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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). The solenoid to open the Top Cover will be energized for 5 seconds. The Message "OPEN COVER!" is displayed. If the password is entered incorrectly, "ACCESS DENIED!" is displayed. To reenter the correct password, press *0 followed by the correct password. To open the Top Cover using a key, insert the key in the keyhole and turn it clockwise ¼ turn.
R
·
·
150i
7-4
Removal and Replacement
Changing the Password
The default password shipped from the factory for the 150i is *00000. The password can be changed by doing the following:
Change Password Code
*1[0000][5555]
Old Password New Password
Enter *1 (change password code) followed by the current password and then the new password. For example, to change the default password 0000 to 5555, enter *100005555. In this example, the keystrokes to open the Top Cover again using the new password would be *05555. If you do not remember your current password, use the key or contact your Datacard Service Representative for information on how to reset it. By entering the 8 digit Financial Card Password enable, the Top Cover access will be reset to the 0000 default password.
150i Card Personalization System Maintenance Manual
7-5
Top Cover
The Top Cover can be locked to protect unauthorized access to the inside of the 150i. Use the following procedure to remove and replace the Top Cover. Tools
· · · ·
Phillips screwdriver #10 Torx driver 11/32 inch nut driver 5/16 inch nut driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Remove four nuts (1 in Figure 7-1) holding the two ribbon cable straps (2) 4. Disconnect Display Cable connector P4 (3) and place the cable inside the 150i. 5. Remove one nut (4) holding the cover grounding strap and place inside the 150i. 6. Loosen two screws (5) retaining the cover holding pins (left-hand side of the 150i). 7. Manually rotate the Card Transport carriage lead screw to the left-hand side of the 150i. 8. Loosen one screw (6) that retain the cover holding pins. 9. Remove four Phillips screws (7)holding the right Top Cover bracket and the Input Hopper shield (8). Fold the hinge out of the way. 10. Remove three Phillips screws (9) holding the left Top Cover bracket. Fold the hinge out of the way. 11. Close the Top Cover and remove the three cover holding pins (10). 12. Remove the Top Cover. Replace 1. Transfer the Display/Keyboard, Key Lock and the Alignment Pin bracket for the old Top Cover over to the new Top Cover (see Display/Keypad and Key Lock). 2. Place the Top Cover on the 150i. Insert and center the cover holding pins so the screws align with the cover holding pin groves. Tighten all three screws to retain the cover holding pins. 3. Lift up the Top cover and place the left Top Cover bracket in place, securing it with three screws. 7-6 Removal and Replacement
4. Place the right Top Cover bracket and the Input Hopper shield in place and attach with four screws. 5. Place the grounding strap in position and attach with one nut. 6. Reconnect the Display Cable to P4. 7. Replace the ribbon cable straps and attach with four screws. 8. Ensure that the Top Cover opens and closes properly with no binding. 9. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
4 3
2 (2x) 1 (4x)
9 (3x)
5 (2x)
6 10 (3x)
8 7 (4x)
Figure 7-1: Top Cover
150i Card Personalization System Maintenance Manual
7-7
Front Access Panel
The Front Access Panel is used to restrict access to the Main Control Board. Use the following procedure to remove and replace the Front Access Panel. Tools
·
#20 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. The Topper Platen May Be Very Hot. 3. Lift up on the Topper Solenoid Ring and remove the Topping Foil Cassette. 4. Loosen two screws (1 in Figure 7-2) but do not remove, then remove the Front Access Panel (2). Replace 1. Place the Front Access Panel in position and tighten two screws. 2. Plug in the power cord and power ON the 150i. 3. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-8
Removal and Replacement
1 (2x)
2
Figure 7-2: Front Access Panel
150i Card Personalization System Maintenance Manual
7-9
Single Card Access Door
The Single Card Access Door is used to insert one plastic card at a time for embossing. Use the following procedure to remove and replace the Single Card Access Door. Tools
·
#20 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Open the Single Card Access Door (1 in Figure 7-3) and remove two screws (2) securing the door to the base of the cabinet. 4. Lift the access door so the door arms (3) are in a vertical position. Squeeze the access door arms together to remove them from the access door guides (4). Replace 1. Place the new Single Card Access Door in position and attach with two screws. Check the door for proper movement and alignment. 2. Plug in the power cord and power ON the 150i. 3. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-10
Removal and Replacement
3
4 4
3
2 (2x) 1
Figure 7-3: Single Card Access Door
150i Card Personalization System Maintenance Manual
7-11
Output Hopper Door
The Output Hopper Door holds cards that have been produced by the 150i. Use the following procedure to remove and replace the Output Hopper Door. Tools
· ·
#10 Torx driver #20 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Remove two screws (1 in Figure 7-4) attaching the Output Hopper Door (2) to the base of the 150i. 4. Remove two screws (3) from the pivot arm block (4) and remove Output Hopper Door. Replace 1. Place the new pivot arm block in position and attach with two screws. 2. Position the Output Hopper Door in place and attach with two screws. Check the door for proper movement and alignment. 3. Plug in the power cord and power ON the 150i. 4. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-12
Removal and Replacement
Inside View Of Output Door
2
1 3 1 4 3
Figure 7-4: Output Hopper Door
150i Card Personalization System Maintenance Manual
7-13
Key Lock
The Key Lock is designed to secure the top cover preventing unauthorized access to the inside of the cabinet Use the following procedure to remove and replace the Key Lock. Tools
·
Adjustable crescent wrench
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Remove the Paddle Nut (1 in Figure 7-5) and the Paddle (2) from the Key Lock. 4. Remove the Key Lock Securing Nut (3) and remove the Key Lock (4) from the Top Cover. Replace 1. Place the new Key Lock on the Top Cover and screw on the Securing Nut. 2. Place the Paddle on the Key Lock and screw on the Paddle Nut. 3. Plug in the power cord and power ON the 150i. 4. Test the Key Lock using a key and also by using the password control to open the Top Cover. (see Opening the Top Cover.) 5. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-14
Removal and Replacement
2 3 4
1
Figure 7-5: Key Lock
150i Card Personalization System Maintenance Manual
7-15
Input/Output Hopper
The Input/Output Hopper is a main assembly used for stacking cards (or a single card) to be embossed and as an output receptacle for completed cards. Use the following procedure to remove and replace the Input/Output Hopper. Tools
· ·
¼ inch box wrench #20 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually rotate the Card Transport carriage lead screw to the center of the 150i. 4. Remove the Input Hopper card weight and all cards from the 150i. 5. Remove the Single Card Access Door. 6. Remove two screws (1 in Figure 7-6) and remove the Input/Output Hopper holding plate (2). 7. Open the Output Hopper Door. 8. Loosen the rear mounting screw (3) and rotate the hold down plate (4) 180 degrees and partially remove the Input/Output Hopper from the base to gain access to the cable connectors. Remove cable ties as necessary. 9. Disconnect the following cable connectors:
· · · · · · · ·
Motor Cable (5) Input Empty Sensor (6) Input Home Sensor (7) Card Picked Sensor (8) Card Registration Sensor (9) Output Full Sensor (10) Throat Gap Motor (11) Throat Gap Sensor (12)
