Datacard Datacard 150i free download

File name 0.Index Service manual.pdf

Datacard I50i Card Personalization System Maintenance Manual June 2001 Part No. 539110-001 Rev. B Liability Statement This product has been built to the high standards of Datacard Group. Please do not attempt to operate or repair this equipment without adequate training. Any use, operation, or repair in contravention of this document is at your own risk. By acceptance of this system you hereby assume all liability consequent to your use or misuse of this equipment. Datacard assumes no liability for incidental, special, or consequential damage of any kind. Equipment specifications, applications, and options are subject to change at the sole discretion of Datacard without notice. Proprietary Notice All drawings and information herein are the property of Datacard Corporation. All unauthorized use and reproduction is prohibited. Trademark Acknowledgments Datacard is a registered trademark and LaserGrafix is a trademark of Datacard Corporation. Torx is a registered trademark of Textron, Inc. Windows is a registered trademark of Microsoft Corporation. All other product names are the property of their respective owners. Datacard Group 11111 Bren Road West Minnetonka, MN 55343-9015 952.933.1223 Fax: 952.933.7971 www.datacard.com © 2001 Datacard Corporation. All rights reserved. Printed in the United States of America. ii Contents Chapter 1: System Description ___________________________________________________ 1-1 Audience____________________________________________________________________________ 1-2 Repair Ability ________________________________________________________________________ 1-2 Serial Numbers _______________________________________________________________________ 1-2 Use of this Document _________________________________________________________________ 1-3 Product Specifications _______________________________________________________________ 1-4 Electrical ________________________________________________________________________ 1-4 Environmental ___________________________________________________________________ 1-4 Communications ________________________________________________________________ 1-4 Card Capacities_________________________________________________________________ 1-4 Input Hopper Capacity ______________________________________________________ 1-4 Reject Hopper Capacity _____________________________________________________ 1-4 Output Hopper Capacity ____________________________________________________ 1-4 Topper Cassette Capacity _______________________________________________________ 1-4 Protocols ________________________________________________________________________ 1-4 Physical Specifications ___________________________________________________________ 1-5 Card Specifications ______________________________________________________________ 1-5 Magnetic Stripe Encoding Specifications ______________________________________________ 1-6 Standard Financial Emboss Line Locations _____________________________________________

File name 1.System Description.pdf

Chapter 1: System Description The 150i Card Personalization System operates as a standalone card embosser. This chapter provides a system description of the 150i embosser. Audience 1-2 Repair Ability 1-2 Serial Numbers 1-2 Use of this Document 1-3 Product Specifications 1-4 Electrical 1-4 Environmental 1-4 Communications 1-4 Card Capacities 1-4 Input Hopper Capacity 1-4 Reject Hopper Capacity 1-4 Output Hopper Capacity 1-4 Topper Cassette Capacity 1-4 Protocols 1-4 Physical Specifications 1-5 Card Specifications 1-5 1 Magnetic Stripe Encoding Specifications 1-6 Standard Financial Emboss Line Locations 1-6 Standard Emboss Character Height 1-7 Standard Emboss Character Spacing 1-7 150i Card Personalization System Maintenance Manual 1-1 Audience This document is intended for use by authorized representatives of Datacard Corporation who are responsible for the maintenance, service, and repair of the Datacard® 150i Card Personalization System, which is also referred to in this document as the 150i. Repair Ability The authorized Datacard representative must possess the following ability: · · · · · Ability to set up the 150i communication parameters. Ability to check 150i configuration against purchase order agreement and, if necessary, change configuration. Ability to run and interpret software diagnostics. Ability to remove and replace all FRUs (Field Replaceable Units). Ability to diagnose mechanical and electrical failures and correctly adjust all mechanical components including software adjustments. Serial Numbers Information in this document applies to all 150i Card Personalization Systems beginning with serial number 0350 and higher. 1-2 System Description Use of this Document This document contains the following chapters to assist the service representative in the maintenance, service, and repair of the 150i: Chapter 1: System Description Provides general information about this document and service data for the 150i. Chapter 2: Installation Provides information for site preparation, unpacking, inspection, setup, configuration, and initial checkout of a 150i. Chapter 3: Preventive Maintenance Provides a preventive maintenance schedule with procedures and tool requirements for periodic maintenance of the 150i. Chapter 4: Theory of Operation Provides basic electrical theory for the 150i. Chapter 5: Troubleshooting Provides a troubleshooting guide to determine which FRU needs to be replaced or what adjustment needs to be performed for proper operation of the 150i. Chapter 6: Adjustments Provides detailed procedures for mechanical, electrical, and software adjustments. Chapter 7: Removal and Replacement Provides removal and replacement procedures for field replaceable items in the 150i. Appendix A- Glossary Provides definitions of terms used throughout the this maintenance manual. Appendix B ­ Wheel Table Configurations Provided wheel table information and configurations of all available character wheels for the 150i. 150i Card Personaliz

