Mx 2000 Owners

Datacard® MX2000™ C ard Issua Issuanc nce e Syst ystem O w n e rs rs M a n u a l

Sep tember temb er 2011 2011

Part No. 539675-001, Rev J

Liability Statement Please do not attempt to operate o perate or repair this equipment without adequate training. Any use, operation, or repair in contravention of this document is at your own risk.

Pro Pro p rietar eta ry Noti No tic ce All drawings and information herein are the property of DataCard Corporation. C orporation. All unauthorized use and reproduction is prohibited.

Tr Tra demar de mark k Ac knowledgment nowledg ments s Datacard is a registered trademark and service mark of DataCard Corporation in the United States and other countries. MX2000 and CardGard are trademarks of DataCard Corporation. 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 Phone: 952-933-1223 Fax: 952-933-7971

www.datacard.com

© 2006-2010, 2011 DataCard Corporation. All rights reserved. Printed in the United States of America.

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Liability Statement Please do not attempt to operate o perate or repair this equipment without adequate training. Any use, operation, or repair in contravention of this document is at your own risk.

Pro Pro p rietar eta ry Noti No tic ce All drawings and information herein are the property of DataCard Corporation. C orporation. All unauthorized use and reproduction is prohibited.

Tr Tra demar de mark k Ac knowledgment nowledg ments s Datacard is a registered trademark and service mark of DataCard Corporation in the United States and other countries. MX2000 and CardGard are trademarks of DataCard Corporation. 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 Phone: 952-933-1223 Fax: 952-933-7971

www.datacard.com

© 2006-2010, 2011 DataCard Corporation. All rights reserved. Printed in the United States of America.

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C ontent ontents s Chapt Ch apter er 1: In Inttrodu oduc c tion ____ ________ _________ _________ ________ _________ _________ _________ _________ _______ ___

1-1

System Overview ________________ ________ _______________ ______________ ______________ ______________ ______________ _________ __ 1-2 Related Documents___________________________________________________ 1-4 Start arting ing and St Stoppin opping th the Sys Systtem ______ ___ _____ ____ _____ _____ ____ _____ _____ ____ _____ _____ ____ _____ _____ ____ __ 1-5 Pausing ing and Resu esumin ming the the Syst ystem _____ __ _____ ____ _____ _____ ____ _____ _____ ____ _____ _____ ____ _____ _____ ____ __ 1-6 Module Interlocks_____________________________________________________ 1-7 Remov emoviing AC Power ower_______ ______________ ______________ ______________ ______________ _______________ _______________ _______ 1-8 Interpreting Module Status Lights_______________________________________ 1-9 Comput Computer BIOSBatt attery _______ ___ _______ _______ _______ _______ ________ _______ _______ _______ _______ _______ _______ _____ _ 1-10 -10 Ordering Supplies____________________________________________________ 1-10 C ardGar ardGard d Modu Module Safet afety y Inf Informatio mation n ____ __ _____ _____ _____ _____ _____ ______ ______ ______ _____ _____ _____ __ 1-11 C ardGard ardG ard Supply Supply Fi Film Prec Prec autions autions ________________________________ 1-11 -11 Ultr Ultraviolet aviolet (UV) (UV) Light Warning Warning ______________ _______ ______________ ______________ ______________ _________ __ 1-12 1-12 Modul odule Warn arning Labels abels _______ ____ _______ _______ _______ _______ _______ _______ _______ _______ _______ _______ _______ ____ 1-13 -13

Chaptter 2: In Chap Ins stal alllat atiion ______ _ _________ ________ _________ _________ _________ _________ ________ _________ _______ __

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Specificat pecification ions s and Requir equirement ements ____ __ _____ ______ ______ _____ _____ _____ _____ _____ ____ _____ _____ ____ _____ ____ _ 2-2 2-2 Elec tri tric al Requirement equirements___________ s____________________________________________ _________________________________ 2-2 Power C onsumpt onsumptiion _______________________________ ___________________________________________ ____________ 2-2 Permi Permis ssible C urr urrent Load _______________________________ _______________________________________ ________ 2-2 Elec trost trostatic atic Disc Disc harge Sus Susc c epti ep tibil biliity_________________ ty__________ ______________ ___________ ____ 2-2 2-2 Phys Physic al Requirements equirements____________________________________ _____________________________________________ _________ 2-3 Dimens Dimensiions_________________________________ ons ____________________________________________________ ___________________ 2-3 Floor Spac e __________ _______________ __________ __________ ___________ ___________ __________ __________ __________ _____ 2-5 Envir nvironmental Requi eq uirrements_________________ ements_________ _______________ ______________ ______________ ________ _ 2-5 Storag torage e Envir nvironment___________________________________ onment___________________________________________ ________ 2-5 O perating perating Envi nvironment _______________________________________ ________________________________________ _ 2-5 Audible Audible Nois Noise __________ _______________ __________ ___________ ___________ ___________ ___________ __________ _______ __ 2-5 Unpacking npacking and Ins Installation allation of New Syst ystem ____ __ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ ___ _ 2-7 Adding a Module to an Existing System ________________________________ 2-7 Prepa Prepa ring the the System __________________________________ ______________________________________________ ____________ 2-7 Ins Inserti erting the the New Mo Module_________________________________ dule_________________________________________ ________ 2-11 -11 CardGard Module Adjustments_______________________________________ 2-14 UV Lamp Housin Housing g Gask G asket et and Latch Ad justment_________ tment___ _____________ __________ ___ 2-14 2-14 UV Hous Housin ing g Interloc Interlock k Acti Ac tivator vator Adju Ad jus stment___________________ tment____________ _____________ ______ 2-17 2-17 Remov emovin ing g Pan Panel els s and and Hood Hoods s _______ ___ ________ ________ ________ _______ _______ ________ _______ _______ _______ ____ _ 2-19 -19 C ontroll ontroller er Rear ea r Sec urit urity y Panel______ Pane l_____________ _______________ _______________ _______________ _________ _ 2-19 2-19 C ontroll ontroller er Front Panels Pane ls_______ ______________ ______________ ______________ _______________ _______________ ________ _ 2-21 2-21 C ontroll ontroller er Side Pa nel _________________________________________ _____________________________________________ ____ 2-22 -22 Hood Endca p C over __________ ________________ ___________ ___________ ____________ ___________ __________ _______ __ 2-23 -23 Module Mo dule Front Panel ________________________________ ______________________________________________ ______________ 2-24 -24 Module Mo dule Rea Rearr Panel and Hood Hoo d A ssembly___________________________ 2-24 -24 Disconnecting Cover Latches_________________________________________ 2-26 Expan xpans sion ion Kits ________ ____ ________ ________ _______ _______ _______ _______ ________ _______ _______ ________ ________ ________ ______ __ 2-27 -27

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Addit Ad ditiional C ool oo ling Fans __________________________________ __________________________________________ ________ 2-27 -27 Ad ditiona ditionall Ethernet thernet Switc witc hes__________ hes___ _______________ _______________ ______________ _____________ ______ 2-27 -27 Auxili Auxiliary ary AC Power Po wer Inlet_____________ Inlet____________________ ______________ ______________ ______________ _________ __ 2-27 2-27 Optional Kits_________________________________________________________ 2-27 Ins Installat allation ion Troubl oubles esh hootin ooting_ g___ ____ _____ _____ _____ ______ _____ ____ _____ _____ ____ _____ _____ _____ _____ ____ _____ ____ _ 2-29

Chapter Chapt er 3: Preven eventtiv ive e Main Maintten enance ance ___ ______ ______ ______ ______ ______ ______ ______ ______ ______ ___

3-1

Overview_____________________________________________________________ 3-2 C leaner leaners s, Tools ools, and Suppl upplies__ ies____ _____ _____ ____ _____ ______ _____ ____ _____ _____ ____ _____ _____ ____ _____ _____ ____ __ 3-2 Syst ystem Pr Prevent eventive ive Main Maintenance enance Tasks asks _____ ___ ____ _____ _____ ____ ____ _____ _____ ____ _____ _____ ____ _____ ___ 3-3 Module-S Module-Spec pecif ific Pr Preventive ive Maint Maintenanc enanc e Tasks asks ____ __ ____ ____ ____ ____ ____ ____ ____ ____ ____ ____ __ 3-4 C ard ard C leaning eaning Mod ule ule ___________ _________________ ___________ ___________ ___________ __________ __________ ______ _ 3-4 C ard ard Output Mo dule dule ___________ ________________ __________ ___________ ____________ ___________ __________ ________ ___ 3-4 C ardG ardG ard ard Topc oat Mo Modul dule_______ e____________ __________ __________ ___________ ___________ __________ _______ __ 3-4 Single-S ngle-Step tep C olor Pr Printi nting M odul od ule e __________________________________ 3-5 C ontroll ontroller er Mo Module dule _______________________________________ _________________________________________________ __________ 3-7 G raphi ap hic c s Pri Printi nting Modules Mo dules _________________________________ _________________________________________ ________ 3-7 Ma gnetic gnetic Str Striipe Enco Enco ding ding Modul Mod ule e ________________________________ 3-11 -11 Top Topper per Mo Module________________ dule___________________________________________________ ___________________________________ 3-13 -13 Smart mart C ard Mo Module dule __________________________________ ______________________________________________ ____________ 3-14 -14 Basi asic Top Topc c oat oa t Module____________________________________________ 3-15 -15