10. Lift the Input/Output Hopper from the 150i.
7-16
Removal and Replacement
12 11 10 5 9 8 7 1 (2x) 2 6
3
4
Figure 7-6: Input/Output Hopper
150i Card Personalization System Maintenance Manual
7-17
Replace 1. Partially place the new Input/Output Hopper in position. 2. Reconnect the following inline connectors:
· · · · · · · ·
Motor Cable (5) Input Empty Sensor (6) Input Home Sensor (7) Card Picked Sensor (8) Card Registration Sensor (9) Output Full Sensor (10) Throat Gap Motor (11) Throat Gap Sensor (12)
3. After connecting the inline connectors, place the new Input/Output Hopper in position and rotate the hold down back into place, then tighten the rear mounting screw. 4. Place the Input/Output Hopper holding plate in position and attach with two screws. 5. Replace the Single Card Access Door. 6. Replace any cable ties that were removed. Make sure wires are not pinched. Secure wires with tie wraps. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 7. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-18
Removal and Replacement
12 11 10 5 9 8 7 1 (2x) 2 6
3
4
150i Card Personalization System Maintenance Manual
7-19
Output Hopper Drive Belt
The Output Hopper Drive Belt provides movement to transport an embossed card into the Output Hopper. Use the following procedure to remove and replace the Output Hopper Drive Belt. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Open the Output Hopper Door. 4. Remove one screw (1 in Figure 7-7) holding the upper Output Guide Card Transport Drive Roller (2) and remove the roller. 5. Slip the Output Hopper Drive Belt (3) off the Output Hopper drive motor pulley and remove the belt from the assembly. Replace 1. Place the new Output Hopper Drive Belt in position. 2. Replace the upper output guide Card Transport drive roller in position and hold in place with one screw. 3. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-20
Removal and Replacement
2 1
3
Input/Output Hopper
Figure 7-7: Output Hopper Drive Belt
150i Card Personalization System Maintenance Manual
7-21
Output Hopper Drive O-Ring
The Output Hopper Drive O-Rings provide traction for moving an embossed card into the Output Hopper. Use the following procedure to remove and replace the Output Hopper Drive O-Ring. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Open the Output Hopper Door. 4. Remove one screw (1 in Figure 7-8) holding the upper Output Guide Card Transport Drive Roller (2). This will allow better access for the removal of the Output Hopper Drive O-Rings (3). 5. Roll all four Output Hopper Drive O-Rings off from the upper and lower Output Hopper drive rollers. Replace 1. Place all new Output Hopper Drive O-Rings on the upper and lower Output Hopper drive rollers. 2. Place the upper output guide Card Transport drive roller in position and hold in place with one screw. 3. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-22
Removal and Replacement
2 1
3
Input/Output Hopper
Figure 7-8: Output Hopper Drive O-Ring
150i Card Personalization System Maintenance Manual
7-23
Card Registration Sensor
The Card Registration Sensor detects when a card first enters the 150i. Use the following procedure to remove and replace the Card Registration Sensor. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Open the Output Hopper Door for better access. 4. Remove the Output Hopper Drive Belt (1 in Figure 7-9) from the drive motor pulley. 5. Disconnect the Output Full Sensor cable connector (2) and the Card Registration Sensor cable connector (3). Cut cable ties as necessary. 6. Remove four screws (4) holding the Card Transport Drive assembly. 7. Remove two screws (5) holding the Card Registration Sensor (6) and remove the sensor from the Card Transport assembly. Replace 1. Place the new Card Registration Sensor in position with emitter pointing down and attach with two screws. 2. Place the Card Transport Drive assembly in place and attach with four screws. 3. Place the Output Hopper Drive Belt back on the drive motor pulley. 4. Connect the Output Full Sensor and the Card Registration Sensor cable connectors. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 5. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-24
Removal and Replacement
6
5 (2x)
2 3
4 (4x) 1
Figure 7-9: Card Registration Sensor
150i Card Personalization System Maintenance Manual
7-25
Input Hopper Empty Sensor
The Input Hopper Empty Sensor detects when the Input Hopper has no more cards. Use the following procedure to remove and replace the Input Hopper Empty Sensor. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Open both input and output doors for better accessibility. 4. Disconnect the Input Hopper Empty Sensor cable connector (1 in Figure 7-10). Cut cable ties as necessary. 5. Remove one screw (2) holding the Input Hopper Empty Sensor (3) to the Input/Output Hopper assembly and remove the sensor. Replace 1. Place the new Input Hopper Empty Sensor in position and attach with one screw. 2. Reconnect the Input Hopper Empty Sensor connector. 3. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 4. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-26
Removal and Replacement
1 3 2
Figure 7-10: Input Hopper Empty Sensor
150i Card Personalization System Maintenance Manual
7-27
Input Home Sensor
The Input Home Sensor detects when the card picking mechanism is at its home position. Use the following procedure to remove and replace the Input Home Sensor. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually rotate the Card Transport carriage lead screw to the center of the 150i. 4. Open both input and output doors for better accessibility. 5. Disconnect the Input Home Sensor cable connector (1 in Figure 7-11). Remove cable ties as necessary. 6. Remove one screw (2) holding the Input Home Sensor (3) to the Input/Output Hopper assembly. Replace 1. Place the new Input Home Sensor in position and attach with one screw. 2. Reconnect the Input Home Sensor connector. 3. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 4. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-28