File name 2.Installation.pdf

Chapter 2: Installation The 150i Card Personalization System operates as a standalone card embosser. This chapter provides instructions for installing the 150i at a customer's site. Preparing the Site 2-2 Unpacking/Packing 2-3 Functional Tests 2-6 Administrator Setups 2-6 Standard CPX Used 2-6 Baud Rates 2-6 Parity Bits 2-7 Bit Size 2-7 Format Types 2-7 Protocol 2-7 Sweden Stripe 2-7 Auto Retry 2-7 Topper Select 2-8 Monitor 2-8 Test Card 2-8 Stripe Retries 2-8 Write Only Once 2-8 Door Password 2-8 Save Changes 2-8 Baud Rate 2-9 Parity Bits 2-9 Bits Size 2-9 Monitor 2-9 Test Card 2-9 Stripe Retries 2-9 Write Only Once 2-10 Door Password 2-10 Save Changes 2-10 Financial Card Password 2-10 150i Card Personalization System Maintenance Manual 2-1 Preparing the Site The site requirements are as follows: · · · · · The desk or table for the 150i to be placed on must be flat, level, and capable of supporting 70 pounds (31.8 kg). The 150i must have 2 inches of clearance all around the cabinet for ventilation and 18 inches of clearance for the Top Cover to open fully. Unpack the delivered equipment and check for any cosmetic damage. Connect the cables. Power on the 150i. The following table lists special equipment, materials and special tools required for 150i installation. Table 2-1: Installation Materials and Special Tools Equipment/Material/Tool 25 Blank White Cards with Magnetic Stripe Vernier Calipers Magnetic Stripe Sight Glass Magnetic Tape Developer Note Shipped with the 150i Standard tool Datacard Part No. 594895-001 Datacard Part No. TUL001-014 Shipped with the 150i 150i Setup Utility Part No. 555071-001 Shipped with the 150i (if so equipped) Required for Testing general 150i operation. Measuring distances on card. Checking encoding specifications. Checking encoding specifications for magnetic stripe. Checking Topper operation. Running diagnostics, uploading Flash memory, Setting offsets. Checking OCR Indent module operation. Topper Foil Laptop PC equipped with 150i Setup Utility OCR Indent Ribbon (option) 2-2 Installation Unpacking/Packing Refer to the unpacking illustration in Figure 2-1 for details. Strapping Cut Apart Cut Apart 150i001s Cut Tape Figure 2-1: Unpacking/Packing 150i Card Personalization System Maintenance Manual 2-3 1. 2. Cut the plastic strapping band and remove the top outer container and the protective plastic bag covering the 150i. Remove the following items from the container: · · · · · · · · · Blank cards (25) Input Hopper card weight Power cord Null modem cable (if ordered) Administrator's Guide MasterCardTM Insertion tool (if ordered) Topper Cassette Top Cover access keys Datacard 150i Operator Training Video (if ordered) Blank Cards Input Hopper Card Weight Power Cord Null Modem Cable Insertion Tool Administrator's Guide Keys 150i002s Topper Cassette (Located inside the 150i in the Topper Module) Datacard Operator Training Video Figure 2-2: Included Packed Materials 2-4 Installation 3