C hapt apter er 4: Loadi oadin ng Suppl pplies ies ___ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ____ _

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Introdu oducti ction ______________ _______ _______________ _______________ ______________ ______________ ______________ ______________ ________ _ 4-2 Card Card Cleani Cleaning Modu Module ______________ _______ _______________ _______________ ______________ ______________ ____________ _____ 4-2 Card Input Module____________________________________________________ 4-4 Car Ca rdGard dGard Topcoat Module___ odule______ _______ _______ _______ _______ _______ _______ _______ _______ _______ _______ ______ ___ 4-6 Replac ing C ardGa rd Supp Supplly Fi Film___________________________________ 4-6 Repa iring Br Broken CardG C ardGard ard Fi Film ___________________________________ 4-8 Embossing and Indent Module_________________________________________ 4-9 Label Aff Affixin ixing g Modu Module le _______ ___ ________ ________ ________ _______ _______ _______ _______ _______ _______ _______ _______ _____ _ 4-1 4-11 1 Graphics Printing Modules____________________________________________ 4-13 Toppi opping Module odule _______ ____ _______ _______ _______ _______ _______ _______ _______ ________ _______ _______ ________ ________ ______ __ 4-1 4-14 4 Basic asic Topcoat Mo Modu dule le _____ __ ______ _______ _______ _______ ________ _______ _______ _______ _______ ________ ________ ______ __ 4-16 4-16 Singl ingle-S e-Sttep Col C olor or Module odule _______ ____ ______ _______ _______ _______ _______ _______ ________ _______ _______ ________ _____ _ 4-17 -17

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Revision Log MX2000 Card Issuance System Owners Manual Revision

Date

A

April 2007

B

August 2007

C

Sep temb er 2007

D

August 2008

E

May 2009

F

February 2010

G

J une 2010

H

O c to ber 2010

J

September 2011

Description of Changes First release of this document Release of Multi-C ard Buffer module Relea se of Ba r C o de Sc anner mo dule Release of Basic Topc oat module Add card loading information to chapter 4. Fix information for new PC . Update for agency compliance and changes to PM. Up da te to mo ve insta lla tio n info rma tio n with unpa cking instructions. Update for release of Single-Step Co lor module.

Regulatory Compliance Notice for USA (FC C 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 C anada 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. The term “IC:” before the equipment certification number only signifies that the Industry Canada technical specifications were met. 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.

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Notice for Europe We hereby certify that this Datacard system complies with EMC Directive 89/ 336/EEC and R&TTE Directive 1999/5/EC. This system conforms to Class A of EN 55022 and to EN 301 489-5. 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 Taiwan/China

Notice for J apan This equipment is in the Class A category of information technology equipment based on the rules of the Voluntary Control Council for Interference by Information Technology Equipment (VCCI). When used in a residential area, radio interference may be caused. In this case, the user may be required to take appropriate corrective actions.

Safety All Datacard products are built to strict safety and reliability specifications in accordance with UL60950-1 and CUL requirements; 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 make sure of safe installation, operation, and maintenance of Datacard equipment and are not to be considered as comprehensive on matters of safety.

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Safe Environment •

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Connect equipment to a grounded facility power source. Do not defeat or bypass the ground lead. Place the equipment on a stable surface, and make sure that the floors in the 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. Do not use this product in an environment containing volatile or flammable compounds.

Safe Human Interface •

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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: Introduction This chapter provides general information related to the MX Series systems.

System Overview_____________________________________________________ 1-2 Related Documents __________________________________________________ 1-4 Starting and Stopping the System _____________________________________ 1-5 Pausing and Resuming the System ____________________________________ 1-6 Module Interlocks____________________________________________________ 1-7 Removing AC Power _________________________________________________ 1-8 Interpreting Module Status Lights______________________________________ 1-9 Computer BIOS Battery ______________________________________________ 1-10 Ordering Supplies___________________________________________________ 1-10 CardGard Module Safety Information ________________________________ 1-11 C ardGard Supply Film Prec autions ________________________________ 1-11 Ultraviolet (UV) Light Warning _____________________________________ 1-12 Module Warning Labels______________________________________________ 1-13

MX2000 Card Issuance System Owner’s Manual

1-1

System Overview The MX Series systems are modular card issuance systems with a series of modules that work together to complete the personalization of elements on a card. Each possible module in the MX2000 system is described in the following table.

Module

Description

Bar C ode Scanner/ Buffer

This optional module reads the bar code on a ca rd, sends the information to the C ontroller (for Rea d/ Loo kup function), and pa sses the c ard to the next module.

Card Cleaning

This module cleans the card in the system prior to printing graphics or color or before applying c oa tings. The module provides a dua l cleaning system that removes dirt and dust co ntaminants from the card.

Card Flipper

This module rotates cards around a vertical axis for back side persona lization in the downstrea m modules. An MX Series system is typica lly configured with a p air of Flipper mod ules. The first flipper rotates the card 180 degrees. After processing, the second flipper rotates the card back to its initial orientation.

C a rd Inp ut

This mo dule feed s c a rd s into the system. M ultip le C ard Inp ut modules can be installed in a system to allow multiple card stocks to be selec ted within a single c ard run or to increase the mac hine’s card supply cap ac ity for large jobs.

Card Output

This module has a tray to receive good cards and one for rejected cards.Multiple C ard Output modules may be installed within a system in order to expand o utput ca pa city or to allow c ards groupings to be separated for quality control, downstream proc essing/ handling, or varying delivery methods.

CardGard UV-Curable Topcoat

Single-Step C olor Printing

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This module covers the entire front surfac e of a card with a transpa rent, UV-cured, topcoat film. The topc oa t film is first laminated onto the c ard's surfac e a nd then c ured by UV light pulses. The C ardG ard module should be p laced in the system downstream of any printing modules and just upstream of the Embo ssing module(s). Systems that have a C ardGard module should also have an upstream Card C leaning module (even when there is no G rap hics module), so that the C ardG ard top coa t is plac ed o nto a clean card. This module prints full-color, high-resolution photos and images directly on the card. This module allows near-edge printing using dye diffusion, thermal transfer technology.

Introduction

Module

Description

Embossing/Indent

This module performs embossing on the front of a c ard. It can embo ss multiple fonts and a wide range of spec ial charac ters with the 112-charac ter emboss wheel. A mod ule with the indent op tion installed c an also perform indent printing on the front, ba ck, or both sides of the c ard. Up to two Embossing mod ules can be used in a single system. Position all Embo ssing modules upstrea m of any Top ping mod ules and downstream of a C ardGard module.

Graphics Printing

The Front or Back Graphics modules print monochrome custom grap hics on PVC cards using thermal transfer tec hnology.

Label Affixing

This module applies a removable preprinted or blank adhesive label to the front of a card. A set of C ard Rotation (Flipper) modules is required to apply a label to the bac k side of a c ard. The first Card Rotation module will rotate the card so the label is affixed to the back when it goes through the Label Affixing module. The other C ard Rotation mod ule will rotate the c ard b ac k to its original position. Blank lab els can be printed on a per-card ba sis. Position the Label Affixing module(s) direc tly upstrea m of the G raphic s Printing module when using Datac ard®UltraPrint™ labels. If app lying o nly preprinted lab els, Datac ard recommends po sitioning the Lab el Affixing mod ule direc tly upstrea m from the Output module.

Ma gnetic Stripe Encoding

This module provides high speed and reliable magnetic stripe encoding. The write/read head writes the magnetic data at specific track loc ations on the front or ba ck of the c ard; it then reverses and read s the information to verify it.

Smart C ard Personalization

This module provides flexible, high quality smart card persona lization of contact or contac tless cards. The modular architecture a llows for the growth of smart card c ap ac ity, as needed, to ac commoda te longer encoding times for contac t cards without limiting system throughput. The c ontactless stations persona lize c ards with speed, ac curac y and sec urity. The module can be configured with either up to six contac tless programming stations or up to 11 contac t stations to load any c ombination of applications onto c ards within the same job.

System Controller

The System Controller provides the controls for the MX Series system and is the primary interface point for the operator. It includes the hardware and software needed to c ontrol the activities performed by each module and to manage the system as a whole. Each system has a dongle plugged into the C ontroller co mputer. The dongle needs to be in plac e for the system to work.


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Module Basic Top coa t

Topping

Description This module ap plies a protec tive coa ting of clear or holograp hic coa ting to monochrome o r color-printed surfac es on a card. The topc oa t material is ap plied horizontally from ed ge to edge o n a card. Special rollers enable laminate patterns that protec t certain card fea tures such as a smart card c hip. This module applies a color foil to the tops of embossed c haracters on the c ard surfac e. The module has the cap ab ility of topping charac ters from the lower edge of the card up to the bo ttom of the magnetic stripe.

Related Documents The following documents provide information for the user of an MX2000 system. Description

Part No.