Removal and Replacement
3 2 1
Figure 7-11: Input Home Sensor
150i Card Personalization System Maintenance Manual
7-29
Output Full Sensor
The Output Full Sensor detects when the Output Hopper is full of embossed cards and should be emptied. Use the following procedure to remove and replace the Output Full Sensor. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Open both input and output doors for better accessibility. 4. Disconnect the Output Full Sensor cable connector (1 in Figure 7-12). Remove cable ties as necessary. 5. Remove one screw (2) holding the Output Full Sensor (3) to the Input/Output Hopper assembly. Replace 1. Place the new Output Full Sensor in position and attach with one screw. 2. Reconnect the Output Full Sensor connector. 3. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 4. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-30
Removal and Replacement
2
3
1
Figure 7-12: Output Full Sensor
150i Card Personalization System Maintenance Manual
7-31
Card Picked Sensor
The Card Picked Sensor detects when a card has been selected by the card picking mechanism. Use the following procedure to remove and replace the Card Picked Sensor. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Disconnect the Card Picked Sensor cable connector (1 in Figure 7-13). Remove cable ties as necessary. 4. Remove one screw (2) holding the Card Picked Sensor (3) to the Input/Output Hopper assembly and remove the sensor from the 150i. Replace 1. Place the new Card Picked Sensor in position and attach with one screw. 2. Reconnect the Card Picked Sensor connector. 3. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 4. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-32
Removal and Replacement
3
2
1
Figure 7-13: Card Picked Sensor
150i Card Personalization System Maintenance Manual
7-33
Throat Gap Motor
The Throat Gap Motor provides movement to the throat gap mechanism to accommodate preembossed card. Use the following procedure to remove and replace the Throat Gap Motor. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Disconnect the TG Motor cable connector (1 in Figure 7-14). Remove cable ties as necessary. 4. Remove two screws (2) holding the Throat Gap Motor (3) and the ground wire (4) to the Input/Output Hopper assembly. 5. Move the Throat Gap Motor away from the Throat Gap Motor drive belt (5) to allow removal of the motor. Replace 1. Place the new Throat Gap Motor in place and attach with two screws. Make sure to attach the ground wire. Make sure the Throat Gap Motor drive belt is positioned properly on the motor shaft and pulley. 2. Reconnect the TG Motor connector. 3. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 4. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-34
Removal and Replacement
2 4
2
3
5 1
Figure 7-14: Throat Gap Motor
150i Card Personalization System Maintenance Manual
7-35
Throat Gap Motor Belt
The Throat Gap Motor Belt provides a means to move the throat gap mechanism to accommodate pre-embossed card. Use the following procedure to remove and replace the Throat Gap Motor Belt. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. Remove cable ties as necessary. 3. Remove two screws (1 in Figure 7-15) holding the Throat Gap Motor (2) and the ground wire (3) to the Input/Output Hopper assembly. 4. Move the Throat Gap Motor (3) away from the Throat Gap Motor Belt (4) to allow removal of the motor. 5. Remove the Throat Gap Motor Belt. Replace 1. Position the new belt over the motor shaft and pulley, then attach the Throat Gap Motor with two screws. Make sure to attach the ground wire. Make sure the Throat Gap Motor drive belt is positioned properly on the more shaft and pulley. 2. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 3. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-36
Removal and Replacement
1 3
1
2
4
Figure 7-15: Throat Gap Motor Belt
150i Card Personalization System Maintenance Manual
7-37
Throat Gap Sensor
The Throat Gap Sensor detects when the throat gap mechanism has reached its home position. Use the following procedure to remove and replace the Throat Gap Sensor. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually move the Card Transport carriage to the left-hand side of the 150i. 4. Disconnect the Throat Gap Sensor cable connector (1 in Figure 7-16). Remove cable ties as necessary. 5. Remove one screw (2) holding the Throat Gap Sensor (3) to the Input/Output Hopper assembly. Replace 1. Place the new Throat Gap Sensor in position and attach with one screw. 2. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 3. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-38
Removal and Replacement
1 2
3
Figure 7-16: Throat Gap Sensor
150i Card Personalization System Maintenance Manual
7-39
Card Transport
The Card Transport consists of a screw mechanism for moving a card through different stages of production to produce a final card. Use the following procedure to remove and replace the Card Transport. Tools
· ·
#10 Torx driver #20 Torx driver
Remove 4. Unlock and lift up the Top Cover (see Opening the Top Cover). 5. Power OFF the 150i and remove the power cord from the wall outlet. 6. Manually rotate the Card Transport carriage lead screw so the Y-Transport is centered between the Embosser Wheel and the Magnetic Stripe Head. Make sure not to crimp or damage the Card Transport Flex Cable. 7. Remove two screws (1 in Figure 7-17) holding the Card Transport Flex Cable retaining clamp (2). Remove cable ties as necessary. 8. Disconnect the following cable connectors:
· ·
Card Transport Flex Cable (3) Transport Lead Screw Motor (4)
9. Remove two screws (5) holding the Card Transport (6). 10. Lift up and move the Card Transport to the right. Tilt the Card Transport towards the front of the 150i, then lift the Card Transport up to remove. Replace 11. Place the new Card Transport on the locating pins on the base of the 150i and attach with two screws. Make sure to include one grounding wire when attaching the left-hand screw. 12. Reconnect the following cable connectors.