File name 3.Preventive Maintenance.pdf

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 Eve

File name 4.Theory of Operation.pdf

Chapter 4: Theory of Operation The 150i Card Personalization System operates as a standalone card embosser. This chapter provides general theory of operation for the 150i. 150i Overview 4-2 Component Identification 4-2 Inside View of the 150i 4-3 Rear View of the 150i 4-4 Sequence of Operation 4-5 Memory Map 4-7 Electrical Block Diagram 4-8 Microprocessor 4-9 CPLD 4-9 Flash 4-9 DRAM 4-9 FPGA Controller 4-10 ROM 4-10 EEPROM 4-10 Power Inlet Module 4-10 36 Volt Power Supply 4-10 5 Volt Regulator 4-10 12 Volt Regulator 4-11 System Interlock 4-11 RS232 Transceiver 4-11 LCD Display/Keypad and LEDs 4-11 4 Main Control Board Schematics 4-12 150i Card Personalization System Maintenance Manual 4-1 150i Overview The 150i is a full featured single-pass card personalization system. The 150i embosses, encodes, and tops financial plastic cards. Depending on the options ordered, the 150i is also capable of indent printing and smart card personalization. Component Identification The follow bulleted list identifies the major components of the 150i. See Figure 4-1 for their location. · · · · · · Output Hopper Door Single Card Access Door Keyhole Keypad Display Indicators and icons on display: · · · · · Power Indicator Ready Indicator Error Indicator Service Indicator · · Optional Indicator Top Cover Power Switch Indicators Display Keypad Keyhole Output Hopper Door Single Card Access Door Power Switch Figure 4-1: Component Identification 4-2 Theory of Operation Inside View of the 150i The following bulleted list identifies the major modules inside of the 150i. See Figure 4-2 for their location. · · · · · · · · · · Card Transport Module Embosser Module Front Indent Printing Module Good Card Tray (Output tray) Input Hopper Magnetic Stripe Encoding Module Reject Tray Smart Card Personalization (Optional) Topper Module Front/Rear Indent (Optional) Top Cover Reject Tray Front Indent Printing Module Topper Module Card Transport Module Embossing Module Input Hopper SmartCard Personalization Module Magnetic Stripe Encoding Module Good Card Tray Figure 4-2: Inside View of the 150i 150i Card Personalization System Maintenance Manual 4-3 Rear View of the 150i The following bulleted list identifies the components on the rear of the 150i. See Figure 4-3 for their location. · · · · · · On/Off Switch Communication Ports · Host · Service Smart Card 1 (Option) Smart Card 2 (Option) · Diagnose (Option) · Development (Option) Power Receptacle Fan Communication Ports On/Off Switch Diagnose Communication Ports Host Development Service Power Receptacle Smart Card 1 Smart Card 2 C ommun ica tion Po rts D iagno se De ve lopm ent Figure 4-3: Rear View of the 150i 4-4 Theory of Operation Sequence of Operation When reading the Sequence of Operation, reference Figure 4-4. 1. After the 150i initializes on power up, cards can be produced. a. Once the system detects that a block of data has been received, the 150i acknowledges the data and signals the T

