Remove cable ties as necessary.

5. Remove one screw (2) holding the Output Full Sensor (3) to the Input/Output Hopper assembly. Replace 1. Place the new Output Full Sensor in position and attach with one screw. 2. Reconnect the Output Full Sensor connector. 3. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


7-30


2

3

1

Figure 7-12: Output Full Sensor


7-31

Card Picked Sensor The Card Picked Sensor detects when a card has been selected by the card picking mechanism. Use the following procedure to remove and replace the Card Picked Sensor.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Disconnect the Card Picked Sensor cable connector (1 in Figure 7-13). Remove cable ties as necessary.

4. Remove one screw (2) holding the Card Picked Sensor (3) to the Input/Output Hopper assembly and remove the sensor from the 150i. Replace 1. Place the new Card Picked Sensor in position and attach with one screw. 2. Reconnect the Card Picked Sensor connector. 3. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


7-32


2

3

1

Figure 7-13: Card Picked Sensor


7-33

Throat Gap Motor The Throat Gap Motor provides movement to the throat gap mechanism to accommodate preembossed card. Use the following procedure to remove and replace the Throat Gap Motor.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Disconnect the TG Motor cable connector (1 in Figure 7-14). Remove cable ties as necessary.

4. Remove two screws (2) holding the Throat Gap Motor (3) and the ground wire (4) to the Input/Output Hopper assembly. 5. Move the Throat Gap Motor away from the Throat Gap Motor drive belt (5) to allow removal of the motor. Replace 1. Place the new Throat Gap Motor in place and attach with two screws. Make sure to attach the ground wire. Make sure the Throat Gap Motor drive belt is positioned properly on the motor shaft and pulley. 2. Reconnect the TG Motor connector. 3. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


7-34


2 4

2

3

5 1

Figure 7-14: Throat Gap Motor


7-35

Throat Gap Motor Belt The Throat Gap Motor Belt provides a means to move the throat gap mechanism to accommodate pre-embossed card. Use the following procedure to remove and replace the Throat Gap Motor Belt.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. Remove cable ties as necessary.

3. Remove two screws (1 in Figure 7-15) holding the Throat Gap Motor (2) and the ground wire (3) to the Input/Output Hopper assembly. 4. Move the Throat Gap Motor (3) away from the Throat Gap Motor Belt (4) to allow removal of the motor. 5. Remove the Throat Gap Motor Belt. Replace 1. Position the new belt over the motor shaft and pulley, then attach the Throat Gap Motor with two screws. Make sure to attach the ground wire. Make sure the Throat Gap Motor drive belt is positioned properly on the more shaft and pulley. 2. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


7-36


1 3

1

2

4

Figure 7-15: Throat Gap Motor Belt


7-37

Throat Gap Sensor The Throat Gap Sensor detects when the throat gap mechanism has reached its home position. Use the following procedure to remove and replace the Throat Gap Sensor.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually move the Card Transport carriage to the left-hand side of the 150i. 4. Disconnect the Throat Gap Sensor cable connector (1 in Figure 7-16). Remove cable ties as necessary.

5. Remove one screw (2) holding the Throat Gap Sensor (3) to the Input/Output Hopper assembly. Replace 1. Place the new Throat Gap Sensor in position and attach with one screw. 2. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


7-38


1 2

3

Figure 7-16: Throat Gap Sensor


7-39

Card Transport The Card Transport consists of a screw mechanism for moving a card through different stages of production to produce a final card. Use the following procedure to remove and replace the Card Transport.

Tools • •


Remove 4. Unlock and lift up the Top Cover (see Opening the Top Cover). 5. Power OFF the 150i and remove the power cord from the wall outlet. 6. Manually rotate the Card Transport carriage lead screw so the Y-Transport is centered between the Embosser Wheel and the Magnetic Stripe Head. Make sure not to crimp or damage the Card Transport Flex Cable.

7. Remove two screws (1 in Figure 7-17) holding the Card Transport Flex Cable retaining clamp (2). Remove cable ties as necessary.

8. Disconnect the following cable connectors: • •

Card Transport Flex Cable (3) Transport Lead Screw Motor (4)

9. Remove two screws (5) holding the Card Transport (6). 10. Lift up and move the Card Transport to the right. Tilt the Card Transport towards the front of the 150i, then lift the Card Transport up to remove. Replace 11. Place the new Card Transport on the locating pins on the base of the 150i and attach with two screws. Make sure to include one grounding wire when attaching the left-hand screw. 12. Reconnect the following cable connectors. • •

Card Transport Flex Cable (3) Transport Lead Screw Motor (4)

13. Place the new Cable Transport Flex Cable retaining clamp in position and attach with two screws.

7-40


14. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


Figure 7-17: Card Transport


7-41

X-Transport Drive Belt The X-Transport Drive Belt drives the transport screw mechanism for moving cards through the 150i. Use the following procedure to remove and replace the X-Transport Drive Belt.

Tools •

#20 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually rotate the Card Transport carriage lead screw so the Y-Transport is on the lefthand side of the 150i. 4. Remove two screws (1 in Figure 7-18) holding the X-Transport Drive Motor (2). 5. Remove the X Transport Drive Belt (3) from the Card Transport (4) assembly. Replace 1. Place the new X-Transport Drive Belt in position and attach the X-Transport Drive Motor with two screws. Make sure belt tension is sufficient to ensure that no slippage will occur. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


7-42


1

2

3

Figure 7-18: X-Transport Drive Belt


7-43

X-Home Sensor The X-Home Sensor detects when the X card transport mechanism is at its home position. Use the following procedure to remove and replace the X-Home Sensor.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually rotate the Card Transport carriage lead screw to the center of the 150i. 4. Disconnect the X-Home Sensor cable connector (1 in Figure 7-19). 5. Remove one screw (2) holding the X-Home Sensor (3) to the base of the 150i. Replace 1. Place the new X-Home Sensor in position and attach with one screw. 2. Reconnect the X-Home Sensor connector. Make sure wires are not pinched. Make sure connector and wires will not interfere with any mechanical movement inside the 150i. Make sure the sensor is correctly positioned so the sensing flag will not hit it.


7-44


Figure 7-19: X-Home Sensor


7-45

Y-Home Sensor The Y-Home Sensor detects when the Y card transport mechanism is at its home position. Use the following procedure to remove and replace the Y-Home Sensor.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually rotate the Card Transport carriage lead screw to the center of the 150i. Remove cable ties as necessary.

4. Disconnect Y-Home Sensor cable connector (1 in Figure 7-20). 5. Remove one screw (2) holding the Y-Home Sensor (3). Replace 1. Place the new Y-Home Sensor in position and attach with one screw. 2. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure the connector and wires will not interfere with any mechanical movement inside the 150i. Make sure the sensor is correctly positioned so the sensing flag will not hit it.


7-46


Figure 7-20: Y-Home Sensor


7-47

Card Transport Flex Cable The Card Transport Flex Cable provides a means to power the Y-Transport Motor and communication with the Y-Home Sensor. Use the following procedure to remove and replace the Card Transport Flex Cable.

Tools • • •

Hex key set #10 Torx driver #20 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Remove two screws (1 in Figure 7-21) and remove the Cable Plate (2) from the 150i base. 4. Remove one screw (3) and remove the Flex Cable Holding Plate (4). Remove cable ties as necessary.

5. Remove two screws (5) and remove the Cable Holding Clamp (6). 6. Remove one screw (7), one nut (8) and the Top Cover Grounding Wire (9) on the lefthand side of the Inner Fan Guard (10). 7. Manually rotate the Card Transport lead screw to the left-hand side of the 150i. 8. Remove one screw (11) from the right-hand side of the Inner Fan Guard, then lift the Inner Fan Guard out. 9. Disconnect the Card Transport Flex Cable (12) at both ends. 10. Peel the flex cable from the back panel, then completely remove it from the 150i. Replace 1. Place the new Card Transport Flex Cable in place making sure it adheres to the back panel of the 150i. 2. Reconnect both ends of the flex cable to their connectors. 3. Make sure the Cable Back Plate is against the back panel of the 150 and attach it with one screw. 4. Placed the Cable Holding Clamp in position and attach with two screws.

7-48


5. Place the Inner Fan Guard in position and attach with one screw and one nut on the lefthand side. Make sure to attach the Top Cover Grounding Wire. On the right-hand side, attach with one screw. 6. Place the Cable Plate in position and attach with two screws. 7. Replace any cable ties that were removed. 8. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.

Figure 7-21: Card Transport Flex Cable


7-49

Carriage Transport Motor The Carriage Transport consists of a screw mechanism for moving cards in the Y-axis through different stages of production to produce a final card. Use the following procedure to remove and replace the Carriage Transport Motor.

Tools • •


Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually rotate the Card Transport carriage lead screw so the Y-Transport is centered between the Embosser Wheel and the Magnetic Stripe Head. Make sure not to crimp or damage the Card Transport Flex Cable.

4. Remove two screws (1 in Figure 7-22) holding the Card Transport (2). Remove cable ties as necessary.

5. Disconnect the Carriage Transport Motor connector (3). 6. Carefully lift up and tilt the Card Transport towards the front of the 150i, but do not remove. 7. Remove two screws (4) holding the Carriage Transport Motor (5). 8. Remove the Carriage Transport Motor Belt (6) from the motor pulley, and then remove the Carriage Transport Motor. Replace 1. Place the new Carriage Transport Motor in place making sure the Carriage Transport Motor Belt is in position, and then tighten the two mounting screws. 2. Place the Card Transport on the locating pins on the base of the 150i and attach with two screws. Make sure to include one grounding wire when attaching the left-hand screw. 3. Reconnect the Carriage Transport Motor connector. 4. Replace any cable ties that were removed.

7-50


Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


Figure 7-22: Carriage Transport Motor


7-51

Magnetic Stripe Assembly The Magnetic Stripe Assembly head reads and writes data on the magnetic stripe on a card. Use the following procedure to remove and replace the Magnetic Stripe Assembly.

Tools •

Hex key set

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Open up the Output Tray for better access to the connectors. Remove cable ties as necessary.

4. Disconnect the following cable connectors: • •

Magnetic Stripe Head Cable (1 in Figure 7-23) Encoder Cable (2)

5. Remove one screw (3) and the ground wire (4) attaching the Magnetic Stripe Assembly (5) to the 150i base. Replace 1. Place the new Magnetic Stripe Assembly in position and attach with one screw. Make sure to ground wire is also attached. 2. Reconnect the following cable connectors: • •

Magnetic Stripe Head Cable (1) Encoder Cable (2)

3. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. Make sure the Magnetic Stripe module is aligned parallel to the 150i base casting.


7-52


Follow-up Adjustments This remove and replace procedure affects the following adjustments which must be performed after this procedure. • • •

Magnetic Stripe Start Sentinel Offset Magnetic Stripe Head Height Adjustment Magnetic Stripe Track Location Offset

Figure 7-23: Magnetic Stripe Assembly


7-53

Embosser Assembly The Embosser Assembly, comprised of two rotating disks of punches and dies, provides a means to make embossed characters on a plastic card. Use the following procedure to remove and replace the Embosser Assembly.

Tools •

#20 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Open up the Output Tray for better access to the connectors. The Topper Platen May Be Very Hot.