Available on CD

C IS Data Formatting Manual

539684-001

this library and 539341-001

C IS So ftwa re A dministra to r’s G uid e

539523-00x

539787-001

Unpacking and Installation Manual

539925-001

In paper with system and on this library

Illustrated Parts Manuals for Modules

many

this library

C ardGard Material Safety Data Sheet

---

this library

System Safety Rules

539576-001

this library

Preventive Maintenanc e Too ls and Supplies List

---

this library

Datacard C ertified Supplies

---

this library and newer ones on www.datacard.com

User Animations

---

this library

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Introduction

Starting and Stopping the System Once the system is plugged into AC power, turn on the Controller computer by pressing the power button on the front of the computer.

Turn off the Controller computer by using the standard shutdown command through the computer software as described in the CIS Administrator’s Guide. Turn the system hardware on or off by using the E-stop switch on the front of the Controller module. This switch controls all AC power to the modules, the cooling fans, and to all additional power cords that have been installed on the system. •

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Turn on the system by rotating the switch clockwise. The current state (ON or OFF) is visible in the dial cutout.

Turn off the hardware by turning the switch counterclockwise.


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Pausing and Resuming the System Pause a system to change supplies, perform preventive maintenance, or perform other activities. The system can be paused using the mouse, monitor, and software, or by pressing the Pause/Resume button located on the Card Output module. The Pause/Resume button is useful when the operator needs to stop the machine but is not near the Controller computer. The Pause/Resume button on the Output module shows the following machine states. Green flashing light—Machine is in the paused state. Green light on, but not flashing—Machine is in the normal running or idle state.

No light—Machine is temporarily between the pause and running states.

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Introduction

Module Interlocks Module interlocks are a safety feature that protects operators from injury. Lifting a hood causes the motors to be disabled and the interlock indicator light for the module(s) to go off. Interlock lights for the adjoining modules go off, but the adjoining modules finish processing cards, park them, and then sit idle with motors enabled. Most systems have connected hoods so that all or many modules lose power to the motors when hoods are opened. Wider modules have one interlock on the upstream side. The Output module has a special Pause/Resume switch and a special interlock that does not affect other modules if the Output module cover is opened.

Interlock Light

Top of Module Right Side


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Removing AC Power Any time service is being performed on the system—especially at the rear enclosure where high voltage power is present—AC power should be removed from the system. Turning off the E-Stop switch on the Controller module removes power from all modules and the system fans. It also removes power from modules that are supplied by additional power cord inlets. The Controller computer and the Ethernet switch box are disconnected from the AC main by first shutting down the Controller computer and then removing the power cord, or by switching off the customer-provided circuit breaker. Once the computer has been turned off, the power cord(s) can be unplugged. Procedure 1. Turn off the Controller computer using the standard shutdown instructions for the computer software. 2. Rotate the E-stop switch counterclockwise to OFF.

3. Unplug the power cord(s) from the AC power source.

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Introduction

Interpreting Module Status Lights Each module (except for the Card Input and Output modules) has a status light located on the front panel to alert the operator when the module needs attention. When the light is either flashing or solid on, refer to the error message on the Controller screen for more information.

Flashing—Module error or failure in normal operation; failure in module firmware download during boot. Not Flashing—Supplies are low or the module is in a paused state.

No Light—Module is running normally or power is off.

When a module error occurs, the other modules will process their current tasks until completed. At that point, the system enters a paused state (all module status lights are on, but not flashing).


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Computer BIOS Battery The motherboard in the Controller computer contains a battery backup for the system BIOS. If the battery is improperly connected, damage to the motherboard can result. Replace the battery with only the same or equivalent type recommended by the manufacturer. Dispose of used batteries according t o the manufacturer’s instructions.

Ordering Supplies Supplies for the modules are listed in the following locations. Refer to these resources for supplies ordering information. •

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Supplies ordering information file (pdf) on the Owners Library CD that ships with the system. Datacard Web Site (www.datacard.com) Datacard Home | Products & Solutions | Supplies

Introduction

CardGard Module Safety Information If your system includes a CardGard module, be aware of the following safety precautions when working with the CardGard supply film and around the ultraviolet (UV) light used in the module.

CardGard Supply Film Precautions The CardGard topcoat material is a clear, plastic, UV-curable film. The film is sensitive to heat and UV light. Excessive heat can cause a roll of film to telescope. To prevent this, place the supply weight on top of the supply roll. UV exposure can cause discoloration or opacity on the edges of the film. UV light can also dry the coating so that it does not stick as easily to cards, hampering machine performance. To protect the film from UV light, always store partial rolls of CardGard film in the original container. If the CardGard module will not be used for three or more days, remove the CardGard film from the module and store it in the original container. For instructions on removing and replacing the CardGard film, refer to page 4-6. Caution: Repeated contact of the skin to uncured CardGard coating material can cause minor skin irritation or sensitization (possibly leading to allergic reactions) in some individuals. Sensitive individuals should wear gloves when handling the uncured rolls of film. As a safeguard, wash your hands with soap and water after touching the uncured material. Caution: Do not touch eyes with gloves or hands that have been in contact with the uncured CardGard material. Accidental transfer of uncured CardGard particles (acrylate monomers) to the eyes can cause redness and tears. If you experience these symptoms, flush eyes with large quantities of water. Contact a physician if irritation persists.

For more material safety information, refer to the CardGard Material Safety Data Sheet on the Owner’s Library CD.


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Ultraviolet (UV) Light Warning Caution: Ultraviolet (UV) light is used in the CardGard module to cure the laminated film on the card’s surface. UV light can cause sunburns and damage to the retina of the eye; however, the CardGard module is designed to prevent leakage of UV light. Special gaskets, shutters, and materials shield the user from exposure to UV light. Interlocks are designed to break the electrical connection when the UV lamp housing assembly is opened. Caution: When working around the CardGard module, observe standard precautions. Do not attempt to defeat any of the safety mechanisms in the module. Although UV light leakage is unlikely, it is recommended that you wear UV eye protection that blocks UV radiation under 400nm as a precaution.

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Introduction

Module Warning Labels When working around the system, observe the following warning and caution labels affixed to various areas on the equipment. Warning Label

Description Heat Source Parts that contain this warning label can b ec ome very hot during operation. Wait until the part cools or wear protective gloves to prevent burns when making c ontac t. •

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High Voltage Power Supply This warning lab el is found on parts that contain a high voltage current. To avoid a possible elec tric shock, always remove power from the module (as well as turning off power to the C ontroller) before servicing. •

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Pinch-Point This warning lab el is found on moving parts that ca n potentially crush and cut. Do not op erate with the gua rd removed. •

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Introduction

Chapter 2: Installation This chapter provides information such as requirements, site preparation, and installation.

Specifications and Requirements _____________________________________ 2-2 Elec trical Requirements____________________________________________ 2-2 Power Consumption ___________________________________________ 2-2 Permissible Current Loa d _______________________________________ 2-2 Electrostatic Discharge Susceptibility ____________________________ 2-2 Physical Requirements_____________________________________________ 2-3 Dimensions ____________________________________________________ 2-3 Floor Spa ce ___________________________________________________ 2-5 Environmental Requirements_______________________________________ 2-5 Storage Environment___________________________________________ 2-5 Operating Environment ________________________________________ 2-5 Audible Noise__________________________________________________ 2-5 Unpacking and Installation of New System ____________________________ 2-7 Adding a Module to an Existing System________________________________ 2-7 Prepa ring the System ______________________________________________ 2-7 Inserting the New Mo dule _________________________________________ 2-11 CardGard Module Adjustments______________________________________ 2-14 UV Lamp Housing Gasket and Latch Ad justment ___________________ 2-14 UV Housing Interloc k Activator Adjustment_________________________ 2-17 Removing Panels and Hoods ________________________________________ 2-19 C ontroller Rear Sec urity Panel _____________________________________ 2-19 C ontroller Front Panels____________________________________________ 2-21 C ontroller Side Panel _____________________________________________ 2-22 Hood Endca p C over _____________________________________________ 2-23 Module Front Panel _______________________________________________ 2-24 Module Rear Panel and Hood Assembly ___________________________ 2-24 Disconnecting Cover Latches________________________________________ 2-26 Expansion Kits_______________________________________________________ 2-27 Additional C ooling Fans __________________________________________ 2-27 Ad ditional Ethernet Switches ______________________________________ 2-27 Auxiliary AC Power Inlet___________________________________________ 2-27 Optional Kits________________________________________________________ 2-27 Installation Troubleshooting __________________________________________ 2-29


2-1

Specifications and Requirements Prior to installing an MX Series system, make sure the site meets the requirements listed in the following sections.

Electrical Requirements The system requires single-phase, grounded, 180 to 264-volt, AC power source at 47 to 63 Hz. The Controller standard system power cord requires a dedicated power drop with a 15-amp circuit (U.S.) or 16-amp circuit (most other countries).

Power Consumption The power consumption of the system is the sum of the power consumption of the Controller and all of the modules in the system. To see the maximum current draw for each module, refer to the product’s data sheet on the Datacard Web Site (www.datacard.com) or in the Sales section on PartnerPage.

Permissible C urrent Load Because the system is modular, it is possible to exceed the permissible load on the main Controller power cord. If the calculated load on the Controller power cord or an auxiliary power cord exceeds 12.8 amps, additional power inlets and cord(s) must be added to the system.