File name 5.Troubleshooting.pdf

Chapter 5: Troubleshooting The 150i Card Personalization System operates as a standalone card embosser. This chapter of the manual provides information and procedures to isolate a fault to the part, and/or component level. It includes symptoms, fault isolation procedures, use of diagnostic tools, and error codes. Troubleshooting Tips 5-3 Prerequisite Skills 5-4 Diagnostic Routines 5-4 Diagnostic Routines Menu 5-5 Sensors 5-6 MS Start Sentinel (NTT) 5-7 MS Start Sentinel (Standard) 5-7 Transport 5-7 Pick & Stack 5-7 Pick & Reject 5-7 Calibration Menu 5-8 Test Cards Menu 5-9 Standard Test Card 5-10 Mag Stripe Test Card 5-10 Indent Test Card 5-10 MagStripe/Emboss Test Card 5-10 MagStripe/Emboss/Top Test Card 5-10 Smart Card Test Card 5-11 Wheel Test Card 5-11 Topper Test Card 5-12 Run Without Cards 5-12 Preembossed Test Card 5-12 Character Height Test Card 5-12 Position Offsets Menu 5-13 Wheel Parameters Menu 5-15 Topper Parameters Menu 5-16 Configuration Menu 5-16 Status Request Menu 5-17 5 150i Card Personalization System Maintenance Manual 5-1 Restore MCB Defaults 5-17 Restore Mfg Settings 5-17 Save Changes 5-17 150i Interconnect Diagrams 5-18 Main Control Board Connections 5-19 Main Control Board Cable Connections 5-20 AC Wiring Diagram 5-21 Pin-Out Tables 5-22 Motor Pin-Outs 5-22 Sensor Pin-Outs 5-24 Serial Communications Pin-Outs 5-26 Identifying Errors Using Error Codes 5-27 Group xx 5-27 Group yy 5-28 Group zz 5-28 Error Codes 5-32 Main Control Board LEDs 5-38 5-2 Troubleshooting Troubleshooting Tips When correcting errors, it is a good idea to perform the following: · · · · · · · Always power OFF the 150i. Load the Input Hopper if the card stock is low. Clear any rejected cards from the Reject Tray. Replace the foil in the Topper Module if it is getting low. Replace the Indent Ribbon if it is getting low. Make sure the Top Cover is closed and locked. Output Hopper door is fully closed. Use these tips to correct the following general problems. If A Card Is Loose In The 150i · · Check the inside of the 150i for cards that may have fallen from the Card Transport module. Remove the cards and attempt to resume printing. If A Card Is Jammed In The Input Hopper · · Remove any jammed cards from the Input Hopper module by pulling cards from the back of the Input Hopper through the card throat. Attempt to resume printing. If A Card Is Jammed In The Embosser Module · · Remove any jammed cards from the Embosser module. Attempt to resume printing. If A Card Is Jammed In The Topper Module · · Remove any jammed cards from the Topper module. Attempt to resume printing. If A Card Is Jammed In The Front Or Rear Indent Module · · Remove any jammed cards from the front or rear Indent module. Attempt to resume printing. If A Card Is Jammed In The Smart Card Module · · Remove any jammed cards from the Smart Card module. Attempt to resume printing. When removing jammed cards from the 150i, care must be taken not to damage components. 150i

File name 6.Adjustments.pdf

Chapter 6: Adjustments The 150i Card Personalization System operates as a standalone card embosser. This chapter provides information for adjusting the 150i. Introduction 6-2 Mechanical Adjustments 6-2 Magnetic Stripe Head Height Adjustment 6-2 Rear Indent Drive Belt Adjustment 6-4 Interlock Switch Adjustment 6-6 Electrical Adjustment 6-8 Display Contrast Adjustment 6-8 Software Offsets 6-10 Start Diagnostic Routines 6-10 Position Offsets Menu 6-11 Pick Offset 6-13 Smart Card Offset 6-14 MagStripe NTT Offset 6-15 MagStripe Standard Offset 6-16 MagStripe Variables Offset 6-18 Emboss Location Offset 6-19 Topper Offset 6-20 Topper Noise Offset 6-21 Exit Offset 6-22 Emboss Height Offset 6-23 Indent Depth Offset 6-24 Throat Gap Offset 6-25 Wheel Home Offset 6-26 Card Bow Offset 6-27 150i Card Personalization System Maintenance Manual 6-1 Introduction This chapter presents mechanical, electrical, and software adjustment procedures for the 150i. These procedures are not part of preventive maintenance and are performed only as unscheduled maintenance requirements identified during fault isolation. Mechanical Adjustments The following pages describe the mechanical adjustments for the 150i. The software offset adjustments appear after the mechanical adjustments. Magnetic Stripe Head Height Adjustment The purpose of this adjustment is to insure proper pressure and contact of the encoding head with card stripe. Symptoms If this adjustment is not correct, the magnetic head will not come in contact with the magnetic stripe and read/write errors will occur. If the magnetic head is too high, card jamming may occur. Tools · Hex key set Procedure 1. 2. 3. 4. 5. 6. Unlock and lift up the Top Cover (see Opening the Top Cover in Chapter 7, Removal and Replacement). Power OFF the 150i and remove the power cord. Loosen one Magnetic Stripe height holding screw on the side of the Magnetic Stripe module. Manually rotate the Card Transport carriage lead screw so the Card Transport carriage is in front of the Magnetic Stripe module. Manually insert a card with the magnetic stripe up in the Card Transport carriage grippers. Position the card over the Magnetic Stripe head. 6-2 Adjustments 7. Adjust the Magnetic Stripe head height so as a card enters the nip of the roller, minimum deflection of the card occurs, while still making good contact with the Magnetic Stripe head. Tighten the Magnetic Stripe height holding screw. 8. Head Height Adjustment Wheel Height Holding Screw Figure 6-1: Magnetic Stripe Head Height Adjustment 150i Card Personalization System Maintenance Manual 6-3 Rear Indent Drive Belt Adjustment The purpose of this adjustment is to ensure the Rear Indent Drive Belt engages with the motor and drive pulleys. Symptoms If this adjustment is not correct, the Indent ribbon will not advance. Tools · #10 Torx driver Procedure 1. 2. 3. 4. 5. Unlock and lift up the Top Cover (see Rear Indent Drive Belt Adjustment in Chapter 7, Removal and Replacemen