4. Lift up on the Topper Solenoid Ring and remove the Topping Foil Cassette. Remove cable ties as necessary.

5. Disconnect the following cable connectors: • • • • • •

Wheel Home Sensor (1 Figure 7-24) Die Home Sensor (2) Die Motor (3) Wheel Motor (4) Punch Motor (5) Punch Home Sensor (6)

6. Remove three mounting screws (7) attaching the Embosser to the 150i base. The front Embosser mounting screw can be removed by spreading unused emboss wheel fingers. 7. Lift and remove the Embosser. Replace 1. Place the new Embosser in position and attach with three screws. 2. Reconnect the following cable connectors: • • • • • •

7-54

Wheel Home Sensor (1) Die Home Sensor (2) Die Motor (3) Wheel Motor (4) Punch Motor (5) Punch Home Sensor (6)



4. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification. When a new Embosser is installed, verify that all special punches and dies are installed on the new Embossing Wheel. 5

7 1 3

2 6 7 7 4

Figure 7-24: Embosser


7-55

Wheel Home Sensor The Wheel Home Sensor detects when the embossing wheel is at its home position. Use the following procedure to remove and replace the Wheel Home Sensor.

Tools •

#10 Torx driver


3. Disconnect the Wheel Home Sensor cable connector (1 in Figure 7-25). 4. Remove one screw (2) and remove the Wheel Home Sensor (3). Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.

5. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification. Replace 1. Place the new Wheel Home Sensor in position and attach with one screw. 2. Reconnect the Wheel Home Sensor cable connector. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.

3. Replace any cable ties that were removed. 4. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification. Follow-up Adjustments This remove and replace procedure affects the following adjustments which must be performed after this procedure. •

7-56

Wheel Offset


2

1

3

Figure 7-25: Wheel Home Sensor


7-57

Punch Home Sensor The Punch Home Sensor detects when the punch cam has returned to its home position. Use the following procedure to remove and replace the Punch Home Sensor.

Tools •

#10 Torx driver


3. Remove the Embosser Assembly far enough to gain access to the Punch Home Sensor. 4. Disconnect the Punch Home Sensor (1 in Figure 7-26) cable connector: 5. Remove one screw (2) and remove the Punch Home Sensor (3). Replace 1. Place the new Punch Home Sensor in position and attach with one screw. 2. Reconnect the Punch Home Sensor cable connector. 3. Replace the Embosser assembly and attach with three screws. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.

4. Replace any cable ties that were removed. 5. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.

7-58


2

3

1

Figure 7-26: Punch Home Sensor


7-59

Punch Cam Motor The Punch Cam Motor applies pressure to the embossing punch on the character wheel to form a character on plastic cards. Use the following procedure to remove and replace the Punch Cam Motor.

Tools •

#20 Torx driver


3. Remove the Embosser Assembly. 4. Remove two screws (1 in Figure 7-27) and one nut (2), then remove the Punch Cam Motor (3) from the Embosser Assembly. Replace 1. Place the new Punch Cam Motor in position and attach with two screws and one nut, but do not fully tighten. 2. Tension the Punch Cam Motor against the Punch Cam Belt, then completely tighten the screws. 3. Replace the Embosser Assembly. 4. Make sure all connectors are firmly connected. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


7-60


1 (2x)

3 2 Figure 7-27: Punch Cam Motor


7-61

Punch Cam Belt The Punch Cam Belt transfers motion from the Punch Cam Motor to the cam, which in turn applies pressure to the embossing punch on the character wheel. Use the following procedure to remove and replace the Punch Cam Belt.

Tools • •



3. Remove the Embosser Assembly. 4. Remove two screws (1 in Figure 7-28) and one nut (2), then remove the Punch Cam Motor (3) from the Embosser Assembly. 5. Remove one screw (4) holding the Punch Cam Home Sensor (5) to the Embossing Assembly and remove the sensor. 6. Remove the Punch Cam Belt (6). Replace 1. Place the new Punch Cam Belt in position around the idler pulley. 2. Place the Punch Cam Home Sensor in position and attach with one screw. 3. Place the Punch Cam Motor in position and attach with two screws and one nut, but do not fully tighten. 4. Tension the Punch Cam Motor against the Punch Cam Belt, then completely tighten the screws. 5. Replace the Embosser Assembly. 6. Make sure all connectors are firmly connected. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


7-62


4 5

(2x) 1 3

3

6

2

Figure 7-28: Punch Cam Belt


7-63

Die Home Sensor The Die Home Sensor detects when the embossing die cam has reached its home position. Use the following procedure to remove and replace the Die Home Sensor.

Tools •

#10 Torx driver


3. Disconnect the Die Home Sensor cable connector (1 in Figure 7-29). 4. Remove one screw (2) and remove the Die Home Sensor (3). Replace 1. Place the new Die Home Sensor in position and attach with one screw. 2. Reconnect the Die Home Sensor cable connector. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


7-64


3 2

1

Figure 7-29: Die Home Sensor


7-65

Die Cam Motor The Die Cam Motor applies pressure to the embossing die on the character wheel to form a character on plastic cards. Use the following procedure to remove and replace the Die Cam Motor.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Disconnect the Die Cam Motor connector. 4. Remove two screws (1 in Figure 7-30) and one nut (2), then remove the Die Cam Motor (3) from the Embosser Assembly. Replace 1. Place the new Die Cam Motor in position and attach with two screws and one nut, but do not fully tighten. 2. Tension the Die Cam Motor against the Die Cam Belt, then completely tighten the screws. 3. Reconnect the Die Cam Motor connector. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


7-66


3

1 (2x)

2

Figure 7-30: Die Cam Motor


7-67

Die Cam Belt The Die Cam Belt transfers motion form the Die Cam Motor to the cam, which in turn, applies pressure to the embossing die on the character wheel. Use the following procedure to remove and replace the Die Cam Belt.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Disconnect the Die Cam Motor connector. 4. Remove two screws (1 in Figure 7-31) and 7-31) and one nut (2), then remove the Die Cam Motor (3) from the Embosser Assembly. Assembly. 5. Remove one screw (4) holding the Die Cam Home Sensor (5) to the Embossing Assembly and remove the sensor. 6. Remove the Die Cam Belt (6). Replace 1. Place the new Die Cam Belt in position around the idler pulley. 2. Place the Die Cam Home Sensor in position and attach with one screw. 3. Place the Die Cam Motor in position and attach with two screws and one nut, but do not fully tighten. 4. Tension the Die Cam Motor against the Die Cam Belt, then completely tighten the screws. 5. Reconnect the Die Cam Motor connector. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


7-68


6 3 3

1 (2x)

2 5 4

Figure 7-31: Die Cam Belt


7-69

Punch and Die The punches and dies are used in conjunction with each other to emboss individual characters and letters on a plastic card. Use the following procedure to remove and replace individual punches and dies.

Tools •

Insertion tool (PN 556335-001)

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. To remove a punch (1) or die (2), clip one side of the wheel fingers of the punch or die to be removed. removed. Replace 1. To replace a punch or die, select an unused wheel finger and press the punch or die in using the special insertion tool. The dot on the punch or die must face out from the center of the Embosser Wheel.

Do not deform the punch or die or the wheel fingers.

2. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification. Follow-up Adjustments This remove and replace procedure affects the following adjustments which must be performed after after this procedure. procedure. •

7-70

Wheel Parameters Menu (Remap)


2

1

Dot

Figure 7-32: Punch and Die


7-71

Topper Assembly The Topper Assembly places a colored layer on the top of embossed characters on a plastic card. Heat is used to affix this layer to the plastic card. Use the following procedure to remove and replace the Topper Assembly.

Tools •

#27 Torx driver

Remove Cover). 1. Unlock and lift up the Top Cover (see Opening the Top Cover).

2. Power OFF the 150i and remove the power cord from the wall outlet. The Topper Platen May Be Very Hot.

3. Lift up on the Topper Solenoid Ring and remove the Topping Foil Cassette. Remove cable ties as necessary.

4. Disconnect the following cable connectors: • • • • • •

Topper Motor (1 in Figure 7-33) RTD (2) Topper Heat (3) Topper Sol (4) Platen Sensor (5) Foil Motion Sensor (6)

5. Remove four screws (7) lift up the Topper Assembly (8) of the 150i. Replace 1. Place the new Topper Assembly in position and attach with four screws. 2. Connect the following connectors: • • • • • •

Topper Motor (1) RTD (2) Topper Heat (3) Topper Sol (4) Platen Sensor (5) Foil Motion Sensor (6)


7-72


4. Replace the Topping Foil Cassette. 5. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification. 8 5 4

3 1 2 6

7 (4x)

Figure 7-33: Topper Assembly


7-73

Topper Foil Motion Sensor The Toper Foil Motion Sensor detects physical motion of a slotted wheel insuring that the topper foil has advanced. Use the following procedure to remove and replace the Topper Foil Motion Sensor.

Tools • •

Hex key set #10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Lift up on the Topper Solenoid Ring and remove the Topping Foil Cassette. The Topper Platen May Be Very Hot. Remove cable ties as necessary.

4. Disconnect the Topper Foil Motion Sensor (1 in Figure 7-34) cable connector. 5. Loosen the Topper Foil Motion Sensor pivot bolt (2). This allows the assembly to move forward past the stop peg (3). 6. Remove one screw (4) from the Topper Foil Motion Sensor (5) and sensor. Replace 1. Place the new Topper Foil Motion Sensor in position and attach with one screw. 2. Move the Topper Foil Motion Sensor back into position and tighten down the pivot hex bolt. Make sure there is spring tension on the pivoting assembly. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.

3. Connect the Topper Foil Motion Sensor cable connector. 4. Replace the Topping Foil Cassette. 5. Replace any cable ties that were removed. 6. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.

7-74


4

5

3 2

1

Figure 7-34: Topper Foil Motion Sensor


7-75

Topper Platen Sensor The Toper Platen Sensor detects when the Topper Platen is in its home position. Use the following procedure to remove and replace the Topper Platen Sensor.

Tools •

#10 Torx driver


4. Disconnect the Topper Platen Sensor (1 in Figure 7-35)cable connector. 5. Remove one screw (2) from the Topper Platen Sensor (3) and remove sensor. Replace 1. Place the new Topper Platen Sensor in position and attach with one screw. 2. Connect the Topper Platen Sensor cable connector. 3. Replace the Topping Foil Cassette. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


7-76


3 2

1

Figure 7-35: Topper Platen Sensor


7-77

Topper Motor The Topper Motor is a DC motor used to advance the topping foil in the Topper Foil Cassette. Use the following procedure to remove and replace the Topper Motor.

Tools • •

#10 Torx driver Hex key set


4. Disconnect the Topper Motor connector (1 in Figure 7-36). 5. Remove two screws (2) and two star washers (3), then remove the Topper Motor (4). Replace 1. Transfer the Topper Motor Coupler (5) from the old motor to the new motor. Make sure the coupler is flush with the top of the motor shaft. 2. Place the new Topper Motor in place and secure with two screws and two star washers. 3. Reconnect the Topper Motor connector. 4. Replace the Topping Foil Cassette. 5. Replace any cable ties that were removed. 6. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.

7-78


3 (2x)

4

2 (2x)

Flush

5

1

Figure 7-36: Topper Motor


7-79

Main Control Board The Main Control Board is the main processor board of the 150i. Use the following procedure to remove and replace the Main Control Board (MCB).

Tools • • •

PC (minimum requirements: Windows 95/66 MHz/32K of RAM) Disk Assy, Diag Install Utility (PN 555071-001) J-TAG Cable (PN 557028-001) (Required when reformatting the Main Logic Board memory.)