· ·
Card Transport Flex Cable (3) Transport Lead Screw Motor (4)
13. Place the new Cable Transport Flex Cable retaining clamp in position and attach with two screws.
7-40
Removal and Replacement
14. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 15. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
Figure 7-17: Card Transport
150i Card Personalization System Maintenance Manual
7-41
X-Transport Drive Belt
The X-Transport Drive Belt drives the transport screw mechanism for moving cards through the 150i. Use the following procedure to remove and replace the X-Transport Drive Belt. Tools
·
#20 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually rotate the Card Transport carriage lead screw so the Y-Transport is on the lefthand side of the 150i. 4. Remove two screws (1 in Figure 7-18) holding the X-Transport Drive Motor (2). 5. Remove the X Transport Drive Belt (3) from the Card Transport (4) assembly. Replace 1. Place the new X-Transport Drive Belt in position and attach the X-Transport Drive Motor with two screws. Make sure belt tension is sufficient to ensure that no slippage will occur. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 2. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-42
Removal and Replacement
1
2
3
Figure 7-18: X-Transport Drive Belt
150i Card Personalization System Maintenance Manual
7-43
X-Home Sensor
The X-Home Sensor detects when the X card transport mechanism is at its home position. Use the following procedure to remove and replace the X-Home Sensor. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually rotate the Card Transport carriage lead screw to the center of the 150i. 4. Disconnect the X-Home Sensor cable connector (1 in Figure 7-19). 5. Remove one screw (2) holding the X-Home Sensor (3) to the base of the 150i. Replace 1. Place the new X-Home Sensor in position and attach with one screw. 2. Reconnect the X-Home Sensor connector. Make sure wires are not pinched. Make sure connector and wires will not interfere with any mechanical movement inside the 150i. Make sure the sensor is correctly positioned so the sensing flag will not hit it. 3. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-44
Removal and Replacement
Figure 7-19: X-Home Sensor
150i Card Personalization System Maintenance Manual
7-45
Y-Home Sensor
The Y-Home Sensor detects when the Y card transport mechanism is at its home position. Use the following procedure to remove and replace the Y-Home Sensor. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually rotate the Card Transport carriage lead screw to the center of the 150i. Remove cable ties as necessary. 4. Disconnect Y-Home Sensor cable connector (1 in Figure 7-20). 5. Remove one screw (2) holding the Y-Home Sensor (3). Replace 1. Place the new Y-Home Sensor in position and attach with one screw. 2. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure the connector and wires will not interfere with any mechanical movement inside the 150i. Make sure the sensor is correctly positioned so the sensing flag will not hit it. 3. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-46
Removal and Replacement
Figure 7-20: Y-Home Sensor
150i Card Personalization System Maintenance Manual
7-47
Card Transport Flex Cable
The Card Transport Flex Cable provides a means to power the Y-Transport Motor and communication with the Y-Home Sensor. Use the following procedure to remove and replace the Card Transport Flex Cable. Tools
· · ·
Hex key set #10 Torx driver #20 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Remove two screws (1 in Figure 7-21) and remove the Cable Plate (2) from the 150i base. 4. Remove one screw (3) and remove the Flex Cable Holding Plate (4). Remove cable ties as necessary. 5. Remove two screws (5) and remove the Cable Holding Clamp (6). 6. Remove one screw (7), one nut (8) and the Top Cover Grounding Wire (9) on the lefthand side of the Inner Fan Guard (10). 7. Manually rotate the Card Transport lead screw to the left-hand side of the 150i. 8. Remove one screw (11) from the right-hand side of the Inner Fan Guard, then lift the Inner Fan Guard out. 9. Disconnect the Card Transport Flex Cable (12) at both ends. 10. Peel the flex cable from the back panel, then completely remove it from the 150i. Replace 1. Place the new Card Transport Flex Cable in place making sure it adheres to the back panel of the 150i. 2. Reconnect both ends of the flex cable to their connectors. 3. Make sure the Cable Back Plate is against the back panel of the 150 and attach it with one screw. 4. Placed the Cable Holding Clamp in position and attach with two screws.
7-48
Removal and Replacement
5. Place the Inner Fan Guard in position and attach with one screw and one nut on the lefthand side. Make sure to attach the Top Cover Grounding Wire. On the right-hand side, attach with one screw. 6. Place the Cable Plate in position and attach with two screws. 7. Replace any cable ties that were removed. 8. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
Figure 7-21: Card Transport Flex Cable
150i Card Personalization System Maintenance Manual
7-49
Carriage Transport Motor
The Carriage Transport consists of a screw mechanism for moving cards in the Y-axis through different stages of production to produce a final card. Use the following procedure to remove and replace the Carriage Transport Motor. Tools
· ·
#10 Torx driver #20 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually rotate the Card Transport carriage lead screw so the Y-Transport is centered between the Embosser Wheel and the Magnetic Stripe Head. Make sure not to crimp or damage the Card Transport Flex Cable. 4. Remove two screws (1 in Figure 7-22) holding the Card Transport (2). Remove cable ties as necessary. 5. Disconnect the Carriage Transport Motor connector (3). 6. Carefully lift up and tilt the Card Transport towards the front of the 150i, but do not remove. 7. Remove two screws (4) holding the Carriage Transport Motor (5). 8. Remove the Carriage Transport Motor Belt (6) from the motor pulley, and then remove the Carriage Transport Motor. Replace 1. Place the new Carriage Transport Motor in place making sure the Carriage Transport Motor Belt is in position, and then tighten the two mounting screws. 2. Place the Card Transport on the locating pins on the base of the 150i and attach with two screws. Make sure to include one grounding wire when attaching the left-hand screw. 3. Reconnect the Carriage Transport Motor connector. 4. Replace any cable ties that were removed.
