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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 _____________________________________________ 1-6 Standard Emboss Character Height ___________________________________________________ 1-7 Standard Emboss Character Spacing _________________________________________________ 1-7
Chapter 2: Installation ___________________________________________________________ 2-1
Preparing the Site ____________________________________________________________________ 2-2 Unpacking/Packing ____________________________________________________________________ 2-3 Functional Tests ______________________________________________________________________ 2-6 Administrator Setup ______________________________________________________________ 2-6 Standard CPX Used__________________________________________________________ 2-6 Baud Rate __________________________________________________________________ 2-9 Parity Bits____________________________________________________________________ 2-9 Bits Size _____________________________________________________________________ 2-9 Monitor _____________________________________________________________________ 2-9 Test Card ___________________________________________________________________ 2-9 Stripe Retrys ________________________________________________________________ 2-10 Write Only Once____________________________________________________________ 2-10 Door Password _____________________________________________________________ 2-10 Save Changes _____________________________________________________________ 2-10 Financial Card Password ____________________________________________________________ 2-10
Chapter 3: Preventive Maintenance ______________________________________________ 3-1
Preventive Maintenance _____________________________________________________________ 3-2 Tools and Material ___________________________________________________________________ 3-3 Preventive Maintenance Procedures __________________________________________________ 3-3
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Cleaning the 150i ________________________________________________________________ 3-4 Cleaning the O-Rings/Drive Rollers ________________________________________________ 3-4 Cleaning the Sensors_____________________________________________________________ 3-5 Cleaning the Magnetic Stripe Head ______________________________________________ 3-6 Verifying Embossing Line Locations and Margins _______________________________________ 3-7 Verify Start Sentinel and Track Locations for Magnetic Stripe ____________________________ 3-9 Verify Even and Uniform Topping _____________________________________________________ 3-11 Verify Throat Gap Adjustment________________________________________________________ 3-12
Chapter 4: Theory of Operation___________________________________________________ 4-1
150i Overview________________________________________________________________________ 4-2 Component Identification ____________________________________________________________ 4-2 Inside View of the 150i ________________________________________________________________ 4-3 Rear View of the 150i _________________________________________________________________ 4-4 Sequence of Operation ______________________________________________________________ 4-5 Memory Map ________________________________________________________________________ 4-7 Electrical Block Diagram______________________________________________________________ 4-8 Microprocessor __________________________________________________________________ 4-9 CPLD____________________________________________________________________________ 4-9 Flash ____________________________________________________________________________ 4-9 DRAM ___________________________________________________________________________ 4-9 FPGA Controller_________________________________________________________________ 4-10 ROM ___________________________________________________________________________ 4-10 EEPROM________________________________________________________________________ 4-10 Power Inlet Module _____________________________________________________________ 4-10 36 Volt Power Supply____________________________________________________________ 4-10 5 Volt Regulator ________________________________________________________________ 4-10 12 Volt Regulator _______________________________________________________________ 4-11 System Interlock ________________________________________________________________ 4-11 RS232 Transceiver _______________________________________________________________ 4-11 LCD Display/Keypad and LEDs___________________________________________________ 4-11 Main Control Board Schematics______________________________________________________ 4-12
Chapter 5: Troubleshooting ______________________________________________________ 5-1
Troubleshooting Tips __________________________________________________________________ 5-3 Prerequisite Skills _____________________________________________________________________ 5-4 Diagnostic Routines __________________________________________________________________ 5-4 Diagnostic Routines Menu ________________________________________________________ 5-5 Sensors _____________________________________________________________________ 5-6 MS Start Sentinel (NTT)________________________________________________________ 5-7 MS Start Sentinel (Standard) __________________________________________________ 5-7 Transport____________________________________________________________________ 5-7 Pick & Stack_________________________________________________________________ 5-7 Pick & Reject ________________________________________________________________ 5-7 Calibration Menu ________________________________________________________________ 5-8