Electrostatic Discharge Susceptibility A system can withstand an electrostatic discharge of 15 kV, 330 pF storage, and 1.5 k series resistance in tests simulating a human discharge to the outer surface of the machine. This does not include direct discharge on printed circuit boards.

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Installation

Physi Physic a l Re Re q uir uire ments The following section contains the physical site requirements needed for an MX Series Series system. system.

Dimensions The dimensions and footprint values for the overall system are the sum of those t hose for the Controller and individual modules. Dimensions of the Controller module are as follows: C o ntrollerntroller-Input Input Width

31.3 31.3 inches inch es (79.5 (79.5 cm) c m)

C o ntro ntro ller ller Wor Wo rk Surface Width

21.3 21.3 inches inch es (54.1 (54.1 cm) c m)

C o nt ntro llller Heig ht ht

37.1 inc he he s (94.2 c m) m)

C ontr ontroll oller Depth Depth

31.8 inches (80 (80.7 cm) deep

To to p o f c ab ab in inet

The dimensions of the standard MX Series module are as as follows: Modu Mo dulle Wi Width dth

10 inches ches (25.4 cm) cm)†

Modul Module Hei Heigh ghtt

50.1 inches ches (127.3 cm) cm)

Modu Mo dulle Dep Deptth

27 inches ches (68.6 cm) cm)‡

† The The C a rdGa rdG a rd module mo dule is 30 inches inche s (76.2 (76.2 c m) wide. wide . ‡ The The Input and a nd O utput modules mod ules a re 33.8 33.8 inches (85.9 cm) deep. The Topcoat module is double wide (20 inches).

The weight of the system should be taken into account before installing it in a particular location. To determine the system weight, calculate the sum of the weights for each module, the Controller, Cont roller, and any additional casters. The weight values are listed in the following table.

Module/ Module/ Item

Weight eight in Pounds/ Pounds/Ki Kilog logrrams (Including (Including Pa Panels and Ca C asters) ers)

Ba r C o d e Sc a nner

93/ 42.2

C a rd C lea ning

132/ 59.9

C a rd Flip p er

93/ 42.2

C a rd Inp ut (a d d itio na l)

100/ 45.4

M X2000 C a rd Issua nc e System O wner’s M a nua l

2-3

Module/ Module/ Item C a rd O utp ut

100/ 45.4

C a rd G a rd To p c o a t

320/ 145.2

Emb o ssing (Ind ent)

123/ 55.8 Plus 7 lbs/ lbs/3. 3.2 2 kg per p er Indent Inde nt mec hanis ha nism

G ra p hic s Printing

116/ 52.6

La b el A ffixing

100/ 45.4

M a g netic Strip e Enc o d ing

85/ 38.6

Smart Ca C a rd Perso Perso nali na liz za tion tion (Contac (C ontac t or Contac C ontac tles tless s)

111/ 111/ 50.3 Plus 1.5 lbs/0.6 lbs/ 0.68 8 kg kg p er prog p rogramming ramming station statio n

System C o ntro ller-Inp ut

300/ 136.1

Ba sic To p c o a t

197/ 89.4

Top Topping ping A d d itio na l C a sters

2-4

Weight eight in Pounds/ Pounds/Ki Kilog logrrams (Including (Including Pane Panels ls and Caster Casters) s)

101/ 45.8 11/ 5 (p er set)

Insta lla tio n

Floor Space The floor space required to install the system is dependent on the number and type of modules included. To determine how much floor space is required, calculate the following: 1. Controller-Input width 31.3 [number of CardGard modules x modules x 31.3 inches inch es (79.5 (79.5 cm) c m) + [number 30 inches (76.2 cm)] + [[number number of all other modules x modules x 10 inches (25.4 cm)] = Total width of system 2. Total width x 33.8-inch (85.9-cm) depth = Floor space used by system 3. Floor space used + 36-inch (45.72-cm) clearance on all sides for service access and airflow = Total floor space

The floor must be level and flat within ± 0.1 inch per foot (1 mm per 10 cm) in any direction.

Environmental Requirements The following tables contain environmental specifications for the system.

Storage torag e Enviro nviro nment Temperatu Temperaturre Relat elatiive Hu Humidit dity

-50 -50º F to 13 130º F (-46 (-46 to 54 54º C ) 0% to 10 100% (Nonon-Conde Conden nsing)

O p erating erating Envir nvironment onme nt Temperatu Temperaturre Relat elatiive Hu Humidit dity

65º F to 80 80º F (18 (18º C to 27 27º C ) 20% to 85 85% (Nonon-Conde Conden nsing)

A udible Nois No ise e The audible noise level of a system is dependent on the installed modules and card personalization data. The following configuration has been measured: Controller, Card Input, Magnetic Stripe, Smart Card, Cleaning, Graphics Printing, Card Output (at maximum speed). Front Bys Bystander Posi Position tion

70.5 dBA dBA to 73 73 dBA dBA

Front Operator Operator Posi Position

72.5 dBA dBA to 74 74.5 dBA dBA

M X2000 C a rd Issua nc e System O wner’s M a nua l

2-5

Measurements are sound pressure measurements with a handheld sound meter at the front bystander bys tander (1.0 meter from machine, 1.5 meters high) or operator (0.25 meter from machine, 1.5 meters high) positions per ANSI S12.10-1985, section 11. All measurements are averages over 60 seconds (60 L equiv.).

2-6

Insta lla tio n

Unpacking and Installation of New System Refer to the unpacking and installation instructions provided in the pocket on the crate. An electronic copy of the instructions is provided on this Owners Library CD.

Adding a Module to an Existing System Perform the following procedure to add a module to an MX Series system. The following diagram shows one possible scenario. When the system is split into two halves, it will be necessary to support both sides of the split. Larger systems have multiple caster sets in the middle of the system that can be relocated to the split. However, for smaller systems, it will be necessary to acquire an additional pair of casters (Part No. 562879-002).

Preparing the System Caution: The system must be powered off and unplugged before beginning this procedure.

You will need four jacks or an extra pair (two sets) of casters for module support during this procedure. 1. Shut down the Controller and unplug the system. Make sure that all power cords on multiple corded systems are unplugged. 2. Locate the point where the new module will be inserted.


2-7

3. Prevent the system from moving by setting the brakes for all casters on the system, based on the type of caster.

Older casters: Turn the dial inside the caster counterclockwise to engage the brakes by lowering the foot.

Newer casters: Press down the ON side to lock the brakes.

4. Disconnect the hoods between the modules to be split by loosening the screws and sliding the bracket away from the other module. Refer to “Disconnecting Cover Latches”on page 2-26 for detailed instructions. 5. Remove the front panels and rear panel/hood assemblies from the two

modules being separated. Refer to the instructions beginning on page 2-19. 6. Install a caster set (or jack) under both the upstream and downstream modules of the split. Except for the Controller and Output module casters, casters may be relocated from other parts of the system for this operation. A. Slide the caster channel (caster assembly) under the module. B. Secure the front and rear of the caster channel to the module frame with two screws on each end.

2-8

Installation

7. Disconnect the AC power cables from the modules being separated. 8. Disconnect all of the downstream module Ethernet cables and lay them to the side for easy reconnection later. Do not remove the cables; just disconnect the downstream end. 9. Remove the two screws that secure the upstream module’s platform to the downstream pier bracket. Save the screws for reuse later in this procedure.

10. Remove the six bolts that secure the two modules together. Save the bolts for reuse later in this procedure.


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11. On both the new module and the last upstream module in the system, loosen the two module platform mounting screws from the upstream side of the module platform (for CardGard, see the note below). This allows the downstream side of the module platform to rise up on the spring-loaded shipping posts.

To secure a CardGard module, make sure that the UV housing assembly is unlatched to release any pressure from around the gasket on the cure assembly. Then loosen the screws (3 and 4 shown in a previous figure) on the mid-module mounting bracket (on the entry side of the cure assembly) instead of on the upstream end as for other modules. 12. Release the caster brakes on the downstream section, and move the downstream section of the system away from the fixed upstream section.

Older casters: Turn the dial inside the caster clockwise to unlock the brakes by raising the foot.

2-10

Newer casters: Press down the OFF side to unlock the brakes.

Installation

Inserting the New Module 1. Secure the new module to the upstream half of the system: A. Insert the two alignment guides (1) of the new module into the alignment openings (2) in the upstream module.

B. Use the two shipping screws (3 in the figure below) to attach the upstream module’s platform to the pier bracket of the downstream module.


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C. Install the six frame bolts (4) that secure the two frames together. 2. Repeat step 1 to secure the downstream half of the system to the new module. 3. Tighten the two module platform mounting screws on the upstream side of the platform (for CardGard, see the note below).

Do not place any screws in the original shipping screw locations (over the mounting posts). This could warp the module platform plate. For a CardGard module, tighten the screws on the module in the following sequence to secure it in place. It is important to use this sequence for correct card track alignment. a. Front platform mounting screw (left side) b. Front mid-module mounting screw (right side of cure assembly) c. Rear platform mounting screw (left side) d. Rear mid-module mounting screw (right side of cure) 4. Remove any jacks. If casters were used, leave them in place. 5. Reconnect the AC power cables on all of the module control boards. (Refer to the figure in the Unpacking/Installation Instructions manual included on the Owners Library CD for details.) A. Connect the AC power cable from the upstream system module to the new module. B. Connect the AC power cable from (Down) on the new module to (Up) on the downstream system module. 6. Compare the length of the new module Ethernet cable with the existing cables and route a new cable of the correct length from the Controller to the module.Reconnect all of the Ethernet cables to the modules, beginning with the shortest cable connected to the new module.

