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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 Stripe 3-9 Verifying Even and Uniform Topping 3-11 Verifying Throat Gap Adjustment 3-12
150i Card Personalization System Maintenance Manual
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
150i
Procedure
Vacuum out the entire inside of the 150i and clean the outside of the cabinet with desk cleaner. Clean O-rings and rubber drive rollers with citrus solvent. Clean sensors with compressed air. Clean head using the Encoder Cleaning Card. Verify throat width: 0.045 ±0.005 inch. Verify horizontal margin, character height and vertical line locations on customer setups. Run a Magnetic Stripe Test Card and verify start sentinel and track locations. Run customer cards and verify cards are top coated evenly and uniformly.
Clean the 150i
Clean the 150i O-Rings/Drive Rollers Clean the 150i Sensors Clean Magnetic Stripe Head Verify Adjustment of Card Feed Throat Verify Adjustment and Operation of the 150i Verify Start Sentinel and Track Locations for Magnetic Stripe
150i 150i Magnetic Stripe Input/Output Hopper Card Transport
Magnetic Stripe
Verify Even and Uniform Topping Topper
3-2
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
Can of compressed air Desk cleaner Encoder cleaning card Lint-free cloth Magnetic stripe sight gage Magnetic stripe tape developer Citrus solvent Vacuum cleaner Vernier calipers Interlock tool TUL001-018 Any type 597729-001 Any type 594895-001 TUL001-014 TUL003-007 Any type 0.00 to 1.00 inch (0.001-inch increments) 805957-901
Datacard Part Number
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
150i Card Personalization System Maintenance Manual
3-3
Cleaning the 150i
1. 2. 3. 4. Unlock and lift up the Top Cover. Power OFF the 150i and remove the power cord. Vacuum out the inside of the 150i. Clean the outside of the cabinet with either a damp lint-free cloth or desk cleaner.
Cleaning the O-Rings/Drive Rollers
1. 2. 3. Unlock and lift up the Top Cover. Power OFF the 150i and remove the power cord. 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 Output Hopper Drive Roller
150i004s
Magnetic Stripe
Output Hopper Drive Belt
Motor
Figure 3-1: Preventive Maintenance for Rollers
3-4
Preventive Maintenance
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 Die Cam Home sensor Input Hopper Empty sensor Punch Cam Home sensor Throat Gap sensor Topper Platen sensor X-Home sensor (located on 150i base) Indent Foil Motion sensor (if so equipped)
Topper Platen Sensor
· · · · · · ·
Card Registration sensor Input Home sensor Output Full sensor Reject Full sensor Topper Foil Motion sensor Wheel Home sensor Y-Home sensor
Topper Foil Motion Sensor
Reject Full 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
150i Card Personalization System Maintenance Manual
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
Preventive Maintenance
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.
150i Card Personalization System Maintenance Manual
3-7
Table 3-3: Line Location and Margins Checklist Check
Characters Tolerances
Values
All present and flawless. Make sure the left margin is parallel to the card's left edge and all lines are parallel to the card's bottom edge. 0.016 to 0.019 inch. 0.015 to 0.018 inch.
OCR character height (top line) AN character height (remaining lines)
150i009s
Figure 3-4: Embossing Line Locations and Margins Card
3-8
Preventive Maintenance
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.
150i Card Personalization System Maintenance Manual
3-9
Magnetic Stripe Sight Gage IATA Track 1 Loc ABA Track 2 Loc TTS Track 3 Loc Place card tight to this corner.
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
Preventive Maintenance
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. 2. 3. 4. 5. 6. 7. 8. 9. Place blank white cards in the Input Hopper. From the READY mode, press *#3253. The message "SELECT EXIT MODE: (1) APP (2) DIAGNOSE" is displayed. Press 2 on the 150i keypad. The message: "BOOT TO SERVICE DIAGS!" is displayed followed by "150i Diags Rev. X.X Service." Press the # key. The message "Loading On Board Diags. Please wait..." is displayed followed by "150i On Board Diagnostics Diagnostic Routines." Press the 8 key twice (2); the message "150i On Board Diagnostics Test Cards" is displayed. Press the # key to select. The message "150i Test Cards Standard" is displayed. Press the 8 key 7 times; the message "Topper" is displayed. Press the # key to select. The message "Stop At One Card?" (#) YES (1) NO (0) ESC" is displayed. 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
Characters Tolerances
Values
All present and flawless. Make sure the left margin is parallel to the card's left edge and all lines are parallel to the card's bottom edge. 0.016 to 0.019 inch. 0.014 to 0.018 inch.
OCR character height (top line) AN character height (remaining lines)
150i Card Personalization System Maintenance Manual
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
Preventive Maintenance