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Test Cards Menu _________________________________________________________________ 5-9 Standard Test Card _________________________________________________________ 5-10 Mag Stripe Test Card _______________________________________________________ 5-10 Indent Test Card____________________________________________________________ 5-10 MagStripe/Emboss Test Card ________________________________________________ 5-10 MagStripe/Emboss/Top Test Card____________________________________________ 5-10 Smart Card Test Card _______________________________________________________ 5-11 Wheel Test Card____________________________________________________________ 5-11 Topper Test Card ___________________________________________________________ 5-12 Run Without Cards__________________________________________________________ 5-12 Preembossed Test Card _____________________________________________________ 5-12 Character Height Test Card _________________________________________________ 5-12 Position Offsets Menu ___________________________________________________________ 5-13 Wheel Parameters Menu ________________________________________________________ 5-15 Topper Parameters Menu _______________________________________________________ 5-16 Configuration Menu ____________________________________________________________ 5-16 Status Request Menu____________________________________________________________ 5-17 Restore MCB Defaults ___________________________________________________________ 5-17 Restore Mfg Settings ____________________________________________________________ 5-17 Save Changes__________________________________________________________________ 5-17 150i Interconnect Diagrams _________________________________________________________ 5-18 Main Control Board Connections ________________________________________________ 5-19 Main Control Board Cable Connections__________________________________________ 5-20 AC Wiring Diagram _____________________________________________________________ 5-21 Pin-Out Tables ______________________________________________________________________ 5-22 Motor Pin-Outs__________________________________________________________________ 5-22 Sensor Pin-Outs _________________________________________________________________ 5-24 Serial Communications Pin-Outs _________________________________________________ 5-26 Identifying Errors Using Error Codes ___________________________________________________ 5-27 Group xx _______________________________________________________________________ 5-27 Group yy _______________________________________________________________________ 5-28 Group zz _______________________________________________________________________ 5-28 Error Codes_____________________________________________________________________ 5-32 Main Control Board LEDs ________________________________________________________ 5-38
Chapter 6: Adjustments __________________________________________________________ 6-1
Introduction _________________________________________________________________________ 6-2 Mechanical Adjustments _____________________________________________________________ 6-2 Magnetic Stripe Head Height Adjustment _________________________________________ 6-2 Rear Indent Drive Belt Adjustment_________________________________________________ 6-4 Interlock Switch Adjustment ______________________________________________________ 6-6 Electrical Adjustment _________________________________________________________________ 6-8 Display Contrast Adjustment ______________________________________________________ 6-8 Software Offsets ____________________________________________________________________ 6-10 Start Diagnostic Routines ________________________________________________________ 6-10 Position Offsets Menu ___________________________________________________________ 6-11 Pick Offset _________________________________________________________________ 6-13
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Smart Card Offset __________________________________________________________ 6-14 MagStripe NTT Offset________________________________________________________ 6-15 MagStripe Standard Offset __________________________________________________ 6-17 MagStripe Variables Offset __________________________________________________ 6-19 Emboss Location Offset _____________________________________________________ 6-20 Topper Offset ______________________________________________________________ 6-21 Topper Noise Offset_________________________________________________________ 6-22 Exit Offset __________________________________________________________________ 6-23 Emboss Height Offset _______________________________________________________ 6-24 Indent Depth Offset ________________________________________________________ 6-25 Throat Gap Offset __________________________________________________________ 6-26 Wheel Home Offset _________________________________________________________ 6-27 Card Bow Offset____________________________________________________________ 6-28