7. Verify that all module platform and module frame bolts are fully tightened.

2-12

Installation

8. Replace the panel and hood assemblies and the front panels. Refer to page 2-19 for instructions. Reconnect the panel hoods and reattach with the bracket screws. 9. Reconnect power to the Controller and power on the system. The Controller should automatically identify the new module. 10. For safety reasons, make sure the interlock switch is working correctly by using Diagnostics. Select Applications | Utilities | Diagnostics and click the Sensors tab.

If the addition of the module requires that an auxiliary power kit be installed on the system, the kit must be installed after the module. Refer to the power kit specification or “Auxiliary AC Power Inlet”on page 2-27 for more information. If your system includes a CardGard module, it is recommended that you adjust the module after installation is complete. Refer to “CardGard Module Adjustments”on page 2-14 for instructions.


2-13

CardGard Module Adjustments If you installed a CardGard module as part of your system, perform the following adjustments after installation is complete.

UV Lamp Housing Gasket and Latch Adjustment The UV lamp housing assembly gasket prevents UV light from leaking out of the cure chamber. The latch holds the UV lamp housing assembly tightly to the cure chamber to prevent light leakage. This adjustment sets the compression of the gasket between the cure chamber and the UV lamp housing assembly and adjusts the tightness of the latch. Adjustment Procedure 1. With the system up and running and the module in Service mode, lift the hood of the module. Caution: Directly viewing UV light for extended periods can result in permanent damage to the retinas. Do not proceed with the next step until the high voltage indicator light on the UV lamp housing assembly is off. 2. After the high voltage indicator light (1 in the following figure) on the UV housing assembly is off, release the latch (2) that secures the UV housing (3) to the cure assembly. Pull the assembly back to open it.

If the left front panel of the module is in the way of completely opening the UV housing assembly, you may need to remove it. For more information, refer to the “Module Front Panel”on page 2-24. 3. Loosen (but do not remove) the screws (4) that secure the rear duct (5) to the module base. 4. Set the UV lamp housing assembly gasket compression: A. Loosen (but do not remove) the three screws (6) on the bottom of the UV housing duct. There is one screw on each side and one in the center front. B. Position each of the three screws in the center of each bracket’s slotted opening, and then partially tighten the screws to hold them in place.

2-14

Installation

C. Push the UV housing assembly against the cure chamber and check to see that there is even compression of the housing gasket (7 in the figure below) against the face of the cure chamber (8) and of the UV assembly against the rear duct (9) when compressing (25% to 75% of full compression). D. Loosen and re-tighten the UV housing screws (6) as needed to adjust the gasket compression and angle.


2-15

5. Adjust the tightness of the UV housing latch: A. Release the latch (2 in the previous figure) that secures the UV housing assembly (3) to the cure assembly, and pull the assembly back to open it. B. Loosen (but do not remove) the two screws that secure the latch (2) to the

side of the cure assembly (3). Caution: Make sure you do NOT remove the screws. They are attached to a small plate inside the assembly. It would require considerable time to repair the assembly if the screws were removed. C. Move the latch forward or backward in the slotted openings to adjust. Partially tighten the screws to hold the latch in place. D. Close the UV assembly and secure the latch. E. Verify that the gasket (7) is compressed (25% to 75% of full compression) on all sides of the face of the cure assembly (8). F. Adjust the latch screws as needed to correct the tightness of the seal, and tighten the screws. 6. Adjust the tightness of the rear duct gasket compression: A. Close the UV assembly (3) and secure the latch (2). B. Align the rear duct (5) with the UV housing assembly, push the rear duct against the UV housing, and partially tighten the screws (4) to hold it in place. C. Check the gasket compression; you want a 1 to 2-card thickness of compression against the housing (0.030 to 0.100 inch or 0.076 to 0.253 cm). D. Once the compression is correct, tighten the screws (4) on the base of the rear duct. E. Unlatch the UV housing and re-latch it to ensure the gasket (9) compression is even and at the thickness described above. 7. Replace the panels and close the hood. 8. Run some test cards. Watch the first cards being processed by the module to be sure no (or minimal) light escapes at the gasket area. 9. If there is still excessive leakage, repeat this procedure until leakage is minimized.

2-16

Installation

UV Housing Interlock Ac tivator Adjustment In the UV lamp housing assembly, the UV housing closed interlock switch detects that the UV housing is in an operational position to prevent exposure to ultraviolet (UV) light. This interlock switch needs to be closed to enable high voltage power to be distributed to the housing for curing. This adjustment controls the pivot throw of the interlock activator to ensure the switch is closed when the UV lamp housing is latched closed. Adjustment Procedure 1. With the system up and running and the module in Service mode, lift the hood of the module. 2. Access the Diagnostics program by selecting Applications | Utilities | Diagnostics. 3. Select the CardGard Module and then display the Sensors tab. The UV housing closed interlock switch is listed on the screen (“High Voltage Interlock”). 4. Make sure that the UV housing is closed and latched (1 in the following figure). 5. Loosen the two locking nuts (2) on either side of the interlock switch (3) on the cure bracket (4). 6. On the cure assembly base, manually adjust the bracket (4) position (forward and back) until there is a transition on the computer screen of the interlock switch changing states from Open to Closed. 7. Tighten the locking nuts (2). There can be a 0.020 to 0.030-inch (0.051 to 0.076cm) overtravel when adjusting the locking nuts.


2-17

T

2-18

Installation

Removing Panels and Hoods Panels are the outside covers for all of the modules in the MX Series system. Hoods are the see-through covers that protect the operator from the modules’ moving parts. All modules have hoods except for Card Input, Card Output, and the Controller. Each module has an independent interlock switch and only one hood interlock. For safety reasons, a module that is more than one module frame wide must have each of its hoods connected together or the interlock on that module will not be functional on all the hoods. Use the procedures in this section to remove the module panels and hoods.

C ontroller Rear Security Panel A security panel covers the back of the Controller computer to prevent tampering or unauthorized connections to the Controller computer. Removal Procedure

Be careful when removing and installing the security panel because the computer’s cables pass through the opening in the panel and can be pulled out of the computer or damaged. 1. Remove the screws from the Controller’s two rear security panels (1 and 2 in the following figure). Remove the screws from the Controller’s rear security panel, and lean the panel against the back of the Controller. 2. As necessary, add or remove any cable connections to the Controller computer.

Make sure that the security dongle is plugged back into the same USB port on the back of the computer. The system will not operate without the security dongle. The dongle is attached to the Controller frame with a steel cable to prevent accidental loss.


2-19

2-20

Installation

C ontroller Front Panels The front panels of the Controller module are different from the front panels of other modules. Use the following procedure for removing either of the Controller’s two front panels. Removal Procedure 1. Loosen, but do not remove, the three screws (1) across the top of the panel (2 or 3). 2. Pull outward on the bottom corners of the panel to release the two latches on the inside of the panel. 3. Pull the unlatched panel down and away from the module.


2-21

C ontroller Side Panel The Controller module has a side panel with a cutout for a fan filter. Use this procedure to remove the Controller side panel. Removal Procedure 1. Loosen the three screws (1) on the front and the three screws (2) on the back of the side panel. 2. Remove the panel (3) from the side of the Controller module. Replacement Note

Inspect and clean the filter (4) before replacing the panel.

2-22

Installation

Hood Endc ap C over A hood endcap cover is installed on two modules: •

The module immediately downstream of the last Input module in the system.

•

The module immediately upstream of the first Output module in the system.

Removal Procedure 1. Remove the three screws (1) that attach the endcap cover (2) to the hood assembly (3). 2. Carefully remove the endcap cover by pulling it down and away from the hood, making sure to detach the clip (4) from the hood assembly.


2-23

Module Front Panel Use this procedure to remove the front panel of any module, other than the Controller. This procedure can also be used to remove the rear panel of the Card Input or Card Output module, and the side panel of the Card Output module. Warning: Removing the front panel from a module exposes high voltage electrical components. Do not remove any panels when the system is plugged into facility power. Removal Procedure

This procedure refers to the figure on the following page. 1. Raise the module’s hood (1). 2. Loosen, but do not remove, the single retaining screw (6) at the bottom center of the front panel. It is in a slotted opening. 3. Lift the front panel (7) up and forward until the two screws on the frame clear the keyhole openings (8) in the panel.

Module Rea r Panel and Hood A ssembly Each module’s rear panel is attached to a hood assembly. The hoods are usually interlocked so they can be opened as a unit. Use this procedure to remove the rear panel and hood assembly of any module. Removal Procedure

This procedure refers to the figure on the following page. 1. Raise the module’s hood (1). 2. Disconnect the latching bar (3) from adjacent hoods by removing the two screws from the bar. Refer to “Disconnecting Cover Latches”on page 2-26 for further instructions. 3. Loosen, but do not remove, the two retaining screws (4) at the bottom of the rear panel. These screws are in a slotted opening. 4. While standing behind the system, grasp the open hood on both sides just above the hinges, and then lift up slightly and pull back to remove the hood (1) and rear panel (5) assembly from the module. 5. Lay the hood assembly on its side on a piece of cardboard to prevent scratching the clear plastic.