File name 7.0Removal and Replacement.pdf

Chapter 7: Removal and Replacement The 150i Card Personalization System operates as a standalone card embosser. This chapter provides instructions for removal and replacement of assemblies and parts. Introduction 7-3 Servicing Guidelines 7-3 Opening the Top Cover 7-4 Changing the Password 7-5 Top Cover 7-6 Front Access Panel 7-8 Single Card Access Door 7-10 Output Hopper Door 7-12 Key Lock 7-14 Input/Output Hopper 7-16 Output Hopper Drive Belt 7-20 Output Hopper Drive O-Ring 7-22 Card Registration Sensor 7-24 Input Hopper Empty Sensor 7-26 Input Home Sensor 7-28 Output Full Sensor 7-30 Card Picked Sensor 7-32 Throat Gap Motor 7-34 Throat Gap Motor Belt 7-36 Throat Gap Sensor 7-38 Card Transport 7-40 X-Transport Drive Belt 7-42 X-Home Sensor 7-44 Y-Home Sensor 7-46 Card Transport Flex Cable 7-48 Carriage Transport Motor 7-50 150i Card Personalization System Maintenance Manual 7-1 Magnetic Stripe Assembly 7-52 Embosser Assembly 7-54 Wheel Home Sensor 7-56 Punch Home Sensor 7-58 Punch Cam Motor 7-60 Punch Cam Belt 7-62 Die Home Sensor 7-64 Die Cam Motor 7-66 Die Cam Belt 7-68 Punch and Die 7-70 Topper Assembly 7-72 Topper Foil Motion Sensor 7-74 Topper Platen Sensor 7-76 Topper Motor 7-78 Main Control Board 7-80 Power Supply Board 7-82 Line Filter 7-84 Fuse 7-86 Fan 7-88 Display/Keypad 7-90 Solenoid Lock Assembly 7-92 Reject Full Sensor 7-94 Front Smart Card Module (Option) 7-96 Front Indent Printer Module (Option) 7-98 Replacing the Front Indent Ribbon 7-100 Rear Indent Printer Module (Option) 7-102 Replacing the Rear Indent Ribbon 7-104 Rear Indent Motor 7-106 Rear Indent Drive Belt 7-108 Rear Indent Solenoid 7-110 7-2 Removal and Replacement Introduction This section gives procedures for the removal and replacement of the 150i Card Personalization System Field Replaceable Units (FRUs) and sub-assemblies. Some FRU replacements may require self-tapping screws to be used. Servicing Guidelines Use the following guidelines when servicing the 150i: · · · · · · Observe warning and caution labels affixed to various areas of the equipment. Use only the recommended tools as specified to perform service. Replacement of certain assemblies and parts requires follow-up adjustments. Make sure these adjustments are performed after replacement. Always perform preventive maintenance as described in Chapter 3, Preventive Maintenance, of this manual after replacement procedures. Verify the 150i functions after replacement by performing and/or observing a limited customer production run. DO NOT defeat the safety interlock. 150i Card Personalization System Maintenance Manual 7-3 Opening the Top Cover The Top Cover can be opened with either a four-digit password or a key. The default password shipped from the factory for the 150i is *00000. This password should be changed upon receipt of the machine (see Changing the Password). · To open the Top Cover using a password, using the keypad, enter *0 (unlock code) followed by your 4 digit password (XXXX).