Chapter 7: Removal and Replacement ___________________________________________ 7-1
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 Magnetic Stripe Assembly ___________________________________________________________ 7-52 Embosser Assembly__________________________________________________________________ 7-54 Wheel Home Sensor_____________________________________________________________ 7-56 Punch Home Sensor_____________________________________________________________ 7-58 Punch Cam Motor ______________________________________________________________ 7-60 Punch Cam Belt ________________________________________________________________ 7-62
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Die Home Sensor _______________________________________________________________ 7-64 Die Cam Motor _________________________________________________________________ 7-66 Die Cam Belt ___________________________________________________________________ 7-68 Punch and Die _________________________________________________________________ 7-70 Topper Assembly ____________________________________________________________________ 7-72 Topper Foil Motion Sensor _______________________________________________________ 7-74 Topper Platen Sensor____________________________________________________________ 7-76 Topper Motor___________________________________________________________________ 7-78 Main Control Board _________________________________________________________________ 7-80 Power Supply Board _________________________________________________________________ 7-82 Line Filter ___________________________________________________________________________ 7-84 Fuse ___________________________________________________________________________ 7-86 Fan ________________________________________________________________________________ 7-88 Display/Keypad_____________________________________________________________________ 7-90 Solenoid Lock Assembly _____________________________________________________________ 7-92 Reject Full Sensor____________________________________________________________________ 7-94 Front Smart Card Module (Option) __________________________________________________ 7-96 Front Indent Printer Module (Option)_________________________________________________ 7-98 Replacing the Front Indent Ribbon______________________________________________7-100 Rear Indent Printer Module (Option) ________________________________________________7-102 Replacing the Rear Indent Ribbon ______________________________________________7-104 Rear Indent Motor _________________________________________________________________7-106 Rear Indent Drive Belt ______________________________________________________________7-108 Rear Indent Solenoid _______________________________________________________________7-110
Chapter 8: Illustrated Parts Breakdown____________________________________________ 8-1
Introduction _________________________________________________________________________ 8-2 General _____________________________________________________________________________ 8-2 Cabinet Parts____________________________________________________________________ 8-3 Input/Output Hopper Assembly ___________________________________________________ 8-4 Card Transport Assembly _________________________________________________________ 8-6 Magnetic Stripe Assembly ________________________________________________________ 8-7 Embosser Assembly ______________________________________________________________ 8-8 Lower Emboss Housing Assembly _________________________________________________ 8-10 Upper Emboss Housing Assembly_________________________________________________ 8-11 Topper Assembly________________________________________________________________ 8-12 Topper Foil _____________________________________________________________________ 8-13 Main Control Board _____________________________________________________________ 8-14 Power Supply ___________________________________________________________________ 8-15 Fan ____________________________________________________________________________ 8-16 Sensor Cable Harness ___________________________________________________________ 8-17 Power Cable Harness ___________________________________________________________ 8-18 Communications Cable_________________________________________________________ 8-19 Cable/Development Cable _____________________________________________________ 8-20
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Display/Keyboard_______________________________________________________________ 8-21 Miscellaneous Spare Parts _______________________________________________________ 8-22 Solenoid Lock Assembly _________________________________________________________ 8-23 Reject Full Photocell ____________________________________________________________ 8-24 Smart Card Assembly ___________________________________________________________ 8-25 Front Indent Print Assembly ______________________________________________________ 8-26 Rear Indent Printer Assembly_____________________________________________________ 8-27 Indent Ribbon __________________________________________________________________ 8-28
Appendix A: Glossary ___________________________________________________________ A-1