7-50
Removal and Replacement
Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 5. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
Figure 7-22: Carriage Transport Motor
150i Card Personalization System Maintenance Manual
7-51
Magnetic Stripe Assembly
The Magnetic Stripe Assembly head reads and writes data on the magnetic stripe on a card. Use the following procedure to remove and replace the Magnetic Stripe Assembly. Tools
·
Hex key set
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Open up the Output Tray for better access to the connectors. Remove cable ties as necessary. 4. Disconnect the following cable connectors:
· ·
Magnetic Stripe Head Cable (1 in Figure 7-23) Encoder Cable (2)
5. Remove one screw (3) and the ground wire (4) attaching the Magnetic Stripe Assembly (5) to the 150i base. Replace 1. Place the new Magnetic Stripe Assembly in position and attach with one screw. Make sure to ground wire is also attached. 2. Reconnect the following cable connectors:
· ·
Magnetic Stripe Head Cable (1) Encoder Cable (2)
3. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. Make sure the Magnetic Stripe module is aligned parallel to the 150i base casting. 4. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-52
Removal and Replacement
Follow-up Adjustments This remove and replace procedure affects the following adjustments which must be performed after this procedure.
· · ·
Magnetic Stripe Start Sentinel Offset Magnetic Stripe Head Height Adjustment Magnetic Stripe Track Location Offset
Figure 7-23: Magnetic Stripe Assembly
150i Card Personalization System Maintenance Manual
7-53
Embosser Assembly
The Embosser Assembly, comprised of two rotating disks of punches and dies, provides a means to make embossed characters on a plastic card. Use the following procedure to remove and replace the Embosser Assembly. Tools
·
#20 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Open up the Output Tray for better access to the connectors. The Topper Platen May Be Very Hot. 4. Lift up on the Topper Solenoid Ring and remove the Topping Foil Cassette. Remove cable ties as necessary. 5. Disconnect the following cable connectors:
· · · · · ·
Wheel Home Sensor (1 Figure 7-24) Die Home Sensor (2) Die Motor (3) Wheel Motor (4) Punch Motor (5) Punch Home Sensor (6)
6. Remove three mounting screws (7) attaching the Embosser to the 150i base. The front Embosser mounting screw can be removed by spreading unused emboss wheel fingers. 7. Lift and remove the Embosser. Replace 1. Place the new Embosser in position and attach with three screws. 2. Reconnect the following cable connectors:
· · · · · ·
Wheel Home Sensor (1) Die Home Sensor (2) Die Motor (3) Wheel Motor (4) Punch Motor (5) Punch Home Sensor (6) Removal and Replacement
7-54
3. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 4. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification. When a new Embosser is installed, verify that all special punches and dies are installed on the new Embossing Wheel.
5 7 1 3
2 6 7 7 4
Figure 7-24: Embosser
150i Card Personalization System Maintenance Manual
7-55
Wheel Home Sensor
The Wheel Home Sensor detects when the embossing wheel is at its home position. Use the following procedure to remove and replace the Wheel Home Sensor. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. Remove cable ties as necessary. 3. Disconnect the Wheel Home Sensor cable connector (1 in Figure 7-25). 4. Remove one screw (2) and remove the Wheel Home Sensor (3). Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 5. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification. Replace 1. Place the new Wheel Home Sensor in position and attach with one screw. 2. Reconnect the Wheel Home Sensor cable connector. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 3. Replace any cable ties that were removed. 4. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification. Follow-up Adjustments This remove and replace procedure affects the following adjustments which must be performed after this procedure.