Remove Before replacing the Main Control Board, backup all stored setting using the 150i Diagnostic Install Utility. This program will give you step by step instructions for backing up the Main Control Board.

1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Remove the Front Access Panel (see Front Access Panel). Use proper anti-static grounding techniques when handling the Main Control Board. Remove any shipping cable ties if present.

4. Unlatch the Main Control Board (1 in Figure 7-37) and pull forward far enough to disconnect the following connectors: • •

J12 (2) J13 (3)

5. Continue to pull the Main Control Board out further and disconnect the following connectors: • •

J7 (4) J16 (5)

6. Pull the Main Control Board out completely from the 150i. Replace Use proper anti-static grounding techniques when handling the new Main Control Board.

1. Slide the new Main Control Board in the board guides and reconnect all cables that were previously disconnected.

7-80


Make sure wires are not pinched and are placed in the casting slot provided. Make sure all cables connectors and the Main Control Board are firmly seated.

2. Reload the saved configurations into the 150i. 3. Replace the Front Access Panel. 4. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification. 2 3 4 5 Pin 1 Pin 1

•

•

J12

J16 J7

J13

1

150i061s

Figure 7-37: Main Control Board


7-81

Power Supply Board The Power Supply Board delivers DC power to the stepper motors, LEDs and powers the Main Control Board. Use the following procedure to remove and replace the Power Supply.

Tools • •

Phillips screwdriver #20 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Remove the Input Hopper card weight and all cards from the 150i. 4. With the Top Cover closed and locked, place the 150i in an upright position on the rear of the machine. 5. Remove four long screws (1 in Figure 7-38), six short screws (2), and one rubber foot (3). 6. Tilt down the Power Supply mounting plate (4) and disconnect connector JP2 (5) from the Power Supply Board (6). 7. Lay the Power Supply mounting plate down and remove two red wires from the + (plus) side of JP1. 8. Remove two black wires from the - (minus) side of JP1. 9. Remove seven screws (7) attaching the Power Supply Board to the mounting plate. Replace 1. Position the new Power Supply Board on the mounting plate and attach with five screws. 2. Attach two black wires to the - (minus) side of JP1. 3. Attach two red wires to the + (plus) side of JP1. 4. Connect JP2 on the Power Supply Board. 5. Attach the Power Supply mounting plate with four long screws, six short screws, and one rubber foot.

7-82


6. Return the 150i to its normal resting position. 7. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification. 7 (2x) 4

5

2 (6x) 3

JP 2

4

1 (4x)

6

7(5x) 4

Black Wires

Red Wires

JP 1

150i062s

Figure 7-38: Power Supply


7-83

Line Filter The Line Filter is used to remove transient spikes of power from the power line and acts as a surge protector. Use the following procedure to remove and replace the Line Filter.

Tools • •

Small flat blade screwdriver #20 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually move the Card Transport carriage to the left-hand side of the 150i. 4. Remove one screw (1 in Figure 7-39), one nut (2) and the Top Cover Grounding Wire (3) on the left-hand side of the Inner Fan Guard (4). 5. Remove one screw (5) from the right-hand side of the Inner Fan Guard, then lift out. 6. Remove one screw (6) and one star washer (7) attaching the grounding wire to the 150i base. 7. Disconnect both fast-on connectors (8) from the Line Filter (9). 8. Compress the locking tabs on the Line Filter to clear the mounting hole opening and remove. Replace 1. Place the new Line filter in position and make sure the locking tabs secure the Line Filter in the mounting hole. 2. Connect the fast-on connector marked “L” (red wire) to the “L” connector on the Line Filter. 3. Connect the fast-on connector marked “N” (blue wire) to the “N” connector on the Line Filter. 4. Attach the grounding wire using one screw and one star washer to the 150i base. When replacing the Inner Fan Guard, insure the Card Transport Flex Cable is correctly positioned or the Card Transport movement may be obstructed.

5. Place the Inner Fan Guard in position and attach with one screw on the right-hand side of the 150i.

7-84


6. Attach the left-hand side of the Inner Fan Guard with one screw and one nut. Make sure to attach the Top Cover Grounding Wire. 7. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification. 3 2 5 ref 4 ref

1 ref

N

6 8 7

L

Figure 7-39: Line Filter


7-85

Fuse The Fuse protects the electronic components inside the 150i. Use the following procedure to remove and replace the Fuse.

Tools •

Flat blade screwdriver

Remove 1. Power OFF the 150i and remove the power cord from the wall outlet. 2. Use a flat blade screwdriver to pry out the Fuse Holder as shown. Replace 1. Place the new fuse in the Fuse Holder and press the Fuse Holder back in place. 2. Plug in the power cord and power ON the 150i. 3. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.

7-86


1

Figure 7-40: Fuse


7-87

Fan The Fan removes excess heat generated by the stepper motors and the power supply from the 150i cabinet. Use the following procedure to remove and replace the Fan.

Tools • •

Nut driver set #20 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually move the Card Transport carriage to the left-hand side of the 150i. 4. Remove one screw (1 in Figure 7-41), one nut (2) and the Top Cover Grounding Wire (3) on the left-hand side of the Inner Fan Guard (4). 5. Remove one screw (5) from the right-hand side of the Inner Fan Guard, then lift out. 6. Disconnect the Fan connector (6). 7. Remove four nuts (7) attaching the Fan (8) to the 150i cabinet and remove the Fan. Replace 1. Place the new Fan in position and attach using four nuts. 2. Connect the Fan connector. When replacing the Inner Fan Guard, insure the Card Transport Flex Cable is correctly positioned or the Card Transport movement may be obstructed.

3. Place the Inner Fan Guard in position and attach with one screw on the right-hand side of the 150i. 4. Attach the left-hand side of the Inner Fan Guard with one screw and one nut. Make sure to attach the Top Cover Grounding Wire. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. Make sure grounding strap is replaced.


7-88


3 2 1 ref 5 ref 4 ref

6

7 (4x)

Figure 7-41: Fan


7-89

Display/Keypad The Display/Keypad allows 150i information to be displayed on a two line LCD display. The keypad provides a means to access the 150i’s operating menu. Use the following procedure to remove and replace the Display/Keypad.

Tools •

11/32 inch nut driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Disconnect the Display/Keypad cable connector P4 (1 in Figure 7-42). 4. Remove four nuts (2) and one grounding wire (3), then remove the Display/Keypad from the top cover. Replace 1. Place the new Display/Keypad in position and attach with four nuts. Make sure to attach the ground wire. 2. Connect the Display/Keypad cable connector P4. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.


7-90


4

3 2 (4x)

1

Figure 7-42: Display/Keypad


7-91

Solenoid Lock Assembly The Solenoid Lock Assembly prevents unauthorized access to the 150i without entering a correct password or using a key. The Top Cover interlock switch is also incorporated in this assembly Use the following procedure to remove and replace the Solenoid Lock Assembly.

Tools •

#20 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Remove three screws on the Embosser so the Embosser can be partially removed. The front Embosser mounting screw can be removed by spreading unused embossing fingers (see Embosser Assembly). 4. Move the Embosser out of the way to allow access for the removal of the Solenoid Lock Assembly. 5. Disconnect two fast-on connects (1 in Figure 7-43) from the Lock Solenoid (2) and two fast-on connectors (3) from the Interlock Switch (4). 6. Remove three screws (5) holding the Solenoid Lock mounting bracket (6) and remove the assembly. Replace 1. Place the new Solenoid Lock Assembly in position and attach with three screws. 2. Connect the fast-on connectors to both the Interlock Switch and the Lock Solenoid. 3. Place the Embosser in position and attach with three screws. 4. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification. Follow-up Adjustments This remove and replace procedure affects the following adjustments which must be performed after this procedure. •

7-92

Interlock Switch Adjustment


2 1 (2x)

5 (3x)

4 6 3 (2x)

Figure 7-43: Solenoid Lock Assembly


7-93

Reject Full Sensor The Reject Full Sensor detects when the reject hopper is filled with cards. Use the following procedure to remove and replace the Reject Full Sensor.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Disconnect the Reject Full Sensor connector (1 in Figure 7-44). 4. Remove one screw (2) from the Reject Full Sensor (3) and remove. Replace 1. Place the new Reject Full Sensor in position and attach with one screw. 2. Reconnect the Reject Full Sensor connector. 3. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.

7-94


3 2 1

Figure 7-44: Reject Full Sensor


7-95

Front Smart Card Module (Option) The Front Smart Card Module allows plastic cards with Smart Card chips (on the front side) to be programmed. Use the following procedure to remove and replace the Front Smart Card Module.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Remove the Indent module if so equipped. See Front Indent Printer Module (Option) or the Replacing the Front Indent Ribbon. 4. Remove three screws (1 in Figure 7-45) holding the Smart Card Pin Block/solenoid (2) and the Smart Card Logic board bracket (3) to the Front Smart Card bracket (4). 5. Disconnect the SC Sol cable connector (5) and cable connector J5 (6) from the Smart Card Logic board (7). 6. Disconnect the communication cable J4 (8) and the power connector J1 (9) from the Smart Card Logic board. Replace 1. Reconnect the SC Sol cable and cable connectors J1, J4, and J5 to the Smart Card Logic board. 2. Place the Smart Card Logic board in position along with the Smart Card Pin Block/solenoid and attach them with three screws to the Front Smart Card bracket. 3. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification. Follow-up Adjustments This remove and replace procedure affects the following adjustments which must be performed after this procedure. •

7-96

Front Smart Card Stop Adjustment (see Front Smart Card Stop Adjustment in Chapter 6)


7

J10 J1

J4

J5

9 6 8

5

1 (3x) 3

2

4

Figure 7-45: Front Smart Card Module


7-97

Front Indent Printer Module (Option) The Front Indent Printer Module provide a means to indent characters (using a colored ribbon) to the front side of a plastic card. Use the following procedure to remove and replace the Front Indent Printer Module.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Remove the Front Indent Print Ribbon (see Replacing the Front Indent Ribbon) 4. Remove the following cable connectors: • • •

OCR Motor (1 in Figure 7-46) OCR Sol (2) OCR Motion (3)

5. Remove four screws (4) attaching the module to the 150i and remove the indent module. Replace 1. Place the Front Indent Printer module in position and secure with four screws. 2. Reconnect the following connectors: • • •

OCR Motor (1 in Figure 7-46) OCR Sol (2) OCR Motion (3)

Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i.

3. Replace the Front Indent Ribbon. 4. Run a Standard Test Card with front indent printing to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.

7-98


4 (4x)

3 2 1

150i114s

Figure 7-46: Front Indent Printer Module


7-99

Replacing the Front Indent Ribbon To change the Rear Indent Ribbon, perform the following steps:

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i. 3. Remove the used indent ribbon from the Take Up Spool (1 in Figure 7-47) by sliding the Take Up Retainer (2) off the Take Up Spool and removing the ribbon and core from the Take Up Spool. 4. Set the Take Up Retainer aside. 5. Remove the Supply Retainer (3) from the Supply Spool (4) as shown in, then remove the core from the Supply Spool and set it aside. Replace 1. Place the new indent ribbon roll on the Supply Spool as shown. 2. Slide the Supply Retainer onto the Supply Spool until it clicks in place. 3. Wrap the indent ribbon around the Ribbon Guide Rollers and Ribbon Foil Motion Wheel (5) as shown. 4. Tape the edge of the ribbon, dull side out, to the core, as shown. 5. Place the core on the Take Up Spool, as shown below, and slide the Take up Retainer on the Take Up Spool until it clicks in place. 6. Close the Top Cover.

