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Datacard MX2000 Card Issuance System

O w n e rs M a n u a l

September 2011

Part No. 539675-001, Rev J

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Contents Chapter 1: Introduction __________________________________________ 1-1

System Overview _____________________________________________________ 1-2

Related Documents___________________________________________________ 1-4Starting and Stopping the System ______________________________________ 1-5Pausing and Resuming the System_____________________________________ 1-6Module Interlocks_____________________________________________________ 1-7Removing AC Power__________________________________________________ 1-8Interpreting Module Status Lights_______________________________________ 1-9Computer BIOS Battery_______________________________________________ 1-10Ordering Supplies____________________________________________________ 1-10CardGard Module Safety Information _________________________________ 1-11

CardGard Supply Film Precautions ________________________________ 1-11Ultraviolet (UV) Light Warning _____________________________________ 1-12

Module Warning Labels ______________________________________________ 1-13

Chapter 2: Installation ___________________________________________ 2-1Specifications and Requirements ______________________________________ 2-2

Elec trical Requirements____________________________________________ 2-2Power Consumption ___________________________________________ 2-2Permissible Current Load _______________________________________ 2-2Elec trostatic Discharge Susceptibility____________________________ 2-2

Physical Requirements_____________________________________________ 2-3Dimensions____________________________________________________ 2-3Floor Spac e ___________________________________________________ 2-5

Environmental Requirements_______________________________________ 2-5Storage Environment___________________________________________ 2-5Operating Environment ________________________________________ 2-5Audible Noise _________________________________________________ 2-5

Unpacking and Installation of New System _____________________________ 2-7Adding a Module to an Existing System ________________________________ 2-7

Prepa ring the System ______________________________________________ 2-7Inserting the New Module_________________________________________ 2-11

CardGard Module Adjustments_______________________________________ 2-14UV Lamp Housing Gasket and Latch Adjustment___________________ 2-14UV Housing Interlock Activator Adjustment_________________________ 2-17

Removing Panels and Hoods _________________________________________ 2-19Controller Rear Security Panel_____________________________________ 2-19Controller Front Panels____________________________________________ 2-21Controller Side Panel _____________________________________________ 2-22Hood Endcap Cover _____________________________________________ 2-23Module Front Panel ______________________________________________ 2-24Module Rear Panel and Hood Assembly___________________________ 2-24

Disconnecting Cover Latches_________________________________________ 2-26Expansion Kits _______________________________________________________ 2-27

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Revision Log

MX2000 Card Issuance System Owners Manual

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 interferewith radio communications. This equipment has been tested and found to bewithin the limits for Class A computing devices, pursuant to Title 47 CFR Part 15Subpart B of FCC rules, designed to provide reasonable protection against radiointerference in a commercial environment. Operation of this equipment in aresidential environment may possibly cause interference. In the event ofinterference, the users, at their own expense, will be required to take whatevermeasures are necessary to correct the problem.

Notice for CanadaThis digital apparatus does not exceed the Class A limits for radio noise fordigital apparatus set out in the Radio Interference Regulations of the CanadianDepartment of Communications. The term IC: before the equipmentcertification number only signifies that the Industry Canada technicalspecifications were met.

Le prsent appareil numrique n'met pas de bruits radiolectriques dpassantles limites applicables aux appareils numriques de la classe A prescrites dans leRglement sur le brouillage radiolectrique dict par le ministre desCommunications du Canada.

Revision Date Description of Changes

A April 2007 First release of this document

B August 2007 Release of Multi-C ard Buffer module

C September 2007 Release of Bar Code Scanner module

D August 2008 Release of Basic Topc oat module

E May 2009 Add card loading information to chapter 4.

F February 2010 Fix information for new PC .

G J une 2010 Update for agency compliance and changes to PM.

H October 2010 Update to move insta lla tion information withunpacking instructions.