2-24

Installation


2-25

Disconnecting Cover Latches When you are adding modules to, moving them within, or removing them from a system, disconnect and reconnect the latches between covers as needed. 1. Remove the two screws from the side of the latch (2) where the module is to be disconnected. 2. Reattach the two screws when adjoining modules are again in position. 3. If the covers will not be reattached, fix them so the latch does not protrude when covers are lifted. A. Remove the other two screws. B. Rotate the latch. C. Reaffix with the two screws.

Wider modules with more than one frame must have the cover latches connected or the module interlock will not function.

2-26

Installation

Expansion Kits The following kits may be needed on large systems. These kits are automatically included in the order if your configuration requires additional cooling fans or power inlets.

Additional Cooling Fans Larger MX Series systems may require that an additional cooling fan be inserted into a Card Output module. The cooling fan is available as an installation kit. Refer to the Card Output Module Illustrated Parts Manual for the part number of this kit. The kit is installed before shipping on new systems, supplied with expansion systems as needed, or it can be ordered for a system. Refer to the kit for installation instructions.

Additional Ethernet Switc hes Systems with more than 24 modules or with more than two cameras need another Ethernet switch installed into the Controller. The switch is installed on any new systems that require one. If additional modules/cameras make one necessary in a field system, the field kit is shipped with the modules.

Auxiliary AC Power Inlet There will be times when a large system needs an auxiliary AC power inlet. Refer to the System and Controller Module Illustrated Parts Manual for the part number of this kit. Refer to the kit for installation instructions and guidelines on determining when a system needs an additional inlet. Kits are sent with expansion systems that exceed the power limit. Each power inlet and power cord requires a dedicated power drop with a 15amp breaker (U.S.) or 16-amp breaker (non-U.S.).

Optional Kits For some modules, an optional kit can be ordered and installed to add more functionality to the module. Part numbers for these kits are provided in the module’s Illustrated Parts Manual. Refer to the kit for installation instructions. •

Magnetic Stripe Encoding Module—Magnetic Head Lift Kit When you are running a job that does not require magnetic encoding, the write/read head of the Magnetic Stripe Encoding module can be retracted by the head lift kit so it is not subjected to unnecessary wear.


2-27

•

Embossing Module—Indent Printing Mechanism With the Indent mechanism, the Embossing module has the option to print indent characters on the front, back, or both surfaces of cards.

•

Basic Topcoat Module—Holographic Topcoat Registration Kit This addition to the Basic Topcoat module enables a site to place a holograph in a precise position on a card.

•

Topping Module—Foil Slitter Assembly The foil slitter assembly is an optional feature with the Topping module. It mounts on the module base and splits the foil ribbon approximately down the center along its length. This provides a higher level of security when disposing of used topping foil because the split halves of foil can be discarded in separate locations.

•

Input and Output Modules—Locking Kit Both Input and Output modules can be installed with locking covers so that only authorized personnel can insert or remove cards.

•

Input Module Thin Card Kit To personalize cards thinner than the standard 30-mil cards on the MX2000 Card Issuance system, an upgrade kit must be installed on the Input module so that only one card is picked at a time. The kit enables the Input module to process 24-mil or 18-mil cards. Thin card stocks must also be defined in Stock Management and selected in the Card Setup. If the system might resume using 30-mil cards in the future, keep the standard upper pick guide to replace the one in the kit.

2-28

Installation

Installation Troubleshooting Before the system left the factory, it was fully tested for proper operation. If the system fails to start properly after installation, use the following guidelines to isolate the most likely cause. Some of these troubleshooting scenarios may require a trained technician to isolate and correct the problem. Controller Problems

If the Controller computer cannot be turned on: •

•

•

Verify that the main power cord is connected to the system and the facility outlet. Verify that the facility power is available and is of the correct voltage for the system. The system requires single-phase, grounded, 180-264-volt, AC power at 47 to 63 Hz. Make sure the power cord on the back of the Controller computer is properly connected.

If the Controller computer starts but does not properly boot up, follow the diagnostic procedures for Microsoft® Windows®. Module Boot Problems

If none of the modules boot up: •

•

•

Verify that the red module power switch on the front of the Controller is on. Verify that the power cable between the Controller and the first module (Input module) is connected. Verify that the Ethernet connection between the Controller computer and the Ethernet switch is correct. Also verify that the Ethernet switch has power.

If all modules boot up except for one, the most likely cause is a bad Ethernet connection. If all modules downstream from a module fail to boot up, the most likely cause is a disconnected power jumper between modules, or there may be an auxiliary power cord on that module that is not plugged in to facility power.


2-29

2-30

Installation

Chapter 3: Preventive Maintenance This chapter provides routine preventive maintenance schedules and procedures for periodic cleaning and inspection of the system.

Overview____________________________________________________________ 3-2 Cleaners, Tools, and Supplies _________________________________________ 3-2 System Preventive Maintenance Tasks ________________________________ 3-3 Module-Specific Preventive Maintenance Tasks _______________________ 3-4 C ard C leaning Mod ule ____________________________________________ 3-4 C ard Output Mo dule ______________________________________________ 3-4 C ardG ard Topc oat Mod ule ________________________________________ 3-4 Single-Step C olor Printing M odule __________________________________ 3-5 C ontroller Module _________________________________________________ 3-7 Grap hics Printing Modules _________________________________________ 3-7 Ma gnetic Stripe Encoding Module ________________________________ 3-11 Topper Module___________________________________________________ 3-13 Smart C ard M odule_______________________________________________ 3-14 Basic Topcoat Module ____________________________________________ 3-15


3-1

Overview MX Series systems require routine preventive maintenance to optimize performance and minimize downtime. Preventive maintenance procedures should be performed either at specified time intervals or machine-cycle intervals, depending on the module in question. In addition, preventive maintenance should be performed after any of the following activities: •

Replacing any module, assembly, sub-assembly or adjustable part

•

Performing any unscheduled maintenance

Some activities require that system power be off. Refer to the information on the following pages for performing preventive maintenance activities.

Cleaners, Tools, and Supplies The cleaners, tools, and supplies required to maintain the MX Series system are listed in the special Preventive Maintenance Tools and Supplies document on this CD.

3-2

Preventive Maintenance

System Preventive Maintenance Tasks Site personnel need to perform the following preventive maintenance procedures on all modules in the system. Procedure

Frequency

C lean all card tracks

Onc e per week or 50,000 ca rds

Comments •

•

•

Clean reflective optical sensors

Check for debris in both upper and lower card guides. Vacuum the area to remove dust and debris as nec essary. Wipe the c ard trac k with a clean cloth dampe ned with isopropyl alcohol.


Wipe the sensors with a soft, dry cloth. This includes all card entry and exit sensors. This excludes all tabbed belt sensors and fiber optic sensors.

C lean c ard trac k sensors


Vacuum clean card sensors (in card trac k only), or wipe with soft brush or cotton swab.

C lea n transport rollers


Wipe the roller surfaces with a soft cloth dampened with isoprop yl alcohol.

Vac uum the upper half of the system


Vacuum dust and debris from the module platform area (above the frame only).

• •

Do not vacuum nea r circuit boards or other electronic devices. Clean Controller air filter

Onc e every two weeks

Remove the filter (it is not necessary to remove the side pa nel) and vacuum it at least once every two weeks.


3-3

Module-Specific Preventive Maintenance Tasks Some modules have no specific operator maintenance tasks; others have preventive maintenance tasks that should be performed by the operator. This section describes those tasks.

C ard C leaning Module Procedure C lean a ll soft rollers

Frequency

Comments

Once p er day

•

•

C lean the tape drive rollers

As needed

•

•

Remove the c leaning rollers and wipe with a soapy wa ter solution. Note: Air dry the rollers after cleaning. Blowdrying c an da mage the rollers. The roller surfac e must remain intac t; if it bec omes damaged, the c ustomer engineer must replac e the roller. Inspect the drive rollers for accumulation of adhesive. If needed, clean the shafts with isopropyl alcohol.

C ard Output Module If the system has an extra cooling kit installed on the Card Output module, vacuum its air filter at least once every two weeks.

C ardG ard Topcoat Module Procedure

Frequency

Comments

Inspec t and c lean the c ard trac k and moving mechanism surfaces

Da ily

Insp ec t the c ard tra c k a nd a ll mo ving mec ha nism surfaces. C lean off any card residue to avoid issues with downstream modules.

C lean the film guide pins

Weekly, or as needed

When the film guides have material sticking to them, clean them with isoprop yl alcohol. Note: Never use sandpaper or other abrasive materials that could scratch the surfac e of the guides.

C lean the grit rollers

Daily

Inspect the grit-coated rollers in the interstage and cure assemblies. Clea n off any card residue from the rollers with the wire bristle tool (or stiff bristle toothbrush). Vacuum away any deb ris or dust.