7-100


Ribbon Guide Rollers (Typical)

5

4

1

Dull Side

3

Core

4

2

Core

1

Figure 7-47: Replacing the Front Indent Ribbon


7-101

Rear Indent Printer Module (Option) The Rear Indent Printer Module provides a means to indent characters (using a colored ribbon) to the rear side of a plastic card. Use the following procedure to remove and replace the Rear Indent Printer Module.

Tools •

Hex key set

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Remove the Rear Indent Ribbon from the Rear Indent Printer Module (see Replacing the Rear Indent Ribbon). 4. Disconnect the OCR Motion sensor cable connector (1 in Figure 7-48). 5. Remove the module return spring (2) from the holding post (3). 6. Loosen the set screw (4) on the Ribbon Take Up Spool shaft and remove the Ribbon Take Up Spool Holding disk. 7. Remove the Rear Indent Printer module (5) from the 150i. Replace 1. Place the new the new Rear Indent Printer module in position. 2. Tighten the set screw on the Ribbon Take Up Spool shaft. Make sure to tighten the set screw on the flat portion of the shaft and check for binding of the Ribbon Take Up Spool on the Rear Indent Printer module. 3. Reconnect the OCR Motion sensor cable connector. Make sure wires are not pinched. Make sure the connector and wires will not interfere with any mechanical movement inside the 150i.

4. Replace the Rear Indent Ribbon (refer to Replacing the Rear Indent Ribbon). 5. Run a Standard Test Card with rear indent printing to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.

7-102


1

OCR Motion

4

Rear Indent Printer

3

5

2

Flat

Figure 7-48: Rear Indent Printer Module


7-103

Replacing the Rear Indent Ribbon To change the Rear Indent Ribbon, perform the following steps:

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Remove the used indent ribbon from the Take Up Spool (1 in Figure 7-49) by sliding the Take Up Retainer (2)off the Take Up Spool and removing the ribbon and core from the Take Up Spool. 3. Set the Take Up Retainer aside. 4. Remove the Supply Retainer (3) from the Supply Spool (4) as shown, then remove the core from the Supply Spool and set it aside. Replace 1. Place the new indent ribbon roll on the Supply Spool as shown. 2. Slide the Supply Retainer on the Supply Spool until it clicks in place. 3. Wrap the indent ribbon around the Ribbon Guide Rollers and Ribbon Foil Motion Wheel (5) as shown. 4. Tape the edge of the ribbon, dull side out, to the core. 5. Place the core on the Take Up Spool, as shown below, and slide the Take up Retainer on the Take Up Spool until it clicks in place. 6. Close the Top Cover.

7-104


Dull Side

5

Shiny Side

3

4 1 2

Figure 7-49: Replacing the Rear Indent Ribbon


7-105

Rear Indent Motor The Rear Indent Motor advances the indent ribbon. Use the following procedure to remove and replace the Rear Indent Motor.

Tools •

#10 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Disconnect the OCR Motor connector (1 in Figure 7-50). 4. Remove two adjustment screws (2) from the Rear Indent Motor bracket (3). 5. Remove the drive belt (4) from the motor pulley (5) and remove the Rear Indent motor (6). Replace 1. Place the Rear Indent motor in position and secure with two adjustment screws, but do not tighten. 2. Install the drive belt and then tension the belt. Tighten the two adjustment screws. 3. Reconnect the OCR Motor connector. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. Refer to Replacing the Rear Indent Ribbon if ribbon replacement is needed.

4. Run a Standard Test Card with rear indent printing to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification. Follow-up Adjustments This remove and replace procedure affects the following adjustments which must be performed after this procedure. •

7-106

Rear Indent Drive Belt Adjustment (see Rear Indent Drive Belt Adjustment in Chapter 6)


2

4 5

3

6

1

OCR Motor

150i111s

Figure 7-50: Rear Indent Motor


7-107

Rear Indent Drive Belt The Rear Indent Drive Belt transfers movement from the Read Indent Motor to move the indent ribbon. Use the following procedure to remove and replace the Rear Indent Drive Belt.

Tools •

#20 Torx driver

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Remove of the Rear Indent Print Module from the 150i. (See Rear Indent Printer Module (Option) removal. 4. Loosen two adjustment screws (1 in Figure 7-51) on the Rear Indent Motor (2) and remove the drive belt (3). Replace 1. Place the new drive belt in position, then tension the Rear Indent motor and tighten down the two adjustment screws. 2. Install the Rear Indent Print Module. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. Refer to Replacing the Rear Indent Ribbon if ribbon replacement is needed.

3. Run a Standard Test Card with rear indent printing to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification. Follow-up Adjustments This remove and replace procedure affects the following adjustments which must be performed after this procedure. •

7-108

Rear Indent Drive Belt Adjustment (see Rear Indent Drive Belt Adjustment in Chapter 6)


1

3

2 150i110s

Figure 7-51: Rear Indent Drive Belt


7-109

Rear Indent Solenoid The Rear Indent Solenoid is used to move the Rear Indent Ribbon in position so printing can occur. Use the following procedure to remove and replace the Rear Indent Solenoid.

Tools •

7/8 inch box wrench

Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Disconnect the OCR Sol cable connector (1 in Figure 7-52). 4. Remove one solenoid retraction spring (2) and move the Rear Indent module out of the way. 5. Remove one solenoid retaining nut (3) on the Rear Indent solenoid (4) and remove. Replace 1. Place the new the Rear Indent Solenoid in position and secure with one retaining nut. 2. Replace the solenoid retraction spring. 3. Reconnect the OCR Sol cable connector. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. Refer to Replacing the Rear Indent Ribbon if ribbon replacement is needed.

4. Run a Indent Test Card with rear indent printing to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.

7-110


3

4

2

1

150i117s

To OCR Solenoid

Figure 7-52: Rear Indent Solenoid


7-111



7-112


Chapter 8: Illustrated Parts Breakdown The 150i Card Personalization System operates as a standalone card embosser. This chapter provides information on assembly and subassembly part numbers for the 150i.

8

Introduction 8-2 General 8-2 Cabinet Parts 8-3 Input/Output Hopper Assembly 8-4 Card Transport Assembly 8-6 Magnetic Stripe Assembly 8-7 Embosser Assembly 8-8 Lower Emboss Housing Assembly 8-10 Upper Emboss Housing Assembly 8-11 Topper Assembly 8-12 Topper Foil 8-13 Main Control Board 8-14 Power Supply 8-15 Fan 8-16 Sensor Cable Harness 8-17 Power Cable Harness 8-18 Communications Cable 8-19 Cable/Development Cable 8-20 Display/Keyboard 8-21 Miscellaneous Spare Parts 8-22 Solenoid Lock Assembly 8-23 Reject Full Photocell 8-24 Smart Card Assembly 8-25 Front Indent Print Assembly 8-26 Rear Indent Printer Assembly 8-27 Indent Ribbon 8-28


8-1

Introduction This chapter provides information on assembly and sub-assembly part numbers for the 150i.

General The 150i Series Card Personalization System final assembly may be configured under different part numbers related to the 150i Series Card Personalization System defined in the customer order. Verify the final assembly part number before replacing components.

8-2

Illustrated Parts Breakdown

Cabinet Parts Description

Part Number

Top Cover Front Access Panel Outside Cabinet Single Access Door Output Hopper Door Output Door Assembly

555120-002 556272-001 596625-001 556277-001 556278-001 556788-001


8-3

Input/Output Hopper Assembly Description

Part Number

Input / Output Hopper Assembly Input Hopper Card Weight Output Hopper Drive Belt Card Registration Photocell Input Hopper Empty Photocell Input Home Photocell Output Full Photocell Card Pick Photocell O-Rings Throat Gap Motor Throat Gap Photocell Throat Gap Motor Belt Assembly, IH/OS Base Plate Plate Assembly, Left Side, IH/OS Plate Assembly, Right Side, IH/OS Roller, Cam Gear, Idler Plate, Card Gap Assembly, Plate, Support, Card Gap Wire Assembly, Input Motor Gnd Shaft, Support Motor Assembly, GFX .5a Stepper,280 Motor Assembly, IH/OS Plate Assembly, Stacker, Output Cam Plate, Support Block, Leadscrew Pulley, Leadscrew-12 Groove Block, Slide Bracket, Support, Motor Pulley, Leadscrew-20 Groove Leadscrew

556787-051 596713-001 803478-018 590067-003 593463-003 593463-003 596463-003 593463-003 803478-009 555938-001 593463-003 803129-126 596695-002 596697-001 596698-001 596328-001 596455-001 596333-001 556473-001 556307-001 596353-001 596104-001 555082-001 596696-001 596454-001 555981-001 556280-001 555986-001 556281-001 555989-001 555990-001 555991-001

8-4


Card Registration Photocell Input Home Photocell

O-Rings

Output Full Photocell

Card Picked Photocell

Output Hopper Drive Belt

Input/Output Hopper

Throat Gap Motor

Throat Gap Motor Photocell

Input Hopper Empty Photocell

Throat Gap Motor Belt


8-5

Card Transport Assembly Description

Part Number

Card Transport (Complete) Transport Flex Cable X Transport Drive Belt Y-Home Photocell X Home Photocell Y Belt Block Assembly, Support, Leadscrew Assembly, Y-Drive Card Carriage Assembly, X-Drive Card Carriage Motor Assembly, X Carriage Pulley, 48 Groove Tube, Support Shaft, Leadscrew, X-Drive Bearing, Guide O-Ring, .114id .06w Buna-N

556787-050 555040-001 803129-122 593463-003 593463-003 803129-123 596690-001 596686-002 555921-002 596691-001 596446-001 596312-001 596311-001 596444-001 803478-006

Y-Belt

Y-Home Photocell

Card Transport

X-Home Photocell

8-6

X-Transport Drive Belt


Magnetic Stripe Assembly Description

Part Number

Magnetic Stripe (IA/IAT) Magnetic Stripe (J) Magnetic Stripe (IAJ)

596663-001 596663-002 596663-003


8-7

Embosser Assembly Description

Part Number

Wheel Home Photocell Driver Arm Assembly, Rocker Shaft, Rocker

593463-003 596421-001 596680-001 596416-001

Emboss Wheel Assembly 150i C. S. EMB-Standard 150i C. S. EMB-Japan Fin 73 Char 150i C. S. EMB-Japanese HC 63 Char 150i C. S. EMB-Swedish 60 Char 150i C. S. EMB-Russian 73 Char 150i C. S. EMB-Japanese Credit 150i C. S. EMB-Visa Elec 37 Char 150i C. S. EMB-Std W/Ind OCR-A1 150i C. S. EMB-Std W/Ind OCR-B1 150i C. S. EMB-Std W/MC 0-9r 150i C. S. EMB-Std W/OCRB1 Fine 150i C. S. EMB-Std W/Inv MC 0-9 150i C. S. EMB-Visa Elec Fine 52 150i C. S. EMB-Visa Elec 52 Char 150i C. S. EMB-Korean 75 Char 150i C. S. EMB-Czech 75 Char 150i C. S. EMB-Poland Visa Elec

