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Chapter 1: System Description
The 150i Card Personalization System operates as a standalone card embosser. This chapter provides a system description of the 150i embosser. 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
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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
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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.
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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.
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Product Specifications
Electrical
·
90-264V AC at 4A, 50/60Hz (Single phase, 3 wire grounded receptacle only)
Environmental
· · · · ·
Noise level: Relative humidity: Maximum heat dissipation: Operating temperature range: ESD susceptibility:
Less than 60dB 20% to 85% non-condensing 1,195 BTU/Hour 60° F to 90° F (15° C to 32° C) The 150i can withstand an ESD discharge of 15kV, 330pF storage and 1.5K ohm series resistance in test simulating a human discharge to the machine's outer surfaces.
Communications
· · · · · ·
RS-232 service port RS-232 host port Smart card 1 port Smart card 2 port Diagnostic port Development port
Card Capacities
Input Hopper Capacity
· · ·
100 cards (automatic card feed) Up to 10 cards Up to 15 cards
Reject Hopper Capacity Output Hopper Capacity
Topper Cassette Capacity
·
1,600 cards (minimum)
Protocols
·
Supports CPX
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System Description
Physical Specifications
· · · ·
Width: Depth: Height: Weight:
24 inches (61.0 cm) 15.5 inches (35.6 cm) 11 inches (25.4 cm) 70 pounds. (31.8 kg)
Card Specifications
The 150i supports only CR80 plastic cards. Dimensions: Length: 3.375 inches (85.7 mm) Height: 2.125 inches (54.0 mm) Thickness: 0.030 ±0.010 inches (0.76 mm) Any gloss or matte finish Any color except clear 0.060 inches maximum from flat PVC laminated or unlamented Optional Standard coercivity: 300 to 600 Oe. ± 1.0% High coercivity, reference ISO/IEC 7811 Part 6
Finish: Color: Bow: Material: IC (Smart Card): Magnetic Stripe:
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Magnetic Stripe Encoding Specifications
The following table gives encoding specifications for magnetic stripe encoding used on the 150i. Table 1-1: Magnetic Stripe Encoding Specifications Track Number
Track 1 (IATA)*** Track 2 (ABA)*** Track 3 (TTS)*** NTT-J1 NTT-J2
Start Bit
(inches) 0.293 ±0.020 0.293 ±0.020 0.293 ±0.40 0.296 ±0.020 0.296 ±0.020
Position*
(millimeters) (7.44 ±0.51) (7.44 ±0.51) (7.44 ±1.02) (6.00 ±0.51) (6.00 ±0.51)
Skew Angle
0° ±20' 0° ±20' 0° ±20' 0° ±10' 0° ±10'
Track
(Max Top in inches) 0.223 0.353 0.493 0.236 0.236
Location**
(Min Bottom in inches) 0.333 0.463 0.603 0.472 0.472
BPI
210 ±8% 75 ±5% 210 ±8% 210 ±8% 210 ±8%
* Start Bit Position is referenced from the right edge of the card as viewed from the magnetic stripe side. ** Track Location is referenced from the top edge of the card. *** Track 1 (IATA) = 76 maximum data characters. *** Track 2 (ABA) = 37 maximum data characters. *** Track 3 (TTS) = 104 maximum data characters. Maximum data characters do not include start, end sentinels, and LCR characters. All magnetic stripe specifications are per ISO 7811-2, 7811-4, and 7811-5.
Standard Financial Emboss Line Locations
L1 L2 L3 L4 L5 = 7CPI = 10CPI = 10CPI = 10CPI = 10CPI V = 0.843 ±0.005 inches OCR V = 0.646 ±0.005 inches 1st AN V = 0.488 ±0.005 inches 2nd AN V = 0.332 ±0.005 inches 3rd AN V = 0.175 ±0.005 inches 4th AN
All lines have a left margin of 0.401 ±0.010 inch. V is the distance from the bottom of the card to the center of the character.
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System Description
Standard Emboss Character Height
OCR Farrington 7B AN Indent Characters Indent Punctuation 7 Characters per inch 0.016 to 0.019 inches 10 Characters per inch 0.015 to 0.018 inches 0.001 to 0.005 inches 0.001 to 0.007 inches
Standard Emboss Character Spacing
OCR Farrington 7B AN Indent Characters Indent Punctuation 7 Characters per inch 0.143 ±0.006 inches 10 Characters per inch 0.100 ±0.006 inches ±0.006 inches ±0.006 inches
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System Description