·
Wheel Offset
7-56
Removal and Replacement
2
1
3
Figure 7-25: Wheel Home Sensor
150i Card Personalization System Maintenance Manual
7-57
Punch Home Sensor
The Punch Home Sensor detects when the punch cam has returned to its home position. Use the following procedure to remove and replace the Punch Home Sensor. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. Remove cable ties as necessary. 3. Remove the Embosser Assembly far enough to gain access to the Punch Home Sensor. 4. Disconnect the Punch Home Sensor (1 in Figure 7-26) cable connector: 5. Remove one screw (2) and remove the Punch Home Sensor (3). Replace 1. Place the new Punch Home Sensor in position and attach with one screw. 2. Reconnect the Punch Home Sensor cable connector. 3. Replace the Embosser assembly and attach with three screws. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 4. Replace any cable ties that were removed. 5. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-58
Removal and Replacement
2
3
1
Figure 7-26: Punch Home Sensor
150i Card Personalization System Maintenance Manual
7-59
Punch Cam Motor
The Punch Cam Motor applies pressure to the embossing punch on the character wheel to form a character on plastic cards. Use the following procedure to remove and replace the Punch Cam Motor. Tools
·
#20 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. Remove cable ties as necessary. 3. Remove the Embosser Assembly. 4. Remove two screws (1 in Figure 7-27) and one nut (2), then remove the Punch Cam Motor (3) from the Embosser Assembly. Replace 1. Place the new Punch Cam Motor in position and attach with two screws and one nut, but do not fully tighten. 2. Tension the Punch Cam Motor against the Punch Cam Belt, then completely tighten the screws. 3. Replace the Embosser Assembly. 4. Make sure all connectors are firmly connected. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 5. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-60
Removal and Replacement
1 (2x)
3 2
Figure 7-27: Punch Cam Motor
150i Card Personalization System Maintenance Manual
7-61
Punch Cam Belt
The Punch Cam Belt transfers motion from the Punch Cam Motor to the cam, which in turn applies pressure to the embossing punch on the character wheel. Use the following procedure to remove and replace the Punch Cam Belt. Tools
· ·
#10 Torx driver #20 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. Remove cable ties as necessary. 3. Remove the Embosser Assembly. 4. Remove two screws (1 in Figure 7-28) and one nut (2), then remove the Punch Cam Motor (3) from the Embosser Assembly. 5. Remove one screw (4) holding the Punch Cam Home Sensor (5) to the Embossing Assembly and remove the sensor. 6. Remove the Punch Cam Belt (6). Replace 1. Place the new Punch Cam Belt in position around the idler pulley. 2. Place the Punch Cam Home Sensor in position and attach with one screw. 3. Place the Punch Cam Motor in position and attach with two screws and one nut, but do not fully tighten. 4. Tension the Punch Cam Motor against the Punch Cam Belt, then completely tighten the screws. 5. Replace the Embosser Assembly. 6. Make sure all connectors are firmly connected. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 7. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-62
Removal and Replacement
4 5
(2x) 1 3
3
6
2
Figure 7-28: Punch Cam Belt
150i Card Personalization System Maintenance Manual
7-63
Die Home Sensor
The Die Home Sensor detects when the embossing die cam has reached its home position. Use the following procedure to remove and replace the Die Home Sensor. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. Remove cable ties as necessary. 3. Disconnect the Die Home Sensor cable connector (1 in Figure 7-29). 4. Remove one screw (2) and remove the Die Home Sensor (3). Replace 1. Place the new Die Home Sensor in position and attach with one screw. 2. Reconnect the Die Home Sensor cable connector. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 3. Replace any cable ties that were removed. 4. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-64
Removal and Replacement
3
2
1
Figure 7-29: Die Home Sensor
150i Card Personalization System Maintenance Manual
7-65
Die Cam Motor
The Die Cam Motor applies pressure to the embossing die on the character wheel to form a character on plastic cards. Use the following procedure to remove and replace the Die Cam Motor. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Disconnect the Die Cam Motor connector. 4. Remove two screws (1 in Figure 7-30) and one nut (2), then remove the Die Cam Motor (3) from the Embosser Assembly. Replace 1. Place the new Die Cam Motor in position and attach with two screws and one nut, but do not fully tighten. 2. Tension the Die Cam Motor against the Die Cam Belt, then completely tighten the screws. 3. Reconnect the Die Cam Motor connector. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 4. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-66
Removal and Replacement
3 2
1 (2x)
Figure 7-30: Die Cam Motor
150i Card Personalization System Maintenance Manual
7-67
Die Cam Belt
The Die Cam Belt transfers motion form the Die Cam Motor to the cam, which in turn, applies pressure to the embossing die on the character wheel. Use the following procedure to remove and replace the Die Cam Belt. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Disconnect the Die Cam Motor connector. 4. Remove two screws (1 in Figure 7-31) and one nut (2), then remove the Die Cam Motor (3) from the Embosser Assembly. 5. Remove one screw (4) holding the Die Cam Home Sensor (5) to the Embossing Assembly and remove the sensor. 6. Remove the Die Cam Belt (6). Replace 1. Place the new Die Cam Belt in position around the idler pulley. 2. Place the Die Cam Home Sensor in position and attach with one screw. 3. Place the Die Cam Motor in position and attach with two screws and one nut, but do not fully tighten. 4. Tension the Die Cam Motor against the Die Cam Belt, then completely tighten the screws. 5. Reconnect the Die Cam Motor connector. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 6. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-68
Removal and Replacement
6 3 3 2 5 4 1 (2x)
Figure 7-31: Die Cam Belt
150i Card Personalization System Maintenance Manual
7-69
Punch and Die
The punches and dies are used in conjunction with each other to emboss individual characters and letters on a plastic card. Use the following procedure to remove and replace individual punches and dies. Tools
·
Insertion tool (PN 556335-001)
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. To remove a punch (1) or die (2), clip one side of the wheel fingers of the punch or die to be removed. Replace 1. To replace a punch or die, select an unused wheel finger and press the punch or die in using the special insertion tool. The dot on the punch or die must face out from the center of the Embosser Wheel. Do not deform the punch or die or the wheel fingers. 2. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification. Follow-up Adjustments This remove and replace procedure affects the following adjustments which must be performed after this procedure.