J September 2011 Update for release of Single-Step Color module.
http://07.pdf/http://07.pdf/http://06.pdf/

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Notice for EuropeWe hereby certify that this Datacard system complies with EMC Directive 89/336/EEC and R&TTE Directive 1999/5/EC. This system conforms to Class A ofEN 55022 and to EN 301 489-5. Operation of this equipment in a residential

environment may possibly cause interference. In the event of interference, theusers, at their own expense, will be required to take whatever measures arenecessary to correct the problem.

Notice for Taiwan/China

Notice for J apanThis equipment is in the Class A category of information technology equipmentbased on the rules of the Voluntary Control Council for Interference byInformation Technology Equipment (VCCI). When used in a residential area,radio interference may be caused. In this case, the user may be required to takeappropriate corrective actions.

SafetyAll Datacard products are built to strict safety and reliability specifications inaccordance with UL60950-1 and CUL requirements; therefore, safety issuespertaining to operation and repair of Datacard equipment are primarilyenvironmental and human interface.

The following basic safety tips are given to make sure of safe installation,operation, and maintenance of Datacard equipment and are not to be consideredas comprehensive on matters of safety.

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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, and make sure that the floorsin the work area are dry and non-slip. Insulated rubber floor mats arepreferred.

Know the location of equipment branch circuit interrupters or circuitbreakers and how to turn them on and off in case of emergency.

Know the location of fire extinguishers and how to use them. Use onlyABC type extinguishers on electrical fires.

Know local procedures for first aid and emergency assistance at thecustomer facility.

Use adequate lighting at the equipment. Maintain the recommended range of temperature and humidity in

equipment area.

Do not use this product in an environment containing volatile orflammable compounds.

Safe Human Interface Use proper lifting techniques when moving or installing the

equipment.

Use standard electrostatic discharge (ESD) precautions when workingon or near electrical circuits.

Do not defeat or disconnect safety interlocks on covers.

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MX2000 Card Issuance System Owners Manual 1-1

Chapter 1: Introduction

This chapter provides general information related to the MX Seriessystems.

System Overview_____________________________________________________ 1-2Related Documents __________________________________________________ 1-4Starting and Stopping the System _____________________________________ 1-5

Pausing and Resuming the System ____________________________________ 1-6Module Interlocks____________________________________________________ 1-7Removing AC Power _________________________________________________ 1-8Interpreting Module Status Lights______________________________________ 1-9Computer BIOS Battery ______________________________________________ 1-10Ordering Supplies___________________________________________________ 1-10CardGard Module Safety Information ________________________________ 1-11

CardGard Supply Film Precautions ________________________________ 1-11Ultraviolet (UV) Light Warning _____________________________________ 1-12

Module Warning Labels______________________________________________ 1-13

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1-2 Introduction

System OverviewThe MX Series systems are modular card issuance systems with a series ofmodules that work together to complete the personalization of elements on a

card. Each possible module in the MX2000 system is described in the followingtable.

Module Description

Bar Code Scanner/Buffer

This optional module reads the bar code on a card, sends theinformation to the C ontroller (for Read/ Lookup function), andpasses the c ard to the next module.

Card Cleaning This module cleans the card in the system prior to printing graphicsor color or before applying coa tings. The module provides a dual

cleaning system that removes dirt and dust contaminants from thecard.

Card Flipper This module rotates cards around a vertical axis for back sidepersona lization in the downstream modules. An MX Series system istypica lly configured with a pair of Flipper modules. The first flipperrotates the card 180 degrees. After processing, the second flipperrotates the card back to its initial orientation.

Card Input This module feeds cards into the system. Multip le Card Inputmodules can be installed in a system to allow multiple card stocksto be selec ted within a single c ard run or to increase the mac hinescard supply capac ity for large jobs.

Card Output This module has a tray to receive good cards and one for rejectedcards.Multiple C ard Output modules may be installed within asystem in order to expand output capacity or to allow cardsgroupings to be separated for quality control, downstreamproc essing/handling, or varying delivery methods.

CardGard UV-Curable Topcoat

This module covers the entire front surface of a card with atranspa rent, UV-cured, topcoat film. The topc oa t film is firstlaminated onto the c ard's surface and then cured by UV lightpulses. The C ardGard module should be p laced in the systemdownstream of any printing modules and just upstream of theEmbossing module(s). Systems that have a CardGard moduleshould also have an upstream Card C leaning module (even whenthere is no G raphics module), so that the C ardGard topcoa t isplaced onto a clean card.