File name 8.Ilustrated Parts Breakdown.pdf

Chapter 8: Illustrated Parts Breakdown The 150i Card Personalization System operates as a standalone card embosser. This chapter provides information on assembly and subassembly part numbers for the 150i. Introduction 8-2 General 8-2 Cabinet Parts 8-3 Input/Output Hopper Assembly 8-4 Card Transport Assembly 8-6 Magnetic Stripe Assembly 8-7 Embosser Assembly 8-8 Lower Emboss Housing Assembly 8-10 Upper Emboss Housing Assembly 8-11 Topper Assembly 8-12 Topper Foil 8-13 Main Control Board 8-14 Power Supply 8-15 Fan 8-16 Sensor Cable Harness 8-17 Power Cable Harness 8-18 Communications Cable 8-19 Cable/Development Cable 8-20 Display/Keyboard 8-21 Miscellaneous Spare Parts 8-22 Solenoid Lock Assembly 8-23 Reject Full Photocell 8-24 Smart Card Assembly 8-25 Front Indent Print Assembly 8-26 Rear Indent Printer Assembly 8-27 Indent Ribbon 8-28 8 150i Card Personalization System Maintenance Manual 8-1 Introduction This chapter provides information on assembly and sub-assembly part numbers for the 150i. General The 150i Series Card Personalization System final assembly may be configured under different part numbers related to the 150i Series Card Personalization System defined in the customer order. Verify the final assembly part number before replacing components. 8-2 Illustrated Parts Breakdown Cabinet Parts Description Top Cover Front Access Panel Outside Cabinet Single Access Door Output Hopper Door Output Door Assembly Part Number 555120-002 556272-001 596625-001 556277-001 556278-001 556788-001 150i Card Personalization System Maintenance Manual 8-3 Input/Output Hopper Assembly Description Input / Output Hopper Assembly Input Hopper Card Weight Output Hopper Drive Belt Card Registration Photocell Input Hopper Empty Photocell Input Home Photocell Output Full Photocell Card Pick Photocell O-Rings Throat Gap Motor Throat Gap Photocell Throat Gap Motor Belt Assembly, IH/OS Base Plate Plate Assembly, Left Side, IH/OS Plate Assembly, Right Side, IH/OS Roller, Cam Gear, Idler Plate, Card Gap Assembly, Plate, Support, Card Gap Wire Assembly, Input Motor Gnd Shaft, Support Motor Assembly, GFX .5a Stepper,280 Motor Assembly, IH/OS Plate Assembly, Stacker, Output Cam Plate, Support Block, Leadscrew Pulley, Leadscrew-12 Groove Block, Slide Bracket, Support, Motor Pulley, Leadscrew-20 Groove Leadscrew Part Number 556787-051 596713-001 803478-018 590067-003 593463-003 593463-003 596463-003 593463-003 803478-009 555938-001 593463-003 803129-126 596695-002 596697-001 596698-001 596328-001 596455-001 596333-001 556473-001 556307-001 596353-001 596104-001 555082-001 596696-001 596454-001 555981-001 556280-001 555986-001 556281-001 555989-001 555990-001 555991-001 8-4 Illustrated Parts Breakdown Card Registration Photocell Input Home Photocell O-Rings Output Full Photocell Card Picked Photocell Output Hopper Drive Belt Input/Output Hopper Throat Gap Motor Throat Gap Motor Photocell Input Hopper Empty Photocell Throat Gap Motor Belt 150i Card Per