·
Wheel Parameters Menu (Remap)
7-70
Removal and Replacement
2
1
Dot
Figure 7-32: Punch and Die
150i Card Personalization System Maintenance Manual
7-71
Topper Assembly
The Topper Assembly places a colored layer on the top of embossed characters on a plastic card. Heat is used to affix this layer to the plastic card. Use the following procedure to remove and replace the Topper Assembly. Tools
·
#27 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. The Topper Platen May Be Very Hot. 3. Lift up on the Topper Solenoid Ring and remove the Topping Foil Cassette. Remove cable ties as necessary. 4. Disconnect the following cable connectors:
· · · · · ·
Topper Motor (1 in Figure 7-33) RTD (2) Topper Heat (3) Topper Sol (4) Platen Sensor (5) Foil Motion Sensor (6)
5. Remove four screws (7) lift up the Topper Assembly (8) of the 150i. Replace 1. Place the new Topper Assembly in position and attach with four screws. 2. Connect the following connectors:
· · · · · ·
Topper Motor (1) RTD (2) Topper Heat (3) Topper Sol (4) Platen Sensor (5) Foil Motion Sensor (6)
3. Replace any cable ties that were removed. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 7-72 Removal and Replacement
4. Replace the Topping Foil Cassette. 5. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
8 5 4
3 1 2 6
7 (4x)
Figure 7-33: Topper Assembly
150i Card Personalization System Maintenance Manual
7-73
Topper Foil Motion Sensor
The Toper Foil Motion Sensor detects physical motion of a slotted wheel insuring that the topper foil has advanced. Use the following procedure to remove and replace the Topper Foil Motion Sensor. Tools
· ·
Hex key set #10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Lift up on the Topper Solenoid Ring and remove the Topping Foil Cassette. The Topper Platen May Be Very Hot. Remove cable ties as necessary. 4. Disconnect the Topper Foil Motion Sensor (1 in Figure 7-34) cable connector. 5. Loosen the Topper Foil Motion Sensor pivot bolt (2). This allows the assembly to move forward past the stop peg (3). 6. Remove one screw (4) from the Topper Foil Motion Sensor (5) and sensor. Replace 1. Place the new Topper Foil Motion Sensor in position and attach with one screw. 2. Move the Topper Foil Motion Sensor back into position and tighten down the pivot hex bolt. Make sure there is spring tension on the pivoting assembly. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 3. Connect the Topper Foil Motion Sensor cable connector. 4. Replace the Topping Foil Cassette. 5. Replace any cable ties that were removed. 6. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-74
Removal and Replacement
4
5
2
3
1
Figure 7-34: Topper Foil Motion Sensor
150i Card Personalization System Maintenance Manual
7-75
Topper Platen Sensor
The Toper Platen Sensor detects when the Topper Platen is in its home position. Use the following procedure to remove and replace the Topper Platen Sensor. Tools
·
#10 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Lift up on the Topper Solenoid Ring and remove the Topping Foil Cassette. The Topper Platen May Be Very Hot. Remove cable ties as necessary. 4. Disconnect the Topper Platen Sensor (1 in Figure 7-35)cable connector. 5. Remove one screw (2) from the Topper Platen Sensor (3) and remove sensor. Replace 1. Place the new Topper Platen Sensor in position and attach with one screw. 2. Connect the Topper Platen Sensor cable connector. 3. Replace the Topping Foil Cassette. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 4. Replace any cable ties that were removed. 5. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-76
Removal and Replacement
2
3
1
Figure 7-35: Topper Platen Sensor
150i Card Personalization System Maintenance Manual
7-77
Topper Motor
The Topper Motor is a DC motor used to advance the topping foil in the Topper Foil Cassette. Use the following procedure to remove and replace the Topper Motor. Tools
· ·
#10 Torx driver Hex key set
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Lift up on the Topper Solenoid Ring and remove the Topping Foil Cassette. The Topper Platen May Be Very Hot. Remove cable ties as necessary. 4. Disconnect the Topper Motor connector (1 in Figure 7-36). 5. Remove two screws (2) and two star washers (3), then remove the Topper Motor (4). Replace 1. Transfer the Topper Motor Coupler (5) from the old motor to the new motor. Make sure the coupler is flush with the top of the motor shaft. 2. Place the new Topper Motor in place and secure with two screws and two star washers. 3. Reconnect the Topper Motor connector. 4. Replace the Topping Foil Cassette. 5. Replace any cable ties that were removed. 6. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-78
Removal and Replacement
3 (2x) 2 (2x)
4
Flush
5
1
Figure 7-36: Topper Motor
150i Card Personalization System Maintenance Manual
7-79
Main Control Board
The Main Control Board is the main processor board of the 150i. Use the following procedure to remove and replace the Main Control Board (MCB). Tools
· · ·
PC (minimum requirements: Windows 95/66 MHz/32K of RAM) Disk Assy, Diag Install Utility (PN 555071-001) J-TAG Cable (PN 557028-001) (Required when reformatting the Main Logic Board memory.)
Remove Before replacing the Main Control Board, backup all stored setting using the 150i Diagnostic Install Utility. This program will give you step by step instructions for backing up the Main Control Board. 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Remove the Front Access Panel (see Front Access Panel). Use proper anti-static grounding techniques when handling the Main Control Board. Remove any shipping cable ties if present. 4. Unlatch the Main Control Board (1 in Figure 7-37) and pull forward far enough to disconnect the following connectors:
· ·
J12 (2) J13 (3)
5. Continue to pull the Main Control Board out further and disconnect the following connectors:
· ·
J7 (4) J16 (5)
6. Pull the Main Control Board out completely from the 150i. Replace Use proper anti-static grounding techniques when handling the new Main Control Board. 1. Slide the new Main Control Board in the board guides and reconnect all cables that were previously disconnected.