3-4


Single-Step C olor Printing Module The preventive maintenance procedures done by the operator are described in the following sections. Remove the ribbon supply from the Supply and Take-Up assemblies before cleaning the module. Start of Shift 1. Remove the print ribbon from the module. 2. Vacuum the card track sensors or wipe them with a soft brush or cotton swab. See the locations of the track sensors in the following figure. Vacuum or wipe the sensors even if the module is operating in pass-through mode.

3. Clean debris from all rollers using a damp cloth. 4. Clean any debris from all upper and lower card tracks. 5. Use isopropyl alcohol to clean the guide pins that route the ribbon. 6. Rethread the print ribbon.


3-5

Weekly 1. Clean the transport rollers weekly or after producing 50,000 cards. Wipe the roller surfaces with a soft cloth dampened with isopropyl alcohol. 2. Clean the print and capstan rollers with a cloth dampened with alcohol. 3. Vacuum the area to remove dust and debris as necessary. 4. Wipe the upper and lower card tracks, especially near the exit and entrance, with a clean cloth dampened with isopropyl alcohol. Only As Needed

The print line or the printhead dot row on the printhead is indicated on the following figure. It needs to be cleaned with lapping paper (Part No. 803359-003) as print quality declines. The dot row also needs to be cleaned with swabs dipped in alcohol to remove residue as part of routine maintenance. Do not use lapping paper more frequently than once every 5,000 cards. The residue is easily removed with a few strokes, applying very light pressure. If print quality declines, perform the following procedure: 1. Power off the system. 2. Open the cover of the module to access the printhead. 3. Put on the special gloves that are shipped with the printhead kit. (The gloves can be ordered as 810750-001 for a pair or 810750-002 for 50 pair). Caution: Never touch the ceramic printhead surfaces or pins with your fingers. Follow proper procedures to avoid electrostatic discharge. 4. Hold the supplied, colored lapping paper with the shiny side toward your hand. Slide the lapping paper up and down the printhead dot row (see the following figure) five to ten times, applying light pressure. 5. Moisten a swab in 90% (or greater) alcohol and remove any residue from the use of the lapping papers. 6. Power on the machine and print a test card. Print quality should have improved significantly. If poor printing continues, replace the printhead.

3-6


Controller Module Procedure C lean the exterior components

Frequency As needed

Comments

1. Shut down the C ontroller and turn off the p owe r. 2. C lean the monitor with a soft cloth dampened with

3. 4. 5. 6.

water. Immediately wipe the monitor dry with a clean cloth. Vacuum the keyboard. If necessary, wipe the keys with a cloth dampened with water. Remove the trac k ball from the mouse a nd wipe it with a lint-free tissue. Wipe the c abinet down with a c lean cloth da mpened in a mild detergent. Remove the filter from the side of the C ontroller (it is not nec essary to remove the side panel) and vac uum it at least onc e every two weeks.

Graphic s Printing Modules Start of Shift 1. Remove the print ribbon from the module. 2. Vacuum clean the card track sensors or wipe them with a soft brush or cotton swab. See the locations of the track sensors in the following figure. Vacuum or wipe the sensors even if the module is operating in pass-through mode.


3-7

3. Clean debris from all rollers using a damp cloth. 4. Clean any debris from all upper and lower card tracks.

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5. Use isopropyl alcohol to clean the guide pins that route the ribbon. 6. Rethread the ribbon using the path in the following figure (Back Graphics module depicted).

Weekly 1. Clean the transport rollers weekly or after producing 50,000 cards. Wipe the roller surfaces with a soft cloth dampened with isopropyl alcohol. 2. Clean the print and capstan rollers with a cloth dampened with alcohol. 3. Vacuum the area to remove dust and debris as necessary. 4. Wipe the upper and lower card tracks, especially near the exit and entrance, with a clean cloth dampened with isopropyl alcohol. Only As Needed

If print quality deteriorates, clean the printhead dot row as described below. Caution: Never touch the ceramic surfaces, printhead face, or pins with your fingers. ESD

The thermal printhead assembly is a static sensitive device. Electrostatic discharge precautions must be followed when handling, installing, or servicing the printhead to prevent damage. If you do not have an ESD kit, always touch the frame of the system before touching a printhead. Always wear special ESD-sensitive gloves when handling the printhead.

1. Power off the system and open the cover. 2. Release the printhead.


3-9

3. Hold the very fine lapping paper (supplied with the printhead) with the shiny side toward your hand and lightly slide the paper up and down the dot row five to ten times. You can also use a cotton swab dipped in alcohol to clean the dot row. The dot row is visible at the left side of the print head. It is the shiny line above the green area.

4. Power on the system and print a test pattern. If print quality is still poor, replace the printhead using instructions supplied with the replacement part.

3-10


Magnetic Stripe Encoding Module Start of Shift 1. Vacuum clean the card track sensors or wipe them with a soft brush or cotton swab. See the locations of the track sensors in the following figure. Vacuum the sensors even if the module is operating in pass-through mode.

2. Clean debris from all rollers using a damp cloth. 3. Clean any debris from all upper and lower card tracks. 4. Check the first card produced using an analyzer to detect proper placement of data. Weekly 1. Clean the transport rollers weekly or after producing 50,000 cards. Wipe the roller surfaces with a soft cloth dampened with isopropyl alcohol. 2. Vacuum the area to remove dust and debris as necessary. 3. Wipe the upper and lower card tracks, especially near the exit and entrance, with a clean cloth dampened with isopropyl alcohol. Clean Heads Only As Needed

When the module requires excessive retries, use a magnetic stripe cleaning card to clean the read/write heads. 1. Place a drop of cleaning solution in the center of the cloth patch on the cleaning card (Part No. 589248-001).


3-11

2. Place the cleaning card into the card guide in the exit area of the upstream module, and feed it into the entrance of the Magnetic Stripe module. 3. Turn the Transport motor drive plate to move the card back and forth under the heads until they are clean. The number of times to move the card back and forth depends on the degree of accumulation.

4. Remove the card from the module.

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Topper Module Start of Shift 1. Vacuum the card track sensors or wipe them with a soft brush or cotton swab. See the locations of the track sensors in the following figure. Vacuum the sensors even if the module is operating in pass-through mode.

2. Use a damp cloth to clean debris from all rollers. 3. Clean any debris from all upper and lower card tracks. Weekly 1. Clean the transport rollers weekly or after producing 50,000 cards. Wipe the roller surfaces with a soft cloth dampened with isopropyl alcohol. 2. Vacuum the area to remove dust and debris as necessary. 3. Wipe the upper and lower card tracks, especially near the exit and entrance, with a clean cloth dampened with isopropyl alcohol.


3-13

Smart Card Module Start of Shift 1. Vacuum the card track sensors or wipe them with a soft brush or cotton swab. See the locations of the track sensors (exit and entry sensors in red) in the following figure. Vacuum these sensors even if the module is operating in pass-through mode.

2. Use a damp cloth to clean debris from all rollers. 3. Clean any debris from all upper and lower card tracks. Weekly 1. Clean the transport rollers weekly or after producing 50,000 cards. Wipe the roller surfaces with a soft cloth dampened with isopropyl alcohol. 2. Vacuum the area to remove dust and debris as necessary. 3. Wipe the upper and lower card tracks, especially near the exit and entrance, with a clean cloth dampened with isopropyl alcohol.

3-14


Basic Topc oa t Module Procedure

Frequency

Comments

C lean the transport rollers


Dampen a cloth with alcohol and rotate the rollers as you wipe.

Clean the guide pins


Dampen a cloth with alcohol and rotate the rollers as you wipe.


3-15

3-16


Chapter 4: Loading Supplies This chapter provides procedures for loading supplies in various modules.

Introduction _________________________________________________________ 4-2 Card Cleaning Module _______________________________________________ 4-2 Card Input Module ___________________________________________________ 4-4 CardGard Topcoat Module ___________________________________________ 4-6 Replac ing C ardGard Supply Film ___________________________________ 4-6 Repa iring Broken CardGard Film ___________________________________ 4-8 Embossing and Indent Module________________________________________ 4-9 Label Affixing Module _______________________________________________ 4-11 Graphics Printing Modules___________________________________________ 4-13 Topping Module ____________________________________________________ 4-14 Basic Topcoat Module_______________________________________________ 4-16 Single-Step Color Module____________________________________________ 4-17


4-1

Introduction Some of the modules have supplies that must be periodically loaded or changed. This section describes the procedures for loading or replacing the supplies.

Card Cleaning Module Datacard cleaning tape is supplied on a disposable core. When the module cleaning tape supply core is empty, replace the tape using the following procedure. An animated version of this procedure is available from the User Animations option on the CD. Cleaning Tape Replacement Procedure 1. Remove the full take-up roll and discard. 2. Move the empty supply core to the take-up spindle. 3. Place the new cleaning tape roll onto the supply spindle so it rotates counterclockwise as the tape unrolls. 4. Thread the new tape. (If re-threading broken tape, start from wherever the tape broke.) A. Peel off the edge of the cleaning tape (1 in the following figure) and wrap it around the idler roller (2) with the adhesive side away from the roller. B. Wrap the tape around the gold drive roller (3) and then around the backup roller (4). C. Wrap the tape around the black drive roller (5) and then onto the empty take-up core (6). Use the small piece of tape on the end of the roll to fasten the cleaning tape to the core.