8-8

556787-001 556787-002 556787-003 556787-004 556787-005 556787-006 556787-007 556787-008 556787-009 556787-012 556787-013 556787-014 556787-015 556787-016 556787-017 556787-018 556787-028


Wheel Home Photocell

Embosser


8-9

Lower Emboss Housing Assembly Description

Part Number

Lower Emboss Housing Assembly Pulley, Cam Cam Belt, Htd .118p 5.787l .354w Motor Assembly, Cam Photocell, 1 Ear Pt Spring, Comp Driver Arm Assembly, Rocker Shaft, Rocker Motor Assembly, Wheel

596683-002 555051-002 555044-002 805727-004 596682-001 593463-003 555610-001 596421-001 596680-001 596416-001 596681-001

Cam

Photocell

Spring Washer Driver Cam Motor

Belt

Rocker Arm Assy

Cam Pulley Shaft

Wheel Motor

8-10


Upper Emboss Housing Assembly Description

Part Number

Upper Emboss Housing Assembly Pulley, Cam Cam Belt, Htd .118p 5.787l .354w Motor Assembly, Cam Photocell, 1 Ear Pt

596684-002 555051-002 555044-002 805727-004 596682-001 593463-003

Cam

Photocell

Cam Pulley

Belt

Cam Motor


8-11

Topper Assembly Description

Part Number

Topper Assembly Topper Platen Photocell Foil Cassette Assembly, Foil Motion Motor Assembly, Topper Ring, Lift Block, Back-Up Block, Cassette Mounting

596665-001 593463-003 596666-002 555092-001 555096-001 597970-001 596393-001 597980-001 Lift Ring

Topper Foil Motion Photocell

Back-Up Block Note: Chamfer location

Topper Platen Photocell

Topper Motor

Topper Foil Motion Assy

Cassette Mounting Blocks

Foil Cassette

8-12


Topper Foil Description

Part Number

Silver Gold Black White Dark Blue Process Blue Red

597950-013 597950-003 597950-002 597950-004 597950-001 597950-008 597950-006


8-13

Main Control Board Description

Part Number

Main Control Board

555112-002

Main

8-14

ontrol Board


Power Supply Description

Part Number

Power Supply Line Filter Fuse Line Cord

555093-001 594032-001 804960-024 804517-001 Fuse

Power Supply

Line Filter

Cord


8-15

Fan Description

Part Number

Fan

594030-001

Fan

8-16


Sensor Cable Harness Description

Part Number

Sensor Cable Harness

555962-001 Y-Home OCR Motion Platen

Sensor Cable Harness

Foil Motion Reject Full

Die Home

RTD

J12

Wheel Home

Punch Home

MS Front MS back Inter Lock

X-Home

J13

Card Picker Registration

IH-Home

IH-Empty Output Full Throat Gap


8-17

Power Cable Harness Description

Part Number

Power Cable Harness

555961-001 POWER SUPPLY FAN Y-MOTOR MPC MOTOR

J11

TOPPER MOTOR TOPPER SOL TOPPER HEAT

J9

POWER MOTOR OCR SOL INPUT MOTOR X-MOTOR

J10 TG MOTOR OCR MOTOR SC OCR WHEEL MOTOR

DIE MOTOR LOCK SOL

8-18


Communications Cable Description Communications Cable

Part Number 555037-002 J7

J8


8-19

Cable/Development Cable Description

Part Number

Cable Assembly, SC Application, 150i

556226-001

J

DEVELOPMENT

DIAGNOSE

8-20


Display/Keyboard Description

Part Number

Display Assembly Display Cable

596289-001 555039-001

Display Assembly

Display Cable


8-21

Miscellaneous Spare Parts Description

Part Number

Character Type Insertion Tool (MasterCard™ Only) 556335-001 Administrator’s Guide 526638-001 CPX Protocol/Setup Manual 526637-001 Software Developer’s Manual 526698-001

8-22


Solenoid Lock Assembly Description Solenoid Lock Assembly Key Lock Assembly (With Key)

Part Number 555113-001 807100-001

Key

Key Lock Assembly

Solenoid Lock

150i220s


8-23

Reject Full Photocell Description

Part Number

Reject Full Photocell

593463-003

Reject Full Photocell

8-24

150i221s


Smart Card Assembly Description

Part Number

Smart Card Front IC Assembly

596668-003

Smart Card Assembly


8-25

Front Indent Print Assembly Description

Part Number

Front Indent Printer Assembly

555110-001 Front Indent Printer

150i223s

8-26


Rear Indent Printer Assembly Description Rear Rear Rear Rear

Indent Indent Indent Indent

Part Number Printer Assembly Motor Drive Belt Solenoid

555111-002 555122-001 803129-123 555932-001

Rear Indent Printer

Rear Indent Solenoid

Rear Indent Motor

Rear Indent Drive Belt


150i224s

8-27

Indent Ribbon Description

Part Number

Black Infill Ribbon

596805-001



8-28


Chapter 8: Illustrated Parts The 150i Card Personalization System operates as a standalone card embosser. This chapter provides information on assembly and subassembly part numbers for the 150i embosser. Introduction 8-3 General 8-3 Parts Lists for Base Assembly 8-3 Base System without Topper (596660-102) 8-3 Base Assembly (555099-002) 8-4 Top C over Assembly (555120-002, FRU is 555120-008) 8-5 Right Door Assembly (556277-001), Rev E 8-5 Bac k Side Panel Assemb ly (555098-002) 8-5 Null Modem C able, DSub,9P-M -F (596813-001) 8-6 Output Door A ssemb ly (556788-001) 8-6

Illustrated Cabinet Parts 8-7 Input/Output Assembly (556787-051), Rev Y 8-8 Input/ Output Assemb ly Parts (596662-002) 8-8 Output Stacker Plate Assembly Parts (596696-001), Rev E 8-9 Illustrated Input/Output A ssembly 8-10

Card Transport Assembly 8-11 C ard Transport Assembly FRU Parts (556787-050) 8-11 C ard Transport Assembly Parts (596661-002) 8-11 X C arriag e Moto r Assemb ly FRU Parts (596691-999) 8-11 Y-Drive C ard Ca rriage Assembly Parts (596686-002) 8-11 Right Supp ort Bloc k Assembly FRU Parts (596690-002) 8-12 Illustrated C ard Transport Assemb ly 8-12

Magnetic Stripe Assembly 8-13 IA/IAT, Hico/Loc o Parts (596663-001 in Kit 555103-001) 8-13 J , Hico/ Loc o Parts (596663-002 in Kit 555103-002) 8-13 Bac k J , Hico/ Loc o Parts (596663-007 in Kit 555103-007) 8-13 IAJ , Hico/ Loc o Floa ting Hea ds Parts (596663-009 in Kit 555103-009) 8-14 IAJ , Hico/ Loc o Floa ting Heads, PR-MBSD (596663-010 in Kit 555103-010) 8-14 Illustrated Magnetic Stripe 8-16

Embosser/Indent Assemblies 8-17 Embo sser Assembly Pa rts (596664-002) 8-17 Daisy Wheel Assembly, 7BSG, 52C har (596678-001) 8-17

150i C ard Persona lization System Maintena nce Manual

8-1

Daisy Wheel Assembly, 7BSG, 50C har (596678-002) 8-17 Emboss Module Wheel A ssemblies 8-18 Illustrated Embosser A ssemb ly 8-19 Upper Emboss Housing Assembly Parts (596684-002) 8-20 Illustrated Upper Emboss Housing Assembly 8-20 Lower Emboss Housing A ssembly Parts (596683-002) 8-21 Illustrated Lower Emboss Housing Assembly 8-22 Front Indent Assembly Parts (555110-001) 8-23 Front Indent Installation Kit Pa rts (555111-003) 8-23 Illustrated Front Indent Assembly 8-23 Rear Indent Assembly (555121-999) 8-24 Rea r Indent Installation Kit Pa rts (555111-002) 8-24 Illustrated Rear Indent Assembly 8-25

Topper Assembly 8-26 C . S. Topper FRU Parts (556787-052) 8-26 Topp er Assembly Parts (596665-002) 8-26 Topper Heater Assembly Parts (555094-001) 8-26 Lower Topper Assembly Parts (596675-001) 8-26 Topper Left Side Plate Assembly Parts (555091-001) 8-26 Topper Right Side Plate Assembly Parts (555090-001) 8-27 Topper C assette Assembly Parts (596666-002) 8-27 Foil Motion Assembly Parts (555092-001) 8-27 Topp er Foil Parts 8-28 Illustrated Topper Assembly 8-28

Main Control Board 8-29 Power Supply 8-30 Power Supply Assembly Parts (555093-999) 8-30 Power Cords 8-30 Illustration of Power Supply 8-31

Fan 8-32 Sensor C able Harness 8-33

Power Cable Harness 8-34 Communications Cable 8-35 Smart Card Development Cable 8-35 Display/ Keyboard 8-36 Miscellaneous Spare Parts 8-36 Solenoid Lock Assembly 8-37 Solenoid Loc k Assembly Parts (555113-002) 8-37 Key Loc k Parts 8-37 Illustrated Solenoid Loc k Assembly 8-38

Reject Full Sensor 8-39 Smart Card Assembly 8-40

8-2

Illustrated Pa rts

Introduction This chapter provides information on assembly and subassembly part numbers for the 150i.

General The 150i Series Card Personalization System final assembly may be configured under different part numbers related to the 150i Series Card Personalization System defined in the customer order. Verify the final assembly part number before replacing components.

Parts Lists for Base Assembly Base System without Topper (596660-102) Item 1 2 3 4 5 6 8 10 11 12 13 14 15 18 19 20 22 23 24 25 27 31 33 37

Item Description Base Assembly Top Cover Assembly Installation, Transport Install, In/Output Assembly Install, Embosser Washer, Flat, Stl 8x.375 Screw, Hex Washer, Tf 8-32x .750 Right Door Assembly Output Hopper Door Pin, Dowel .1252od .50l Front Bottom Panel Front Access Panel Pin, Pivot, Lid Nut, Hex Loc, Nyl Ins.25-20unc Washer, Friction Washer, Belv .500d .258id .035 Screw, Phil, Ph,Tf, 8-18 X 1.0 Container, Shipping, 150i Disk Assembly, Diag Install Utility Manual Assembly, Admin Guide,150i Guard, Output Hopper Screw, Fh100 Phil 4-40x.250 Checklist, 150i Installation Inductor, Ferrite Bead, 250ohm


Qty 1 1 1 1 1 1 9 1 1 1 1 1 3 2 4 4 1 1 0 1 1 2 1 2

Part Number 555099-002 555120-998 555101-002 555102-002 555105-002 800075-004 805991-412 556277-001 556278-001 800257-017 556276-001 556272-001 596767-001 803053-005 555647-001 803297-007 806531-116 552875-001 555071-001 526701-001 555735-001 800072-204 526791-001 805513-007

8-3

Item 39 41

Item Description Clip, Ferrite Bead Pamphlet, Security

Qty 2 1

Part Number 805513-101 598713-001

Qty 6 1 2 1 1 1 48 1 1 1 3 4 2 1 1 1 3 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 2 7 1

Part Number 803323-006 596720-001 800257-017 596719-001 805991-205 555114-001 805991-408 593463-003 555113-002 555040-001 800506-004 552002-001 506021001 555751-003 555751-004 556786-001 803336-408 506022001 596794-001 806553-009 596758-001 555112-998 555962-001 555096-999 805351-002 555037-002 555039-001 555068-001 596793-001 555600-001 555097-002 555723-001 805957-001 555961-002 805991-406 805991-412 805991-416