Glossary of Terms____________________________________________________________________ A-1
Appendix B: Wheel Table Configurations__________________________________________ B-1
Standard ____________________________________________________________________________ B-3 Tilde N (Ñ) ___________________________________________________________________________ B-4 Visa 'V' ______________________________________________________________________________ B-5 Diners Club __________________________________________________________________________ B-6 Barcelona ___________________________________________________________________________ B-7 Barcelona OCR B1 Special____________________________________________________________ B-8 Large Gothic K_______________________________________________________________________ B-9 Indent-Rear OCR-A1 ________________________________________________________________B-10 Indent-Rear OCR-B1_________________________________________________________________B-11 Indent-Rear MasterCard_____________________________________________________________B-12 Common European _________________________________________________________________B-13 Portugal ____________________________________________________________________________B-14 Japanese Financial _________________________________________________________________B-15 Japanese Financial Special__________________________________________________________B-16 Japanese Healthcare _______________________________________________________________B-17 Japan Credit (Amex/Diners and Others) ___________________________________________B-18 Visa/Master/JCB and Co-Branded ___________________________________________________B-19 Indent-Rear Inverted MasterCard ____________________________________________________B-20 Czech ______________________________________________________________________________B-21 Greece ____________________________________________________________________________B-22 Hungary ____________________________________________________________________________B-23 Iceland_____________________________________________________________________________B-24 Latvian _____________________________________________________________________________B-25 Poland _____________________________________________________________________________B-26 Cyrillic ______________________________________________________________________________B-27 Turkey ______________________________________________________________________________B-28 Yugoslavia__________________________________________________________________________B-29 Ukraine _____________________________________________________________________________B-30 Korea ______________________________________________________________________________B-31
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Front Visa Electron Indent____________________________________________________________B-32 Poland-OCR B1 Indent ______________________________________________________________B-33 Latvian-OCR B1 Indent ______________________________________________________________B-34 Barcelona-OCR B1 Indent ___________________________________________________________B-35 Common European -OCR B1 Indent__________________________________________________B-36 Portugal-OCR B1 Indent _____________________________________________________________B-37 Greece-OCR B1 Indent ______________________________________________________________B-38 Hungary-OCR B1 Indent _____________________________________________________________B-39 Iceland-OCR B1 Indent ______________________________________________________________B-40 Turkey-OCR B1 Indent _______________________________________________________________B-41 Yugoslavia-OCR B1 Indent ___________________________________________________________B-42 Ukraine-OCR B1 Indent ______________________________________________________________B-43 Cyrillic-OCR B1 Indent _______________________________________________________________B-44 Korea Visa Electron _________________________________________________________________B-45 Czech Visa Electron _________________________________________________________________B-46 Common European w/MasterCard Indent____________________________________________B-47 Portugal w/MasterCard Indent_______________________________________________________B-48 Greece w/MasterCard Indent _______________________________________________________B-49 Hungary w/MasterCard Indent_______________________________________________________B-50 Iceland w/MasterCard Indent _______________________________________________________B-51 Latvian w/MasterCard Indent________________________________________________________B-52 Poland w/MasterCard Indent ________________________________________________________B-53 Turkey w/MasterCard Indent _________________________________________________________B-54 Yugoslavia w/MasterCard Indent ____________________________________________________B-55
List of Figures