Single-Step ColorPrinting

This module prints full-color, high-resolution photos and imagesdirectly on the card. This module allows near-edge printing usingdye diffusion, thermal transfer technology.

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Embossing/Indent This module performs embossing on the front of a card. It canemboss multiple fonts and a wide range of spec ial charac ters withthe 112-charac ter emboss wheel. A module with the indent op tioninstalled c an also perform indent printing on the front, back, or bothsides of the card.Up to two Embossing modules can be used in a single system.Position all Embossing modules upstream of any Topping modulesand downstream of a CardGard module.

Graphics Printing The Front or Back Graphics modules print monochrome customgraphics on PVC cards using thermal transfer tec hnology.

Label Affixing This module applies a removable preprinted or blank adhesive labelto the front of a card. A set of Card Rotation (Flipper) modules isrequired to apply a label to the bac k side of a c ard. The first Card

Rotation module will rotate the card so the label is affixed to theback when it goes through the Label Affixing module. The otherCard Rotation module will rotate the card bac k to its originalposition.Blank labels can be printed on a per-card basis. Position the LabelAffixing module(s) direc tly upstream of the G raphics Printingmodule when using Datac ard UltraPrint labels.If applying only preprinted labels, Datac ard recommendspositioning the Label Affixing module direc tly upstream from theOutput module.

Magnetic StripeEncoding

This module provides high speed and reliable magnetic stripeencoding. The write/read head writes the magnetic data atspecific track loc ations on the front or back of the c ard; it thenreverses and reads the information to verify it.

Smart CardPersonalization

This module provides flexible, high quality smart cardpersonalization of contact or contac tless cards. The modulararchitecture a llows for the growth of smart card c apac ity, asneeded, to accommoda te longer encoding times for contac tcards without limiting system throughput. The c ontactless stationspersonalize c ards with speed, ac curac y and security. The modulecan be configured with either up to six contac tless programmingstations or up to 11 contac t stations to load any combination ofapplications onto cards within the same job.

System Controller The System Controller provides the controls for the MX Series systemand is the primary interface point for the operator. It includes thehardware and software needed to c ontrol the activities performedby each module and to manage the system as a whole.Each system has a dongle plugged into the C ontroller computer.

The dongle needs to be in plac e for the system to work.

Module Description

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1-4 Introduction

Related DocumentsThe following documents provide information for the user of an MX2000 system.

Basic Topcoa t This module applies a protec tive coa ting of clear or holographiccoating to monochrome or color-printed surfac es on a card. Thetopc oa t material is applied horizontally from edge to edge on acard. Special rollers enable laminate patterns that protec t certaincard fea tures such as a smart card c hip.

Topping This module applies a color foil to the tops of embossed characterson the card surfac e. The module has the capability of toppingcharac ters from the lower edge of the card up to the bottom of themagnetic stripe.

Description Part No. Available on CD

C IS Data Formatting Manual 539684-001 this library and 539341-001

CIS Software Administra tors Guide 539523-00x 539787-001

Unpacking and Installation Manual 539925-001 In paper with system and on thislibrary

Illustrated Parts Manuals for Modules many this library

CardGard Material Safety Data Sheet --- this library

System Safety Rules 539576-001 this library

Preventive Maintenance Tools andSupplies List

--- this library

Datacard Certified Supplies --- this library and newer oneson www.datacard.com

User Animations --- this library

Module Description
http://localhost/var/www/apps/conversion/tmp/scratch_5/http://localhost/var/www/apps/conversion/tmp/scratch_5/http://localhost/var/www/apps/conversion/tmp/scratch_5/http://localhost/var/www/apps/conversion/tmp/scratch_5/

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Starting and Stopping the SystemOnce the system is plugged into AC power, turn on the Controller computer bypressing the power button on the front of the computer.

Turn off the Controller computer by using the standard shutdown commandthrough the computer software as described in the CIS Administrators Guide .