7-80
Removal and Replacement
Make sure wires are not pinched and are placed in the casting slot provided. Make sure all cables connectors and the Main Control Board are firmly seated. 2. Reload the saved configurations into the 150i. 3. Replace the Front Access Panel. 4. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
2 3 4 5
Pin 1
·
J16
Pin 1
·
J12
J7
J13
1
150i061s
Figure 7-37: Main Control Board
150i Card Personalization System Maintenance Manual
7-81
Power Supply Board
The Power Supply Board delivers DC power to the stepper motors, LEDs and powers the Main Control Board. Use the following procedure to remove and replace the Power Supply. Tools
· ·
Phillips screwdriver #20 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Remove the Input Hopper card weight and all cards from the 150i. 4. With the Top Cover closed and locked, place the 150i in an upright position on the rear of the machine. 5. Remove four long screws (1 in Figure 7-38), six short screws (2), and one rubber foot (3). 6. Tilt down the Power Supply mounting plate (4) and disconnect connector JP2 (5) from the Power Supply Board (6). 7. Lay the Power Supply mounting plate down and remove two red wires from the + (plus) side of JP1. 8. Remove two black wires from the - (minus) side of JP1. 9. Remove seven screws (7) attaching the Power Supply Board to the mounting plate. Replace 1. Position the new Power Supply Board on the mounting plate and attach with five screws. 2. Attach two black wires to the - (minus) side of JP1. 3. Attach two red wires to the + (plus) side of JP1. 4. Connect JP2 on the Power Supply Board. 5. Attach the Power Supply mounting plate with four long screws, six short screws, and one rubber foot.
7-82
Removal and Replacement
6. Return the 150i to its normal resting position. 7. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7 (2x)
4
2 (6x) 3
5
JP 2
4
1 (4x)
6
7(5x)
4
Red Wires JP 1
Black Wires
150i062s
Figure 7-38: Power Supply
150i Card Personalization System Maintenance Manual
7-83
Line Filter
The Line Filter is used to remove transient spikes of power from the power line and acts as a surge protector. Use the following procedure to remove and replace the Line Filter. Tools
· ·
Small flat blade screwdriver #20 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually move the Card Transport carriage to the left-hand side of the 150i. 4. Remove one screw (1 in Figure 7-39), one nut (2) and the Top Cover Grounding Wire (3) on the left-hand side of the Inner Fan Guard (4). 5. Remove one screw (5) from the right-hand side of the Inner Fan Guard, then lift out. 6. Remove one screw (6) and one star washer (7) attaching the grounding wire to the 150i base. 7. Disconnect both fast-on connectors (8) from the Line Filter (9). 8. Compress the locking tabs on the Line Filter to clear the mounting hole opening and remove. Replace 1. Place the new Line filter in position and make sure the locking tabs secure the Line Filter in the mounting hole. 2. Connect the fast-on connector marked "L" (red wire) to the "L" connector on the Line Filter. 3. Connect the fast-on connector marked "N" (blue wire) to the "N" connector on the Line Filter. 4. Attach the grounding wire using one screw and one star washer to the 150i base. When replacing the Inner Fan Guard, insure the Card Transport Flex Cable is correctly positioned or the Card Transport movement may be obstructed. 5. Place the Inner Fan Guard in position and attach with one screw on the right-hand side of the 150i.
7-84
Removal and Replacement
6. Attach the left-hand side of the Inner Fan Guard with one screw and one nut. Make sure to attach the Top Cover Grounding Wire. 7. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
3 2 5 ref 1 ref 4 ref
N
6 8 7
L
Figure 7-39: Line Filter
150i Card Personalization System Maintenance Manual
7-85
Fuse
The Fuse protects the electronic components inside the 150i. Use the following procedure to remove and replace the Fuse. Tools
·
Flat blade screwdriver
Remove 1. Power OFF the 150i and remove the power cord from the wall outlet. 2. Use a flat blade screwdriver to pry out the Fuse Holder as shown. Replace 1. Place the new fuse in the Fuse Holder and press the Fuse Holder back in place. 2. Plug in the power cord and power ON the 150i. 3. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-86
Removal and Replacement
1
Figure 7-40: Fuse
150i Card Personalization System Maintenance Manual
7-87
Fan
The Fan removes excess heat generated by the stepper motors and the power supply from the 150i cabinet. Use the following procedure to remove and replace the Fan. Tools
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Nut driver set #20 Torx driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Manually move the Card Transport carriage to the left-hand side of the 150i. 4. Remove one screw (1 in Figure 7-41), one nut (2) and the Top Cover Grounding Wire (3) on the left-hand side of the Inner Fan Guard (4). 5. Remove one screw (5) from the right-hand side of the Inner Fan Guard, then lift out. 6. Disconnect the Fan connector (6). 7. Remove four nuts (7) attaching the Fan (8) to the 150i cabinet and remove the Fan. Replace 1. Place the new Fan in position and attach using four nuts. 2. Connect the Fan connector. When replacing the Inner Fan Guard, insure the Card Transport Flex Cable is correctly positioned or the Card Transport movement may be obstructed. 3. Place the Inner Fan Guard in position and attach with one screw on the right-hand side of the 150i. 4. Attach the left-hand side of the Inner Fan Guard with one screw and one nut. Make sure to attach the Top Cover Grounding Wire. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. Make sure grounding strap is replaced. 5. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limited number of customer produced cards for a final quality verification.
7-88
Removal and Replacement
3 2 5 ref 4 ref
1 ref
6
7 (4x)
Figure 7-41: Fan
150i Card Personalization System Maintenance Manual
7-89
Display/Keypad
The Display/Keypad allows 150i information to be displayed on a two line LCD display. The keypad provides a means to access the 150i's operating menu. Use the following procedure to remove and replace the Display/Keypad. Tools
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11/32 inch nut driver
Remove 1. Unlock and lift up the Top Cover (see Opening the Top Cover). 2. Power OFF the 150i and remove the power cord from the wall outlet. 3. Disconnect the Display/Keypad cable connector P4 (1 in Figure 7-42). 4. Remove four nuts (2) and one grounding wire (3), then remove the Display/Keypad from the top cover. Replace 1. Place the new Display/Keypad in position and attach with four nuts. Make sure to attach the ground wire. 2. Connect the Display/Keypad cable connector P4. Make sure wires are not pinched. Make sure connectors and wires will not interfere with any mechanical movement inside the 150i. 3. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a limite