Figure 2-1: Unpacking/Packing ____________________________________________________________ 2-3 Figure 2-2: Included Packed Materials _____________________________________________________ 2-4 Figure 2-3: Packing Material Removal ______________________________________________________ 2-5 Figure 3-1: Preventive Maintenance Schedule______________________________________________ 3-4 Figure 3-2: Sensor Locations _______________________________________________________________ 3-5 Figure 3-3: Cleaning the Magnetic Stripe Head _____________________________________________ 3-6 Figure 3-4: Embossing Line Locations and Margins Card _____________________________________ 3-8 Figure 3-5: Start Sentinel and Track Locations for Magnetic Stripe ___________________________ 3-10 Figure 3-6: Wheel Test Card ______________________________________________________________ 3-12 Figure 4-1: Component Identification ______________________________________________________ 4-3 Figure 4-2: Inside View of the 150i __________________________________________________________ 4-4 Figure 4-3: Rear View of the 150i ___________________________________________________________ 4-5 Figure 4-4: Sequence of Operation ________________________________________________________ 4-7 Figure 4-5: 150i Embedded System Memory Layout _________________________________________ 4-8 Figure 4-6: 150i Main Control Board Block Diagram _________________________________________ 4-9 Figure 4-7: 150i Main Control Board Schematic (1 of 20) ____________________________________ 4-13 Figure 4-8: 150i Main Control Board Schematic (2 of 20) ____________________________________ 4-14
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Figure 4-9: 150i Main Control Board Schematic (3 of 20) ____________________________________ 4-15 Figure 4-10: 150i Main Control Board Schematic (4 of 20) ___________________________________ 4-16 Figure 4-11: 150i Main Control Board Schematic (5 of 20) ___________________________________ 4-17 Figure 4-12: 150i Main Control Board Schematic (6 of 20) ___________________________________ 4-18 Figure 4-13: 150i Main Control Board Schematic (7 of 20) ___________________________________ 4-19 Figure 4-14: 150i Main Control Board Schematic (8 of 20) ___________________________________ 4-20 Figure 4-15: 150i Main Control Board Schematic (9 of 20) ___________________________________ 4-21 Figure 4-16: 150i Main Control Board Schematic (10 of 20)__________________________________ 4-22 Figure 4-17: 150i Main Control Board Schematic (11 of 20)__________________________________ 4-23 Figure 4-18: 150i Main Control Board Schematic (12 of 20)__________________________________ 4-24 Figure 4-19: 150i Main Control Board Schematic (13 of 20)__________________________________ 4-25 Figure 4-20: 150i Main Control Board Schematic (14 of 20)__________________________________ 4-26 Figure 4-21: 150i Main Control Board Schematic (15 of 20)__________________________________ 4-27 Figure 4-22: 150i Main Control Board Schematic (16 of 20)__________________________________ 4-28 Figure 4-23: 150i Main Control Board Schematic (17 of 20)__________________________________ 4-29 Figure 4-24: 150i Main Control Board Schematic (18 of 20)__________________________________ 4-30 Figure 4-25: 150i Main Control Board Schematic (19 of 20)__________________________________ 4-31 Figure 4-26: 150i Main Control Board Schematic (20 of 20)__________________________________ 4-32 Figure 5-1 : Standard Test Card ___________________________________________________________ 5-10 Figure 5-2: Wheel Test Card ______________________________________________________________ 5-11 Figure 5-3: Topper Test Card______________________________________________________________ 5-12 Figure 4: Main Control Input/Output Block Diagram________________________________________ 5-18 Figure 5-5: Main Control Board Connections ______________________________________________ 5-19 Figure 5-6: Main Control Board Cable Connections ________________________________________ 5-20 Figure 5-7: AC Wiring Diagram____________________________________________________________ 5-21 Figure 5-8: Main Control Board LEDs_______________________________________________________ 5-39 Figure 5-9: Sensor Locations ______________________________________________________________ 5-40 Figure 6-1: Magnetic Stripe Head Height Adjustment________________________________________ 6-3 Figure 6-2: Rear Indent Drive Belt Adjustment _______________________________________________ 6-5 Figure 6-3: Interlock Switch Adjustment_____________________________________________________ 6-7 Figure 6-4: Display Contrast Adjustment ____________________________________________________ 6-9 Figure 7-1: Top Cover _____________________________________________________________________ 7-7 Figure 7-2: Front Access Panel _____________________________________________________________ 7-9 Figure 7-3: Single Card Access Door ______________________________________________________ 7-11 Figure 7-4: Output Hopper Door __________________________________________________________ 7-13 Figure 7-5: Key Lock _____________________________________________________________________ 7-15 Figure 7-6: Input/Output Hopper__________________________________________________________ 7-17 Figure 7-7: Output Hopper Drive Belt ______________________________________________________ 7-21 Figure 7-8: Output Hopper Drive O-Ring ___________________________________________________ 7-23 Figure 7-9: Card Registration Sensor_______________________________________________________ 7-25 Figure 7-10: Input Hopper Empty Sensor ___________________________________________________ 7-27 Figure 7-11: Input Home Sensor ___________________________________________________________ 7-29 Figure 7-12: Output Full Sensor ____________________________________________________________ 