Turn the system hardware on or off by using the E-stop switch on the front of the

Controller module. This switch controls all AC power to the modules, the coolingfans, and to all additional power cords that have been installed on the system.

Turn on the system by rotating the switch clockwise. The current state (ON orOFF) is visible in the dial cutout.

Turn off the hardware by turning the switch counterclockwise.

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1-6 Introduction

Pausing and Resuming the SystemPause a system to change supplies, perform preventive maintenance, or performother activities. The system can be paused using the mouse, monitor, and

software, or by pressing the Pause/Resume button located on the Card Outputmodule. The Pause/Resume button is useful when the operator needs to stop themachine but is not near the Controller computer.

The Pause/Resume button on the Output module shows the following machinestates.

Green flashing lightMachine is in thepaused state.

Green light on, but not flashingMachineis in the normal running or idle state.

No lightMachine is temporarilybetween the pause and running states.

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Module InterlocksModule interlocks are a safety feature that protects operators from injury. Liftinga hood causes the motors to be disabled and the interlock indicator light for the

module(s) to go off. Interlock lights for the adjoining modules go off, but theadjoining modules finish processing cards, park them, and then sit idle withmotors enabled.

Most systems have connected hoods so that all or many modules lose power tothe motors when hoods are opened. Wider modules have one interlock on theupstream side.

The Output module has a special Pause/Resume switch and a special interlockthat does not affect other modules if the Output module cover is opened.

InterlockLight

Top of ModuleRight Side

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1-8 Introduction

Removing AC PowerAny time service is being performed on the systemespecially at the rearenclosure where high voltage power is presentAC power should be removed

from the system.Turning off the E-Stop switch on the Controller module removes power from allmodules and the system fans. It also removes power from modules that aresupplied by additional power cord inlets.

The Controller computer and the Ethernet switch box are disconnected from theAC main by first shutting down the Controller computer and then removing thepower cord, or by switching off the customer-provided circuit breaker. Once thecomputer has been turned off, the power cord(s) can be unplugged.

Procedure1. Turn off the Controller computer using the standard shutdown instructions

for the computer software.

2. Rotate the E-stop switch counterclockwise to OFF.

3. Unplug the power cord(s) from the AC power source.

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Interpreting Module Status LightsEach module (except for the Card Input and Output modules) has a status lightlocated on the front panel to alert the operator when the module needs attention.

When the light is either flashing or solid on, refer to the error message on theController screen for more information.

When a module error occurs, the other modules will process their currenttasks until completed. At that point, the system enters a paused state (allmodule status lights are on, but not flashing).

FlashingModule error or failure innormal operation; failure in modulefirmware download during boot.

Not FlashingSupplies are low orthe module is in a paused state.

No LightModule is runningnormally or power is off.

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1-10 Introduction

Computer BIOS BatteryThe motherboard in the Controller computer contains a battery backup for thesystem BIOS. If the battery is improperly connected, damage to the motherboard

can result. Replace the battery with only the same or equivalent typerecommended by the manufacturer. Dispose of used batteries according to themanufacturers instructions.

Ordering SuppliesSupplies for the modules are listed in the following locations. Refer to theseresources for supplies ordering information.

Supplies ordering information file (pdf) on the Owners Library CD that shipswith the system.

Datacard Web Site ( www.datacard.com )Datacard Home | Products & Solutions | Supplies
http://www.datacard.com/http://www.datacard.com/

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CardGard Module Safety InformationIf your system includes a CardGard module, be aware of the following safetyprecautions when working with the CardGard supply film and around the

ultraviolet (UV) light used in the module.CardGard Supply Film Precautions

The CardGard topcoat material is a clear, plastic, UV-curable film. The film issensitive to heat and UV light. Excessive heat can cause a roll of film to telescope.To prevent this, place the supply weight on top of the supply roll. UV exposurecan cause discoloration or opacity on the edges of the film. UV light can also drythe coating so that it does not stick as easily to cards, hampering machineperformance.