Base Assembly (555099-002) Item 1 2 3 4 5 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 25 26 27 29 31 32 33 34 35 37 41 45 46 49 50 51

8-4

Item Description Clamp, Cable, Adhesive Block, Pivot Pin, Dowel .1252od .50l Link, Tray Screw, Hex Wshr,Tf 4-40x.312 Reject Tray Assembly Screw, Hex Washer, Tf 8-32x.505 Photocell, 1 Ear Pt Lock Bracket Assembly Cable Assembly, Flex Circuit Washer, Lock, Ext Tooth 8 Strap. Black Abs Nut, Hex Ext T Keps 6x32 Lower Left Support Link Assembly Lower Right Support Link Assembly Base, 150i Screw, Cap Button 8-32x.500 Nut, Hex, Ext T Keps 8x32 Strap, Flex Cable Lower Conn, Pin Shroud, Pnl Mt, 9pos Access Panel, Fan Housing Assembly, MCB Plate Cable Assembly, Sensor Assembly, Power Supply Rubber Bumper, No. 8 Cable Assembly, Comm I/O Cable Assembly, Display Spacer Strap, Flex Cable Upper Angle, Display Cable Clamp Assembly, MCB Mounting Pan Cable Assembly, Display Ground Switch-Intlk,Spst,10a,250v,Vde Cable Assembly, Pwr, Blockpoint,150i Screw, Hex Washer, Tf 8-32x.375 Screw, Hex Washer, Tf 8-32x .750 Screw, Hex Washer, Tf 8-32x1.00

Illustrated Pa rts

Top C over Assembly (555120-002, FRU is 555120-008) Item 3 4 5 6 8 9 10 11 13 14 15 16 17 18

Item Description Display Assembly Nut, Hex, Ext T Keps 8x32 Lock-Key,Tubular,1w90,Key Diff Lock, Plate Lid Guide Bracket Assembly Guard, Hopper, Input Upper Left Support Link Assembly Upper Right Support Link Assembly Top Cover,150i Front Panel (Pushes Interlock) Screw, Phil, Ph,Tf 8-18 X 1/2 Nut, Self-Thd, Washer, .12stud Strap. Black Abs Clamp, Cable, Adhesive

Qty 1 4 1 1 1 1 1 1 1 1 16 4 2 3

Part Number 596289-001 506022001 807100-001 596771-001 555755-001 596769-001 555750-003 555750-004 556270-001 556271-001 806531-108 806742-001 552002-001 803323-006

Right Door Assembly (556277-001), Rev E Item 1 2 4 5 6 7 8 9

Item Description Input Door Plate, Cover, Input Right Door Pivot Assembly Pin, Pivot, Door Spacer, Door Hinge Slide Block, Exception Card Spring, Tor 180lh,.348od X.040w Screw, Ph, Tf, Torx 6-19 X.375

Qty 1 1 1 2 2 2 1 4

Part Number 556275-001 596748-001 555753-001 596766-001 560008-001 596718-001 803940-016 806575-406

Back Side Panel Assembly (555098-002) Item 1 2 3 4 7 8 10 12 13 14 15

Item Description Filter-Line Assembly, AC Fuse, Fast-Acting, 6.3a, 250VAC Outside Cabinet Cable Assembly, Power Switch Nut, Hex Ext T Keps 6x32 Fan Assembly, 24 VDC Tape, Double Sided,3/4in X.010 Panel, Right, Front Screw, Phil, Ph,Tf, 8-18 X .375 Bezel-Dsub, Snap-In, 9 Pos Screwlock Assembly, Fem, D Conn


Qty 1 2 1 1 2 1 0 1 4 4 2

Part Number 594032-001 804960-024 596625-001 596679-001 506021001 594030-002 803133-005 556273-001 806531-106 805551-003 803986-101

8-5

Null Modem Cable, DSub,9P-M-F (596813-001) Item 1

Item Description Cable Assembly, Null Modem, 9PM-F, 10FT

Qty 1

Part Number 806771-001

Output Door Assembly (556788-001) Ite m 1 2 3 4

8-6

Item Description

Qty

Part Number

Left Door Assembly Tray Link (from Door to Base) Pivot Block (on Base) Pin, Dowel .1252OD .50L

1 1 1 2

556278-001 596719-001 596720-001 800257-017

Illustrated Pa rts

Illustrated Cabinet Parts


8-7

Input/Output Assembly (556787-051), Rev Y Input/ Output Assembly Parts (596662-002) Item 1 2 3 4 5 6 7 8 9 10 12 19

22 24 26 29 37 38 39 41 43 46 47 48 49 50 51 52

53 60 61 65 66 67 69 70 71 72

8-8

Item Description Base Plate Assembly, IH/OS Left Side Plate Assembly, IH/OS Right Side Plate Assembly, IH/OS Roller, Cam Gear, Idler Plate, Card Gap Assembly Plate, Support, Card Gap Screw, Phil, Fh, Tf 4-24 X .375 Screw, Phil, Ph, Tf, 4-24 X .375 Wire Assembly, Input Motor Ground Shaft, Support Throat Gap Motor Assembly (includes motor 596104-001) (pulley is item 66, 555986-001) Motor Assembly, IH/OS Plate Assembly, Stacker, Output (contains PC flag, output rollers, o-ring) Cam (with Shaft) (Idler gear is item 5.) Spacer Washer, Ins .125x.312x.032 Pin, Dowel .0939od .50l Screw. Hex Washer, Tf 4-40 X.375 Screw, Hex Washer, Tf 4-40x.312 Spacer Washer, Uns .127x.250x.015 Ring, Retaining, Ext- .125sd- .094fd Ball Bearing Mr .13id .38od .16w Ball Bearing Mr .13id .31od .14w Input Hopper Card Weight Screw, Shoulder, .125x.188 4-40 Spacer Washer, Ins .126x.250x.015 Washer-Curved,Spring,No.5 Input Hopper Empty Sensor, Input Home Sensor, Output Full Sensor, Card Picked Sensor, Throat Gap Motor Sensor Card Registration Sensor Spring, Extension .19OD .88L .020W Support Plate Block, Leadscrew Pulley, Leadscrew-12 Groove Block, Slide Bracket, Support, Motor Pulley, Leadscrew-20 Groove Leadscrew Throat Gap Motor Belt

Qty 1 1 1 1 1 1 1 2 6 1 3 1

Part Number 596695-002 596697-001 596698-001 596328-001 596455-001 596333-001 556473-001 806582-106 806531-006 556307-001 596353-001 548992-003

1 1

555082-999 596696-001

1 1 2 6 17 1 1 4 2 1 2 2 2 5

596454-001 803223-016 800257-002 805991-206 805991-205 803112-026 803113-034 803128-004 803128-005 596713-001 803140-001 803223-045 805439-002 593463-003

1 1 1 1 1 1 1 1 1 1

590067-003 803111-058 555981-001 556280-001 555986-001 556281-001 555989-001 555990-001 555991-001 803129-126

Illustrated Pa rts

Item 74 75

Item Description Spacer Washer, Uns .127x.250x.015 Washer, Flat, Stl 6x.267

Qty 3 2

Part Number 803112-026 800718-003

Output Stacker Plate Assembly Parts (596696-001), Rev E Item 1 2 3 5 7 8 10 11 12

Item Description Roller, Output Output Hopper Drive Belt Plate, Support, Stacker Screw, Hex Washer, Tf 4-40x.312 O-Ring, Output Hopper Drive Belt Pulley, Groove Spring, Extension .09od 1.00l .010w Arm, Output Full Flag, Sensor


Qty 2 4 1 3 1 1 1 1 1

Part Number 596458-001 803478-009 596465-001 805991-205 803478-019 596459-001 803111-023 596457-001 596478-001

8-9

Illustrated Input/ Output Assembly

8-10

Illustrated Pa rts

Card Transport Assembly C ard Transport Assembly FRU Parts (556787-050) Item 1 2

Item Description Transport Assembly, 150i Blockpoint Transport FRU Shipping Crate

Qty 1 1

Part Number 596661-002 556791-001

C ard Transport Assembly Parts (596661-002) Item 1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 24 25 26 28

Item Description Block, Support, Leadscrew Y-Drive Card Carriage Assembly X-Carriage Assembly Motor Assembly, 1.0amp,9 Pos Mml Pulley, 48-Groove Nut, Hex, Ext T Keps 10x32 Screw, Set 8-32x.19 Y Transport Drive Belt Screw, Hex Washer, Tf 4-40 X.375 Y-Carriage Motor Assembly Bracket, Mount, Flex Circuit Conn, Pin Shroud, Pnl Mt, 9pos Screw, Hex Washer, Tf 4-40x.312 Y-Home Sensor, X-Home Sensor Screw, Hex Washer, Tf 8-32x.625 Tube, Support X-Drive Leadscrew Shaft Bearing, Guide (brown piece around black tube) X Transport Drive Belt Brg, Ball R .25id .75od .28w Screw, Shoulder .187x.250 8-32 O-Ring, .114id .06w Buna-N Washer, Flat, Stl 8x.375 Pin, Dowel .1877od .50l

Qty 2 1 1 1 3 2 3 1 2 1 1 1 1 1 6 2 1 1 1 2 3 3 3 2

Part Number 596658-001 596686-002 596688-002 598174-002 596446-001 506023001 804020-020 803129-122 805991-206 596687-001 596784-001 806553-009 805991-205 593463-003 805991-410 596312-001 596311-001 596444-001 803129-123 803106-009 803140-010 803478-006 800075-004 800257-025

X Carriage Motor Assembly FRU Parts (596691-999) Item 0

Item Description Motor Assembly, X Carriage

Qty 1

Part Number 596691-001

Y-Drive C ard C arriage Assembly Parts (596686-002) Item 1 2 3 5 6

Item Description Y-Carriage Assembly Cable Assembly, Flex Adapter Screw, Hex Washer, Tf 4-40x.50 Card Pick Cam Link Plate Hinge


Qty 1 1 1 2 2

Part Number 555915-001 555041-001 805991-208 596437-001 596438-001

8-11

Item 7 8 9 10 11 12 13 14

Item Description Pin, Dowel .0939od X .25l Pivot Shaft Lever Assembly (Pin) Spring, Comp .36od 1.25l .026w Shaft, Leadscrew, Y-Drive Screw, Hex Washer, Tf 8-32x.625 Latch Plate (clicks the gripper pens shut) Spring, Ext .12od .67l .014w

Qty 2 2 1 1 1 2 1 1

Part Number 800257-056 596471-001 596782-001 803072-105 596307-001 805991-410 596304-001 803111-076

Right Support Bloc k Assembly FRU Pa rts (596690-002) Item 1 2 4

Item Description Block, Support, Leadscrew Brg, Ball R .25id .75od .28w Pin, Dowel .1877od .50l

Qty 1 1 1

Part Number 596658-001 803106-009 800257-025

Illustrated C ard Transport Assembly

8-12

Illustrated Pa rts

Magnetic Stripe Assembly IA/ IAT, Hico/Loc o Parts (596663-001 in Kit 555103-001) Item 1 2 3 8 11 13 14 15 19