File name 8.Ilustrated Parts.pdf

Chapter 8: Illustrated Parts The 150i Card Personalization System operates as a standalone card embosser. This chapter provides information on assembly and subassembly part numbers for the 150i embosser. Introduction 8-3 General 8-3 Parts Lists for Base Assembly 8-3 Base System without Topper (596660-102) 8-3 Base Assembly (555099-002) 8-4 Top Cover Assembly (555120-002, FRU is 555120-008) 8-5 Right Door Assembly (556277-001), Rev E 8-5 Back Side Panel Assembly (555098-002) 8-5 Null Modem Cable, DSub,9P-M-F (596813-001) 8-6 Output Door Assembly (556788-001) 8-6 Illustrated Cabinet Parts 8-7 Input/Output Assembly (556787-051), Rev Y 8-8 Input/Output Assembly Parts (596662-002) 8-8 Output Stacker Plate Assembly Parts (596696-001), Rev E 8-9 Illustrated Input/Output Assembly 8-10 Card Transport Assembly 8-11 Card Transport Assembly FRU Parts (556787-050) 8-11 Card Transport Assembly Parts (596661-002) 8-11 X Carriage Motor Assembly FRU Parts (596691-999) 8-11 Y-Drive Card Carriage Assembly Parts (596686-002) 8-11 Right Support Block Assembly FRU Parts (596690-002) 8-12 Illustrated Card Transport Assembly 8-12 Magnetic Stripe Assembly 8-13 IA/IAT, Hico/Loco Parts (596663-001 in Kit 555103-001) 8-13 J, Hico/Loco Parts (596663-002 in Kit 555103-002) 8-13 Back J, Hico/Loco Parts (596663-007 in Kit 555103-007) 8-13 IAJ, Hico/Loco Floating Heads Parts (596663-009 in Kit 555103-009) 8-14 IAJ, Hico/Loco Floating Heads, PR-MBSD (596663-010 in Kit 555103-010) 8-14 Illustrated Magnetic Stripe 8-16 Embosser/Indent Assemblies 8-17 Embosser Assembly Parts (596664-002) 8-17 Daisy Wheel Assembly, 7BSG, 52Char (596678-001) 8-17 150i Card Personalization System Maintenance Manual 8-1 Daisy Wheel Assembly, 7BSG, 50Char (596678-002) 8-17 Emboss Module Wheel Assemblies 8-18 Illustrated Embosser Assembly 8-19 Upper Emboss Housing Assembly Parts (596684-002) 8-20 Illustrated Upper Emboss Housing Assembly 8-20 Lower Emboss Housing Assembly Parts (596683-002) 8-21 Illustrated Lower Emboss Housing Assembly 8-22 Front Indent Assembly Parts (555110-001) 8-23 Front Indent Installation Kit Parts (555111-003) 8-23 Illustrated Front Indent Assembly 8-23 Rear Indent Assembly (555121-999) 8-24 Rear Indent Installation Kit Parts (555111-002) 8-24 Illustrated Rear Indent Assembly 8-25 Topper Assembly 8-26 C. S. Topper FRU Parts (556787-052) 8-26 Topper Assembly Parts (596665-002) 8-26 Topper Heater Assembly Parts (555094-001) 8-26 Lower Topper Assembly Parts (596675-001) 8-26 Topper Left Side Plate Assembly Parts (555091-001) 8-26 Topper Right Side Plate Assembly Parts (555090-001) 8-27 Topper Cassette Assembly Parts (596666-002) 8-27 Foil Motion Assembly Parts (555092-001) 8-27 Topper Foil Parts 8-28 Illustrated Topper Assembly 8-28 Main Control Board 8-29 Power Supply 8-30 Power Supply Assembly Parts (555093-999) 8-30 Power Cords 8-30 Illustration of Power Supply 8-31 Fan 8-32 Sensor Cable Harness 8-33 Power Cable Harness 8-34 Communications Cable 8-35 Smart Card Developm