To protect the film from UV light, always store partial rolls of CardGard film inthe original container. If the CardGard module will not be used for three or moredays, remove the CardGard film from the module and store it in the originalcontainer. For instructions on removing and replacing the CardGard film, refer topage 4-6 .

For more material safety information, refer to the CardGard Material Safety DataSheet on the Owners Library CD.

Caution: Repeated contact of the skin to uncured CardGard coating materialcan cause minor skin irritation or sensitization (possibly leading to allergicreactions) in some individuals. Sensitive individuals should wear gloveswhen handling the uncured rolls of film. As a safeguard, wash your handswith soap and water after touching the uncured material.

Caution: Do not touch eyes with gloves or hands that have been in contactwith the uncured CardGard material. Accidental transfer of uncuredCardGard particles (acrylate monomers) to the eyes can cause redness andtears. If you experience these symptoms, flush eyes with large quantities ofwater. Contact a physician if irritation persists.

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1-12 Introduction

Ultraviolet (UV) Light Warning

Caution: Ultraviolet (UV) light is used in the CardGardmodule to cure the laminated film on the cards surface. UVlight can cause sunburns and damage to the retina of theeye; however, the CardGard module is designed to preventleakage of UV light. Special gaskets, shutters, and materialsshield the user from exposure to UV light. Interlocks aredesigned to break the electrical connection when the UVlamp housing assembly is opened.

Caution: When working around the CardGard module,observe standard precautions. Do not attempt to defeat anyof the safety mechanisms in the module. Although UV lightleakage is unlikely, it is recommended that you wear UVeye protection that blocks UV radiation under 400nm as aprecaution.

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Module Warning LabelsWhen working around the system, observe the following warning and cautionlabels affixed to various areas on the equipment.

Warning Label Description

Heat Source Parts that contain this warning label can become very hot

during operation. Wait until the part cools or wear protective gloves to

prevent burns when making c ontac t.

High Voltage Power Supply This warning label is found on parts that contain a high

voltage current. To avoid a possible elec tric shock, always remove power

from the module (as well as turning off power to theController) before servicing.

Pinch-Point This warning label is found on moving parts that can

potentially crush and cut. Do not operate with the guard removed.

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1-14 Introduction

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Chapter 2: Installation

This chapter provides information such as requirements, sitepreparation, and installation.

Specifications and Requirements _____________________________________ 2-2Elec trical Requirements____________________________________________ 2-2

Power Consumption ___________________________________________ 2-2Permissible Current Load _______________________________________ 2-2

Electrostatic Discharge Susceptibility____________________________ 2-2Physical Requirements_____________________________________________ 2-3Dimensions ____________________________________________________ 2-3Floor Space ___________________________________________________ 2-5

Environmental Requirements_______________________________________ 2-5Storage Environment___________________________________________ 2-5Operating Environment ________________________________________ 2-5Audible Noise__________________________________________________ 2-5

Unpacking and Installation of New System ____________________________ 2-7Adding a Module to an Existing System________________________________ 2-7

Prepa ring the System ______________________________________________ 2-7

Inserting the New Module _________________________________________ 2-11CardGard Module Adjustments______________________________________ 2-14UV Lamp Housing Gasket and Latch Adjustment ___________________ 2-14UV Housing Interloc k Activator Adjustment_________________________ 2-17

Removing Panels and Hoods ________________________________________ 2-19Controller Rear Security Panel_____________________________________ 2-19Controller Front Panels____________________________________________ 2-21Controller Side Panel _____________________________________________ 2-22Hood Endcap Cover _____________________________________________ 2-23Module Front Panel_______________________________________________ 2-24Module Rear Panel and Hood Assembly ___________________________ 2-24

Disconnecting Cover Latches________________________________________ 2-26Expansion Kits_______________________________________________________ 2-27Additional Cooling Fans __________________________________________ 2-27Additional Ethernet Switches ______________________________________ 2-27Auxiliary AC Power Inlet___________________________________________ 2-27

Optional Kits________________________________________________________ 2-27Installation Troubleshooting __________________________________________ 2-29

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2-2 Installation

Specifications and RequirementsPrior to installing an MX Series system, make sure the site meets therequirements listed in the following sections.