7-31 Figure 7-13: Card Picked Sensor __________________________________________________________ 7-33 Figure 7-14: Throat Gap Motor____________________________________________________________ 7-35 Figure 7-15: Throat Gap Motor Belt________________________________________________________ 7-37 Figure 7-16: Throat Gap Sensor ___________________________________________________________ 7-39 Figure 7-17: Card Transport _______________________________________________________________ 7-41 Figure 7-18: X-Transport Drive Belt _________________________________________________________ 7-43 Figure 7-19: X-Home Sensor_______________________________________________________________ 7-45 Figure 7-20: Y-Home Sensor_______________________________________________________________ 7-47 Figure 7-21: Card Transport Flex Cable ____________________________________________________ 7-49 Figure 7-22: Carriage Transport Motor _____________________________________________________ 7-51 Figure 7-23: Magnetic Stripe Assembly ____________________________________________________ 7-53
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Figure 7-24: Embosser ____________________________________________________________________ 7-55 Figure 7-25: Wheel Home Sensor __________________________________________________________ 7-57 Figure 7-26: Punch Home Sensor __________________________________________________________ 7-59 Figure 7-27: Punch Cam Motor ___________________________________________________________ 7-61 Figure 7-28: Punch Cam Belt _____________________________________________________________ 7-63 Figure 7-29: Die Home Sensor _____________________________________________________________ 7-65 Figure 7-30: Die Cam Motor ______________________________________________________________ 7-67 Figure 7-31: Die Cam Belt ________________________________________________________________ 7-69 Figure 7-32: Punch and Die_______________________________________________________________ 7-71 Figure 7-33: Topper Assembly _____________________________________________________________ 7-73 Figure 7-34: Topper Foil Motion Sensor_____________________________________________________ 7-75 Figure 7-35: Topper Platen Sensor _________________________________________________________ 7-77 Figure 7-36: Topper Motor ________________________________________________________________ 7-79 Figure 7-37: Main Control Board __________________________________________________________ 7-81 Figure 7-38: Power Supply ________________________________________________________________ 7-83 Figure 7-39: Line Filter ____________________________________________________________________ 7-85 Figure 7-40: Fuse_________________________________________________________________________ 7-87 Figure 7-41: Fan _________________________________________________________________________ 7-89 Figure 7-42: Display/Keypad______________________________________________________________ 7-91 Figure 7-43: Solenoid Lock Assembly ______________________________________________________ 7-93 Figure 7-44: Reject Full Sensor_____________________________________________________________ 7-95 Figure 7-45: Front Smart Card Module _____________________________________________________ 7-97 Figure 7-46: Front Indent Printer Module ___________________________________________________ 7-99 Figure 7-47: Replacing the Front Indent Ribbon ___________________________________________7-101 Figure 7-48: Rear Indent Printer Module __________________________________________________7-103 Figure 7-49: Replacing the Rear Indent Ribbon ___________________________________________7-105 Figure 7-50: Rear Indent Motor __________________________________________________________7-107 Figure 7-51: Rear Indent Drive Belt _______________________________________________________7-109 Figure 7-52: Rear Indent Solenoid ________________________________________________________7-111
List of Tables
Table 1-1: Magnetic Stripe Encoding Specifications_________________________________________ 1-6 Table 2-1: Installation Materials and Special Tools ___________________________________________ 2-2 Table 3-1: Preventive Maintenance Schedule ______________________________________________ 3-2 Table 3-2: Line Location and Margins Checklist _____________________________________________ 3-8 Table 3-3: Even and Uniform Topping Checklist ____________________________________________ 3-11 Table 5-1: Keypad Navigation _____________________________________________________________ 5-5 Table 5-2: Sensor Bit Locations _____________________________________________________________ 5-6 Table 5-3: Test Card Menu ________________________________________________________________ 5-9 Table 5-4 : Smart Card Test Messages _____________________________________________________ 5-11 Table 5-5: Position Offsets Menu __________________________________________________________ 5-14 Table 5-6: Wheel Parameters Menu _______________________________________________________ 5-15 Table 5-7: Spacing and Character Type___________________________________________________ 5-15 Table 5-8: Topper Parameters Menu ______________________________________________________ 5-16 Table 5-9: Configuration Menu ___________________________________________________________ 5-16 Table 5-10: Status Request Menu _________________________________________________________ 5-17 Table 5-11: Motor Pin-Outs for Connector J10______________________________________________ 5-22 Table 5-12: Motor Pin-Outs for Connector J11______________________________________________ 5-23 Table 5-13: Sensor Pin-Outs for Connector J12 _____________________________________________ 5-24 Table 5-14: Sensor Pin-Outs for Connector J13 _____________________________________________ 5-25