Item Description Roller Assembly, Drive,M/S Plate Assembly, Mount, Base Plate Assembly, Support, Mag Stripe Screw, Cap Soc 2-56x.250 Ring, Retaining, Ext- .250sd- .211fd Screw, Set Silver Tip 4-40x.125 Screw, Set, Cup 10-32x.19 Encoder, Optical, 500cpr,1/4dia Mag Stripe Head Assembly, IA/IAT

Qty 1 1 1 2 1 2 2 1 1

Part Number 596692-001 596693-001 596694-001 800200-104 803113-004 805544-202 804020-025 805386-001 555715-003

J , Hico/ Loc o Parts (596663-002 in Kit 555103-002) Item 1 2 3 4 8 10 11 13 14 15 19 20 22

Item Description Roller Assembly, Drive,J,M/S Plate Assembly, Mount, Base Assembly, Mounting Plate,J,M/S,150i Assembly, Support Plate,J,M/S,150i Screw, Cap Soc 2-56x.250 Spring, Comp .30od .62l .022w Ring, Retaining, Ext- .250sd- .211fd Screw, Set Silver Tip 4-40x.125 Screw, Set, Cup 10-32x.19 Encoder, Optical, 500cpr,1/4dia Mag Stripe Head Assembly, NTT Clamp, Cable Routing, Adhes,3/8 Tx, Jumper, Static Protection

Qty 1 1 1 1 2 1 1 2 2 1 1 2 0

Part Number 596692-002 596693-001 555933-001 555934-001 800200-104 803072-047 803113-004 805544-202 804020-025 805386-001 555715-004 806792-001 580197-901

Bac k J , Hic o/ Loco Parts (596663-007 in Kit 555103-007) Item 1 2 3 8 11 13 14 15 19 21

Item Description Roller Assembly, Drive, J Plate Assembly, Mount, Base Plate Assembly, Support, Mag Stripe Screw, Cap Soc 2-56x.250 Ring, Retaining, Ext- .250sd- .211fd Screw, Set Silver Tip 4-40x.125 Screw, Set, Cup 10-32x.19 Encoder, Optical, 500cpr,1/4dia Mag Stripe Head Assembly, NTT Tx, Jumper, Static Protection


Qty 1 1 1 2 1 2 2 1 1 0

Part Number 596692-002 596693-001 596694-001 800200-104 803113-004 805544-202 804020-025 805386-001 555715-004 580197-901

8-13

IAJ , Hico/ Loco Floating Heads Parts (596663-009 in Kit 555103-009) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 26 27 28 29 30 31 32 33 34 35 36 38 39 40

Item Description Plate, Mount, Base Block, Support, Lower Shaft, Support Nut, Thumb Pin, Dowel .2502od 1.00l Block, Support Middle Brg, Ball Mr .25id .50od .19w Pin, Dowel .1252od 1.00l Shaft, Encoder Ring, Retaining, Ext- .125sd- .120fd Ring, Retaining, Ext- .250sd- .211fd Bearing, Head, Roller Roller, Rubber Roller, Rubber .750x.2448x.25 Spring, Comp .30od .62l .022w Block, Upper Plate, Top Cap Yoke Pin, Dowel .0627od .44l Spring, Comp .088od ..38l .010w Block, Mount Head IAJ Encoder, Optical, 500cpr,1/4dia Assembly, M/S Head (IAJ Only) Mag Stripe Head Assembly, NTT Screw, Cap Soc 6-32x1.125 Washer, Lock, Hel Spring 6 Pin, Dowel .0938od .38lg Pin, Dowel .093od 1.0l Screw, Cap Soc 2-56x.250 Screw, Fh100 Phil 4-40x.375 Screw, Set, Cup 4-40x.12 Screw, Set, Cup 10-32x.19 Clamp, Cable Routing,Adhes,3/8 Screw, Cap Soc 8-32x.250 Washer, Lock, Ext Tooth 8 Tx, Jumper, Static Protection

Qty 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 2 6 2 2 1 1 1 2 2 1 1 2 2 4 2 2 1 1 0

Part Number 556283-001 548379-001 555143-001 596432-001 800257-010 548380-001 803128-013 800257-020 555142-001 803113-043 803113-004 590128-004 590127-002 520529-008 803072-047 548376-001 548377-001 555145-001 800257-029 803072-098 548378-001 805386-001 555715-005 555715-004 800200-318 800175-003 800257-001 800257-035 800200-104 800072-206 804020-010 804020-025 806792-001 800200-404 800506-004 580197-901

IAJ , Hico/ Loco Floating Heads, PR-MBSD (596663-010 in Kit 555103-010) Item 1 2 3

8-14

Item Description Plate, Mount, Base Block, Support, Lower Shaft, Support

Qty 1 1 1

Part Number 556283-001 548379-001 555143-001

Illustrated Pa rts

Item 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 26 27 28 29 30 31 32 33 34 35 36 38 39 40

Item Description Nut, Thumb Pin, Dowel .2502od 1.00l Block, Support Middle Brg, Ball Mr .25id .50od .19w Pin, Dowel .1252od 1.00l Shaft, Encoder Ring, Retaining, Ext- .125sd- .120fd Ring, Retaining, Ext- .250sd- .211fd Bearing, Head, Roller Roller, Rubber Roller, Rubber .750x.2448x.25 Spring, Comp .30od .62l .022w Block, Upper Plate, Top Cap Yoke Pin, Dowel .0627od .44l Spring, Comp .088od ..38l .010w Block, Mount Head Iaj Encoder, Optical, 500cpr,1/4dia Assembly, M/S Head (IAJ Only) Mag Stripe Head Assembly, NTT Screw, Cap Soc 6-32x1.125 Washer, Lock, Hel Spring 6 Pin, Dowel .0938od .38lg Pin, Dowel .093od 1.0l Screw, Cap Soc 2-56x.250 Screw, Fh100 Phil 4-40x.375 Screw, Set, Cup 4-40x.12 Screw, Set, Cup 10-32x.19 Clamp, Cable Routing,Adhes,3/8 Screw, Cap Soc 8-32x.250 Washer, Lock, Ext Tooth 8 Tx, Jumper, Static Protection


Qty 1 1 1 2 1 1 2 1 1 1 1 1 1 1 2 6 2 2 1 1 1 2 2 1 1 2 2 4 2 2 1 1 0

Part Number 596432-001 800257-010 548380-001 803128-013 800257-020 555142-001 803113-043 803113-004 590128-004 590127-002 520529-008 803072-047 548376-001 548377-001 555145-001 800257-029 803072-098 548378-001 805386-001 555715-005 555715-004 800200-318 800175-003 800257-001 800257-035 800200-104 800072-206 804020-010 804020-025 806792-001 800200-404 800506-004 580197-901

8-15

Illustrated Magnetic Stripe

8-16

Illustrated Pa rts

Embosser/Indent Assemblies Embosser Assembly Pa rts (596664-002) Item 1 2 4 5 6 7 8 9 10 12 13 14 15 16 17

Item Description Guide, Card Screw, Cap Soc 8-32x.500 Washer, Wave, Gap, 2.425 Od Washer, Driver Spring Spring, Comp Driver Screw, Ca Spc .25-20 X 1.75 Washer, Lock, Hel. Spring, .25 Spacer, Washer, Uns .264x.406x.048 Arm Assembly, Rocker Shaft, Rocker Assembly, Lower Emboss Housing Assembly, Upper Emboss Housing Washer, Flat, Stl 8x.375 Washer, Lock, Hel Spring 8

Qty 1 1 1 1 1 1 3 3 3 1 1 1 1 1 1

Part Number 555996-001 800200-408 806521-001 596415-001 555610-001 596421-001 800200-628 800175-014 803112-057 596680-001 596416-001 596683-998 596684-002 800075-004 800175-004

Daisy Wheel Assembly, 7BSG, 52Char (596678-001) Item 1 2 3 4 5 6

Item Description Wheel, Daisy (Numbered) Gear, Wheel Home Detect Wheel Pin, Dowel .0783od .25l Set, Strip, P/D, Farr-Stdgot,52ch Standard, Wheel Config.

Qty 2 1 1 4 1 0

Part Number 596373-002 596711-001 596712-001 800257-048 596447-001 555970-001

Qty 2 1 1 4 1

Part Number 596373-002 596711-001 596712-001 800257-048 596447-001

Daisy Wheel Assembly, 7BSG, 50Char (596678-002) Item 1 2 3 4 5

Item Description Wheel, Daisy (Numbered) Gear, Wheel Home Detect Wheel Pin, Dowel .0783od .25l Set, Strip, P/D, Farr-Stdgot, 52ch


8-17

Emboss Module Wheel Assemblies

8-18

Description

Part Number

150i C . S. EMB-Standard

556787-001

150i C . S. EMB-J apan Fin 73 C har

556787-002

150i C . S. EMB-J apa nese HC 63 C har

556787-003

150i C . S. EMB-Swedish 60 C har

556787-004

150i C . S. EMB-Russian 73 C har

556787-005

150i C . S. EMB-J apa nese C redit

556787-006 (inactive)

150i C . S. EMB-Visa Elec 37 C har

556787-007

150i C . S. EMB-Std W/Ind OC R-A1

556787-008

150i C . S. EMB-Std W/Ind OC R-B1

556787-009

150i C . S. EMB STD, MC , A1 0-9

556787-010

150i C . S. EMB-Std W/MC 0-9r

556787-012

150i C . S. EMB-Std W/OC RB1 Fine

556787-013

150i C . S. EMB-Std W/Inv MC 0-9

556787-014

150i C . S. EMB-Visa Elec Fine 52

556787-015

150i C . S. EMB-Visa Elec 52 C har

556787-016

150i C . S. EMB-Korean 75 C har

556787-017

150i C . S. EMB-Czec h 75 C har

556787-018

150i C . S. EMB-J apa n C redit W/MPC

556787-019

150i C . S. EMB-J apa n C redit/ Rear J

556787-022

150i C . S. EMB-J apa n FIN W/Rear J

556787-024

150i C . S. EMB-J apa n FIN MPC W/Rear J

556787-025

150i C . S. EMB-J apa n HC W/Rear J

556787-026

150i C . S. EMB-J apa n HC MPC W/Rear J

556787-027

150i C . S. EMB-Poland Visa Elec

556787-028

150i C . S. EMB-Poland FIN IND B1 0-9

556787-029

150i C . S. EMB-J apan FIN Spec 58 C h

556787-030

150i C . S. EMB-STD, Helv, A1 0-9

556787-032

150i C . S. EMB-STD W/Helv 0-9

556787-033

150i Visa Elec t +MC , Indent

556787-034

Illustrated Pa rts

Illustrated Embosser Assembly


8-19

Upper Emboss Housing Assembly Parts (596684-002) Item 1 2 3 4 5 6 8 9

10 12 13

Item Description Housing, Upper Brg, Ball Mf .38id .88od .28w Pulley, Cam Ring, Retaining, Ext- .375sd- .338fd Dual Profile Cam Screw, Set, Cup 10-32x.38 Belt, Htd .118p 5.787l .354w Cam Motor Assembly (includes motor pulley) Nut, Hex Loc, Nyl Ins 8-32unc Photocell, 1 Ear Pt Screw, Hex Washer, Tf 4-40x.312

Qty 1 2 1 1 1 1 1 1

Part Number 555977-001 803128-020 555051-002 803113-025 547634-001 804020-027 805727-004 596682-999