Electrical Requirements

The system requires single-phase, grounded, 180 to 264-volt, AC power source at47 to 63 Hz. The Controller standard system power cord requires a dedicatedpower drop with a 15-amp circuit (U.S.) or 16-amp circuit (most other countries).

Power Consumption

The power consumption of the system is the sum of the power consumption ofthe Controller and all of the modules in the system. To see the maximum currentdraw for each module, refer to the products data sheet on the Datacard Web Site

(www.datacard.com ) or in the Sales section on PartnerPage.

Permissible Current Load

Because the system is modular, it is possible to exceed the permissible load on themain Controller power cord. If the calculated load on the Controller power cordor an auxiliary power cord exceeds 12.8 amps, additional power inlets andcord(s) must be added to the system.

Electrostatic Discharge Susceptibility

A system can withstand an electrostatic discharge of 15 kV, 330 pF storage, and

1.5 k series resistance in tests simulating a human discharge to the outer surfaceof the machine. This does not include direct discharge on printed circuit boards.
http://www.datacard.com/http://www.datacard.com/http://www.datacard.com/http://www.datacard.com/http://www.datacard.com/http://www.datacard.com/http://www.datacard.com/

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2-4 Installation

Card Output 100/45.4

CardGard Topcoat 320/145.2

Embossing (Indent) 123/55.8Plus 7 lbs/3.2 kg per Indent mechanism

Graphics Printing 116/52.6

Label Affixing 100/45.4

Magnetic Stripe Encoding 85/38.6

Smart Card Personalization

(Contac t or Contac tless)

111/50.3

Plus 1.5 lbs/0.68 kg per programming station

System Controller-Input 300/136.1

Basic Topcoat 197/89.4

Topping 101/45.8

Additional Casters 11/5 (per set)

Module/ ItemWeight in Pounds/Kilograms

(Including Panels and Casters)

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Floor Space

The floor space required to install the system is dependent on the number andtype of modules included. To determine how much floor space is required,calculate the following:

1. Controller-Input width 31.3 inches (79.5 cm) + [number of CardGard modules x30 inches (76.2 cm)] + [ number of all other modules x 10 inches (25.4 cm)] = Totalwidth of system

2. Total width x 33.8-inch (85.9-cm) depth = Floor space used by system

3. Floor space used + 36-inch (45.72-cm) clearance on all sides for service accessand airflow = Total floor space

The floor must be level and flat within 0.1 inch per foot (1 mm per 10 cm) in anydirection.

Environmental RequirementsThe following tables contain environmental specifications for the system.

Storage Environment

Operating Environment

Audible Noise

The audible noise level of a system is dependent on the installed modules andcard personalization data. The following configuration has been measured:Controller, Card Input, Magnetic Stripe, Smart Card, Cleaning, Graphics Printing,Card Output (at maximum speed).

Temperature -50 F to 130 F (-46 to 54 C)

Relative Humidity 0% to 100% (Non-Condensing)

Temperature 65 F to 80 F (18 C to 27 C)

Relative Humidity 20% to 85% (Non-Condensing)

Front Bystander Position 70.5 dBA to 73 dBA

Front Operator Position 72.5 dBA to 74.5 dBA

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2-6 Installation

Measurements are sound pressure measurements with a handheld soundmeter at the front bystander (1.0 meter from machine, 1.5 meters high) oroperator (0.25 meter from machine, 1.5 meters high) positions per ANSIS12.10-1985, section 11. All measurements are averages over 60 seconds (60 Lequiv.).

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Unpacking and Installation of New SystemRefer to the unpacking and installation instructions provided in the pocket on thecrate. An electronic copy of the instructions is provided on this Owners Library

CD.

Adding a Module to an Existing SystemPerform the following procedure to add a module to an MX Series system. Thefollowing diagram shows one possible scenario.

Preparing the System

1. Shut down the Controller and unplug the system. Make sure that all powercords on multiple corded systems are unplugged.