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Table 5-15: Serial Communications Pin-Outs (J16) __________________________________________ 5-26 Table 5-16: Error Code Troubleshooting Chart______________________________________________ 5-32 Table 5-17: Main Control Board LEDs ______________________________________________________ 5-38 Table 6-1: Keypad Navigation ____________________________________________________________ 6-10 Table 6-2: Position Offsets Menu __________________________________________________________ 6-11 Table 6-3: Pick Offset ____________________________________________________________________ 6-13 Table 6-4: Smart Card Offset _____________________________________________________________ 6-14 Table 6-5: MagStripe NTT Offset ___________________________________________________________ 6-15 Table 6-6: MagStripe Standard Offset _____________________________________________________ 6-17 Table 6-7: MagStripe Variables Offset _____________________________________________________ 6-19 Table 6-8: Emboss Location Offset ________________________________________________________ 6-20 Table 6-9: Topper Offset__________________________________________________________________ 6-21 Table 6-10: Topper Noise Offset ___________________________________________________________ 6-22 Table 6-11: Exit Offset ____________________________________________________________________ 6-23 Table 6-12: Emboss Height Offset _________________________________________________________ 6-24 Table 6-13: Indent Depth Offset __________________________________________________________ 6-25 Table 6-14: Throat Gap Offset ____________________________________________________________ 6-26 Table 6-15: Wheel Home Offset ___________________________________________________________ 6-27 Table 6-16: Card Bow Offset______________________________________________________________ 6-28
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Revision Log 150i Card Personalization System Maintenance Manual
Revision A Date May 2001 Affected Pages All Description of Changes First release of this document. Information was originally delivered as an online help file. Added Chapter 8, Illustrated Parts Breakdown to his manual.
B
June 2001
Chapter 8
Regulatory Compliance
Notice for USA (FCC Notice)
This equipment generates, uses, and can radiate radio frequency energy. If it is not installed and used in accordance with this instruction manual, it may interfere with radio communications. This equipment has been tested and found to be within the limits for Class A computing devices, pursuant to Title 47 CFR Part 15 Subpart B of FCC rules, designed to provide reasonable protection against radio interference in a commercial environment. Operation of this equipment in a residential environment may possibly cause interference. In the event of interference, the users, at their own expense, will be required to take whatever measures are necessary to correct the problem.
Notice for Canada (CUL)
This digital apparatus does not exceed the Class A limits for radio noise for digital apparatus set out in the Radio Interference Regulations of the Canadian Department of Communications. Le présent appareil numérique n'émet pas de bruits radioélectriques dépassant les limites applicables aux appareils numériques de la classe A prescrites dans le Règlement sur le brouillage radioélectrique édicté par le ministère des Communications du Canada.
Notice for Europe
See the Declaration of Conformity on the following page.
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Safety
All Datacard products are built to strict safety and reliability specifications in accordance with UL1950 and EN60950, therefore, safety issues pertaining to operation and repair of Datacard equipment are primarily environmental and human interface. The following basic safety tips are given to ensure safe installation, operation and maintenance of Datacard equipment and are not to be considered as comprehensive on all matters of safety.
Safe Environment
· · · · · · ·
Connect equipment to a grounded facility power source. Do not defeat or bypass the ground lead. Place the equipment on a stable surface (table), and ensure floors in work area are dry and non-slip. Insulated rubber floor mats are preferred. Know the location of equipment branch circuit interrupters or circuit breakers and how to turn them on and off in case of emergency. Know the location of fire extinguishers and how to use them. Use only ABC type extinguishers on electrical fires. Know local procedures for first aid and emergency assistance at the customer facility. Use adequate lighting at the equipment. Maintain the recommended range of temperature and humidity in equipment area.
Safe Human Interface
· · ·
Use proper lifting techniques when moving or installing the equipment. Use standard electrostatic discharge (ESD) precautions when working on or near electrical circuits. Do not defeat or disconnect safety interlocks on covers.
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