1 2 2

803053-003 593463-003 805991-205

Illustrated Upper Emboss Housing Assembly

8-20

Illustrated Pa rts

Lower Emboss Housing Assembly Parts (596683-002) Item 1 2 3 4 5 6 8 9 10 12 13 14 15 16 18 19 20 21

Item Description Housing, Lower Brg, Ball Mf .38id .88od .28w Pulley, Cam Cam Ring, Retaining, Ext- .375sd- .338fd Screw, Set, Cup 10-32x.38 Belt, Htd .118p 5.787l .354w Motor Assembly, Cam Nut, Hex Loc, Nyl Ins 8-32unc Wheel Home Sensor Screw, Hex Washer, Tf 4-40x.312 Washer, Driver Spring Spring, Comp Driver Arm Assembly, Rocker Shaft, Rocker Motor Assembly, Wheel Screw, Hex Washer, Tf 4-40x.50


Qty 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2

Part Number 555978-001 803128-020 555051-002 555044-002 803113-025 804020-027 805727-004 596682-999 803053-003 593463-003 805991-205 596415-001 555610-001 596421-001 596680-001 596416-001 596681-999 805991-208

8-21

Illustrated Lower Emboss Housing Assembly

8-22

Illustrated Pa rts

Front Indent Assembly Parts (555110-001) Item 1 2 23 27

Item Description Assy, Hsg, Front, Front Indent Assy, Hsg, Rear, Front Indent Flange, Outer Screw. Hex Washer, Tf 4-40 X.375

Qty 1 1 1 2

Part Number 556240-001 556241-001 596789-001 805991-206

Front Indent Installation Kit Parts (555111-003) Item 1 2 4 5

Item Description Screw, Hex Washer, Tf 4-40x.312 Assembly, Indent Front Ribbon Assembly, Indent, Black Bracket, Mounting

Qty 8 1 1 1

Part Number 805991-205 555110-001 596805-001 596701-001

Illustrated Front Indent Assembly


8-23

Rear Indent Assembly (555121-999) Item 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18

Item Description Left Bracket

Pivot Arm Assembly FRU Screw, Hex Washer, Tf 4-40x.312 Screw, Fh100 Phil 4-40x.250 Wheel, Sensing Spacer, Washer, Uns .198x.250x.032 Photocell Roller Assembly FRU Bearing Plate Assembly FRU Bracket, Right Screw, Cap Button 6-32x.250 Supply Reel Assembly FRU Arm, Solenoid Photocell, 1 Ear Pt Spring, Ext .12od 1.13l .016w Roller, Guide, Ribbon Screw, Cap Soc 4-40x.750 Washer, Lock, Ext Tooth 4

Qty 1 1 6 1 1 1 1 1 1 4 1 1 1 1 2 2 2

Part Number 555176-001 555928-999 805991-205 800072-204 590331-001 803112-015 555924-999 555927-999 555175-001 803336-304 555930-999 555174-001 593463-003 803111-005 557006-001 800200-212 800506-002

Rear Indent Installation Kit Parts (555111-002) Item 6 7 9 10 11 12 13 14 15 16 17 29 32 38 51

8-24

Item Description Pulley Assembly, 90t Core, Ribbon Take-Up Hub Assembly Rear Indent Solenoid Assembly Flange, Outer Printer, Rear Indent, Assembly Label, Ribbon Wind, R Indent Screw, Hex Washer, Tf 8-32x.505 Mount, Solenoid Ribbon Assembly, Indent, Black Rear Indent Motor Assembly Rear Indent Drive Belt Screw, Set Loc, Cup 5-40 X .2 Screw, Torx, Ph, Tf 8-32 X .38 Spacer, Washer, Uns .315x.440x.070

Qty 1 1 1 1 1 1 1 2 1 1 1 1 1 2 1

Part Number 555929-999 557205-001 555931-999 555932-999 596789-001 555121-999 555974-001 805991-408 555161-001 596805-001 555122-999 803129-123 804020-036 805314-306 803112-033

Illustrated Pa rts

Illustrated Rear Indent Assembly


8-25

Topper Assembly C . S. Topper FRU Parts (556787-052) Item 1 2

Item Description Topper Assembly Shipping Crate for FRU

Qty 1 1

Part Number 596665-002 556793-001

Qty 1 1 1 4 2 2 1 2 1 1 1

Part Number 555094-001 555096-999 555095-001 806213-610 803072-106 803112-009 597970-001 806213-408 803287-003 804020-037 596675-001

Qty 1 2 1 3 5 1 1

Part Number 597994-001 596403-001 597997-001 596383-001 805314-106 598767-001 597981-001

Qty 1 1 1 4

Part Number 555090-001 555091-001 596393-001 806213-610

Topper Assembly Parts (596665-002) Item 2 3 4 5 6 7 8 9 10 12 13

Item Description Topper Heater Assembly Topper Motor Assembly Topper Solenoid Assembly Screw, Buttonhead Cap 1/4-20x.62 Spring, Comp .36od 0.75l .038w Spacer, Washer, Uns .260x.380x.040 Ring, Lift Screw, Buttonhead Cap 8-32x.5,Tx Conn, Hsg, F, Min, 3 Pos Screw, Set, Knurled 1/4-28x.375 Lower Topper Assembly

Top per Hea ter Assembly Parts (555094-001) Item 1 2 3 7 8 9 10

Item Description Plate, Heater Back-Up Shaft, Bearing Block, Pivot Clamp, Platen Screw, Torx, Ph,Tf 4-40 X .375 Platen Heater Assembly Flag, Photocell, Home

Lower Topper Assembly Parts (596675-001) Item 1 2 3 14

Item Description Topper Right Side Plate Assembly Topper Left Side Plate Assembly Block, Back-Up Screw, Buttonhead Cap 1/4-20x.62

Top per Left Side Plate Assembly Parts (555091-001) Item 1 2 3

8-26

Item Description Plate, Topper Left Side Screw, Ph, Tf, Torx 6-19 X.375 Block, Cassette Mounting

Qty 1 2 1

Part Number 596382-001 806575-406 597980-001

Illustrated Pa rts

Top per Right Side Plate Assembly Parts (555090-001) Item 1 2 3 4

Item Description Plate, Topper Right Side Screw, Ph, Tf, Torx 6-19 X.375 Block, Cassette Mounting Assembly, Foil Motion

Qty 1 2 1 1

Part Number 596382-002 806575-406 597980-001 555092-999

Top per C assette Assembly Parts (596666-002) Item 1 2 3 4 5 7 8 9 10

Item Description Left Cassette Plate Assembly Worm Gear Assembly Right Cassette Plate Assembly Take-up Ribbon Spindle Assembly Hex Flat Head 6-32 X .75 Spacer, Washer, Uns .382x.648x.010 Screw, Button Head Cap 10-32x.38 Rod, Foil Release Spindle, Foil Tube (green)

Qty 1 1 1 1 4 1 1 1 1

Part Number 555083-001 555084-001 555086-002 555087-001 803719-312 803112-048 806213-706 596406-001 597969-001

Foil Motion Assembly Parts (555092-001) Item 1 2 3 4 5 6 7 10 11 12 13 14

Item Description Motion Flag Pivot Arm Washer, Wave Spring, .194 Id Spindle, Flag Screw, Ph Phil 4-40x1.00 O-Ring, .484id .13w Buna-N Spindle, O-Ring Screw, Hex Washer, Tf 4-40x.312 Topper Platen Sensor Nut, Hex Mach, Stl 10-24unc Spring, Torsion Screw, Shoulder .250x1.00 10-24


Qty 1 1 1 1 1 1 1 1 1 1 1 1

Part Number 596398-001 556609-001 803451-001 596399-001 800073-216 803478-004 596400-001 805991-205 593463-003 800074-005 555703-001 803140-017

8-27

Topper Foil Parts Description

Part Number

Silver

597950-015

Gold

597950-003

Black

597950-002

White

597950-004

Dark Blue

597950-001

Proc ess (Light) Blue

597950-008

Red

597950-006

Silver (Taiwan Special)

597950-016

Illustrated Topper Assembly

8-28

Illustrated Pa rts

Main Control Board The Main Control Board Plate FRU is 555112-998.


8-29

Power Supply Power Supply Assembly Parts (555093-999) Item 1 2 3 4

Item Description 36V Power Supply Board Assembly Screw, Ph Phil 6-32x.250 Plate, Mounting, Power Supply Screw, Hex Washer, Tf 8-32x.375

Qty 1 3 1 2

Part Number 555033-001 800073-304 596753-001 805991-406

See Back Side Panel Assembly (555098-002) for Line Filter and Fuse part numbers.

Power Cords Item Description USA, 120V Australia, 10 amp Europe, 10 amp Denmark, 10 amp India, 10 amp Israel, 10 amp Italy, 10 amp Switzerland, 10 amp Japan, 7 amp United Kingdom, 10 amp Hospital, 10 amp China, 10 amp

8-30

Part Number 556766-001 556766-002 556766-003 556766-004 556766-005 556766-006 556766-007 556766-008 556766-009 556766-010 556766-011 556766-012

Illustrated Pa rts

Illustration of Power Supply


8-31

Fan The part number for the Fan is 594030-001.

8-32

Illustrated Pa rts

Sensor C able Harness The part number for the Sensor Cable Harness is 555962-001.


8-33

Power Cable Harness The part number for the Power Cable Harness is 555961-002.

8-34

Illustrated Pa rts

Communications Cable The part number for the Communications Cable is 555037-002. (The Null modem, 9pin to 9-pin communications cable is 806771-001.)

Smart Card Development Cable The Cable Assembly for 150i Smart Card Applications is part number 556226-001.


8-35

Display/Keyboard The part number for the Display Assembly is 596289-001 and for the Display Cable, 555039-001.

Miscellaneous Spare Parts Description

8-36

Part Number

Character Type Insertion Tool (MasterCard™ Only)

556335-001

Administrator’s Guide Kit

526701-001

CPX Protocol/Setup Manual Kit

526716-001

Software Developer’s Manual Kit

526709-001

Illustrated Pa rts

Solenoid Lock Assembly Solenoid Loc k Assembly Parts (555113-002) Item 1 2 3 4 5 6 8 9 10 11

Item Description Assembly, Bracket, Lock Mounting Screw, Ph Phil 4-40x.187 Solenoid, Frame, Pull, 12vdc Pin, Cotter .0620d 0.50l Link, Latch Assembly, Latch Lock Ring, Retaining, Ext- .250sd- .207fd Spring, Ext .188od 1.125l .014w Screw, Hex Washer, Tf 8-32x.375 Bracket, Switch, Interlock*

Qty 0 0 0 0 0 0 0 0 0 0

Part Number 555756-001 800073-203 806747-001 803196-102 596764-001 555754-001 803113-023 803111-088 805991-406 596755-001

* The front panel (556271-001) pushes down on the Interlock Switch.

Key Loc k Parts The part number for the Key Lock Assembly (With Key) is 807100-001. Description

Part Number

DC 1 Key Only

807100-201

DC 2 Key

807100-202

DC 3 Key

807100-203

DC 4 Key

807100-204

DC 5 Key

807100-205

DC 6 Key

807100-206

DC 7 Key

807100-207


8-37

Illustrated Solenoid Lock Assembly

8-38

Illustrated Pa rts

Reject Full Sensor The part number for the Reject Full Sensor is 593463-003.


8-39

Datacard I50i Card Personalization System Maintenance Manual

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