4-2

Loading Supplies


4-3

Card Input Module Use the following procedure to load cards into the card tray. An animated version of this procedure is available from the User Animations option on the CD. Wear lint free gloves to load cards. Finger oils interfere with graphics printing. All cards in the tray should be the same thickness. 1. Open the transport cover. 2. Press and hold the release lever on the stack pusher, and pull the stack pusher all the way to the back of the tray.

3. Release the lever to lock the stack pusher in place.

Visually inspect the card grippers for cracked or damaged plastic. If damaged, they should be replaced before loading cards in the tray. 4. Load cards into the card tray, working from front to back. Cards are usually inserted with the magnetic stripe facing to the back and on top; some jobs may require a different position. See the following figure for placement of various types of cards.

4-4

Loading Supplies

5. When the tray is full, press the lever on the stack pusher again to release the catch, and gently guide the pusher until it is resting against the last card in the stack. Caution: To avoid injury, never manually force the stack (card) pusher into operating position and keep your free hand away as you release the lever. 6. Straighten the cards by aligning them evenly along the top and on one side of the tray.

The following figure shows how to load various types of cards into the Card Input module.


4-5

CardGard Topcoat Module The CardGard topcoat material is a clear, plastic film that includes both a (tacky) carrier layer and a cover layer. The beginning length of the film contains a leader, which is a plastic strip for easy threading. The leader should be long enough to thread around the supply guide pins to the carrier take-up spindle.

Replacing C ardGard Supply Film When the supply is empty, replace it with a new roll as described below. Wear lint-free and powder-free gloves while removing and loading CardGard film. Procedure 1. Remove the cover and weight over the empty supply roll. 2. Turn the carrier and cover knobs clockwise and lift to remove them. 3. Remove any remaining film, carrier, and cover material. 4. Pull about 10 inches of tape leader from the new supply roll. 5. Place the new roll (1 in the following figure) on the supply spindle so it unwinds counterclockwise. 6. Unwind the carrier leader from the roll and thread it around the film guide pins (2 and 3) and capstan roller (4) separating the cover layer before the second pin guide (2).

4-6

Loading Supplies

7. Wrap the film a full turn around the carrier take-up spindle (5). Replace the carrier take-up knob so that the film is enclosed by the pin. Turn the knob to seat it on the spindle. 8. Pull the tab on the cover layer to separate it from the carrier layer. Wind the carrier around the guide pins (6 and 7) and onto the carrier spindle (8). 9. Wrap the carrier a full turn around the spindle (just enough to keep it in place). 10. Simultaneously turn the carrier take up knob (5) and cover take up knob (8) counterclockwise to continue winding the cover and carrier around their spindles and remove any slack in the film. Turning only the cover or carrier spindle will cause slack in the material.

Capstan

Supply

Carrier


Cover

4-7

Repairing Broken C ardGard Film If the CardGard film breaks during operation, use this procedure to re-thread film without leader tape. Procedure 1. Identify where the film break occurred and remove the threaded film from the point of the break to both the carrier and cover spindles. 2. Place a piece of tape on each side of the broken edge of the film. 3. Pull the two pieces of tape apart, separating the cover and carrier layers of the film. 4. Fold back the carrier end over the sticky coating material to form a new tape leader of about 10 inches (25.4 cm). 5. Using the previous threading diagram, thread the tacky carrier layer of the film around the supply film guides (3) and capstan roller (4), and then wind it around the carrier take-up spindle (5). Thread the cover layer around the guide pins (6 and 7) and then wind it around the cover take-up spindle (8). 6. Turn the capstan, take-up, and cover knobs as needed to continue wrapping the film around the spindles until there is no slack.

4-8

Loading Supplies

Embossing and Indent Module Indent mechanisms use a colored supply ribbon to transfer pigment to the indented characters on the card’s surface for readability. When the indent ribbon supply roll is empty, replace it with a new roll as described below. Indent Ribbon Replacement Procedure

The following instructions are for a rear indent mechanism. 1. On the Controller screen, right-click the Embossing module and select access ribbon to raise the card transport, or manually raise the assembly by lifting the lever marked with a green up-arrow label.

2. Tip the indent mechanism back for access to the ribbon. 3. Turn the green t-handle counterclockwise to remove it. 4. Remove the full take-up core and discard. 5. Remove the empty core on the supply hub and place it on the take-up hub. 6. Replace the green t-handle.


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7. Place the new supply roll on the supply hub (1 in the following figure) so it unwinds clockwise and pull the end of the ribbon from the roll. 8. Unwind the ribbon from the roll and thread it under the ribbon guides (2 and 3). 9. Thread the ribbon past the ribbon guide (3). Twist the ribbon so the dull side with pigment faces the cards, and thread the ribbon across the two ribbon guide arms (4). 10. Thread the ribbon down to lay underneath the ribbon guide roller (5), and twist the ribbon again so the shiny side is facing up. 11. Thread the ribbon into the take-up hub from the bottom and pull it through the slot (6) in the hub. Turn the t-handle to wrap the ribbon several turns until it is secure. Tape the end of the ribbon to the side of the take-up plate.

When properly loaded, the shiny (non-pigment) side of the ribbon contacts the roller and guides (2, 3, 4, and 5).

12. Place the Indent mechanism back in position; let the system lower the card transport assembly as it does a reset.

4-10

Loading Supplies

Label Affixing Module The Label supply material consists of a paper or polyester liner with adhesive labels to affix to card surfaces. When the Label supply roll is empty, replace it with a new roll as described below. Label Replacement Procedure 1. Pull out on the knob to remove the supply retainer (1 in the following figure).

2. Lift the shoe mechanism (2) to lock the assembly in the load position. 3. Push the knob (3) forward and then release it to lock the supply and take-up assemblies in the load position. 4. Pull the retainer plate (4) out of the take-up spindle to open the two halves of the spindle, and remove any remaining label supply material from the module. 5. Pull the label material away from the supply and peel labels off approximately 24 inches (60 cm) of the material to form a leader (5). 6. Place the roll on the supply spindle and thread the leader up and over the supply roller, then down under the shoe, and finally up and over the take-up roller as shown. 7. Insert the label material between the spindle halves and push the retainer plate (5) back in to close the take-up spindle (the smooth side of the plate should face the label material).


4-11

8. Wind the label material around the take-up spindle to secure it. Wind up enough material so the leading label is between the supply roller and the peel edge. 9. Simultaneously push the knob (3) forward and the latch lever (7) down to engage the supply and take-up roller assemblies. 10. Push the release lever (6) forward to place the shoe mechanism back into position for production.

4-12

Loading Supplies

Graphics Printing Modules Datacard print ribbon is supplied on a disposable core. Load or replace the ribbon using the following procedure. An animated version of this procedure is available from the User Animations option on the CD. Printing Ribbon Replac ement Procedure 1. Remove the full take-up roll and discard. 2. Move the empty supply core from the supply spindle to the take-up spindle. 3. Load the new tape by placing the new print ribbon roll onto the supply spindle (1) so it will rotate clockwise as the ribbon unwinds. 4. Rotate the knob (2) to move the printhead away from the assembly. 5. Thread the print ribbon in the following manner. A. Peel the edge of the print ribbon from the spool. B. Route the ribbon through the ribbon sensor (3), around the first guide post, and then around guides (4 and 5) and the printhead (6) as shown in the following figure. C. Wrap the ribbon onto the empty take-up core (7) and use a piece of tape to secure it to the core. D. Wind the knob on the roller (8) to remove slack.


4-13

Topping Module The Topping supply material is a colored foil ribbon whose pigment is transferred to the top of the card’s embossed characters for readability. When the supply roll is empty, replace it with a new roll as described below. Topping Foil Replacement Procedure 1. Remove the take-up roll with core from the module and discard.

Light pressure is required to unseat the cores from the retainers on the spindles. 2. Move the empty core from the supply spindle to the take-up spindle. 3. Pull off the end of the new supply roll and place the roll on the supply spindle (1 in the following figures) so that it unwinds in a clockwise direction. 4. Unwind the foil from the spindle and unroll it down the ramp under the card track (2). 5. Thread the foil under the lower foil guide roller (3) and over the lift arm. 6. Raise the lift arm (4) to pull the foil up through the opening in the upper card guide assembly and around its upper guide shaft (5). 7. If you have a foil slitter assembly installed: A. Thread the foil through the assembly and around its foil guide shaft (7) before threading it around the take-up core. B. Pull the operator knob on the slitter assembly downward to thread the foil through. 8. Thread the material around the take-up core (6) from the bottom and tape the leading edge to the core.

4-14

Loading Supplies

Topping Module Without Foil Slitter Assembly

Topping Module with Foil Slitter Assembly


4-15

Basic Topcoat Module Use the following figure as a guide to threading the supply roll through the module. 1. Remove the full take-up roll and discard. 2. Move the empty supply core from the supply spindle to the take-up spindle. 3. Load the new roll onto the supply spindle to unwind in a clockwise direction. 4. Thread the supply in the following manner. A. Peel the edge of the roll from the spool. B. Wrap the supply around the spindles, guides, and heated area. C. Wrap the supply onto the empty take-up core and use a piece of tape to secure it to the core.

4-16

Loading Supplies

Single-Step Color Module


4-17

Mx 2000 Owners

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