2. Locate the point where the new module will be inserted.

When the system is split into two halves, it will be necessary to support bothsides of the split. Larger systems have multiple caster sets in the middle of thesystem that can be relocated to the split. However, for smaller systems, it willbe necessary to acquire an additional pair of casters (Part No. 562879-002).

Caution: The system must be powered off and unplugged before beginningthis procedure.

You will need four jacks or an extra pair (two sets) of casters for modulesupport during this procedure.

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2-8 Installation

3. Prevent the system from moving by setting the brakes for all casters on thesystem, based on the type of caster.

4. Disconnect the hoods between the modules to be split by loosening thescrews and sliding the bracket away from the other module. Refer toDisconnecting Cover Latches on page 2-26 for detailed instructions.

5. Remove the front panels and rear panel/hood assemblies from the two

modules being separated. Refer to the instructions beginning on page 2-19 .

6. Install a caster set (or jack) under both the upstream and downstreammodules of the split. Except for the Controller and Output module casters,casters may be relocated from other parts of the system for this operation.

A. Slide the caster channel (caster assembly) under the module.

B. Secure the front and rear of the caster channel to the module frame withtwo screws on each end.

Older casters: Turn the dial inside the castercounterclockwise to engage the brakes by loweringthe foot.

Newer casters: Press down the ON sideto lock the brakes.

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7. Disconnect the AC power cables from the modules being separated.

8. Disconnect all of the downstream module Ethernet cables and lay them to theside for easy reconnection later. Do not remove the cables; just disconnect thedownstream end.

9. Remove the two screws that secure the upstream modules platform to thedownstream pier bracket. Save the screws for reuse later in this procedure.

10. Remove the six bolts that secure the two modules together. Save the bolts forreuse later in this procedure.

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2-10 Installation

11. On both the new module and the last upstream module in the system, loosenthe two module platform mounting screws from the upstream side of themodule platform (for CardGard, see the note below). This allows thedownstream side of the module platform to rise up on the spring-loadedshipping posts.

12. Release the caster brakes on the downstream section, and move the

downstream section of the system away from the fixed upstream section.

To secure a CardGard module, make sure that the UV housing assemblyis unlatched to release any pressure from around the gasket on the cureassembly. Then loosen the screws (3 and 4 shown in a previous figure) onthe mid-module mounting bracket (on the entry side of the cureassembly) instead of on the upstream end as for other modules.

Older casters: Turn the dial inside the casterclockwise to unlock the brakes by raising the foot.

Newer casters: Press down the OFF sideto unlock the brakes.

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Inserting the New Module1. Secure the new module to the upstream half of the system:

A. Insert the two alignment guides (1) of the new module into the alignment

openings (2) in the upstream module.

B. Use the two shipping screws (3 in the figure below) to attach the upstreammodules platform to the pier bracket of the downstream module.

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2-12 Installation

C. Install the six frame bolts (4) that secure the two frames together.

2. Repeat step 1 to secure the downstream half of the system to the new module.

3. Tighten the two module platform mounting screws on the upstream side ofthe platform (for CardGard, see the note below).

a. Front platform mounting screw (left side)

b. Front mid-module mounting screw (right side of cure assembly)

c. Rear platform mounting screw (left side)d. Rear mid-module mounting screw (right side of cure)

4. Remove any jacks. If casters were used, leave them in place.

5. Reconnect the AC power cables on all of the module control boards. (Refer tothe figure in the Unpacking/Installation Instructions manual included on theOwners Library CD for details.)

A. Connect the AC power cable from the upstream system module to thenew module.

B. Connect the AC power cable from (Down) on the new module to (Up) onthe downstream system module.

6. Compare the length of the new module Ethernet cable with the existing cablesand route a new cable of the correct length from the Controller to themodule.Reconnect all of the Ethernet cables to the modules, beginning withthe shortest cable connected to the new module.

7. Verify that all module platform and module frame bolts are fully tightened.

Do not place any screws in the original shipping screw locations (over themounting posts). This could warp the module platform plate.

For a CardGard module, tighten the screws on the module in thefollowing sequence to secure it in place. It is important to use thissequence for correct card track alignment.

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8. Replace the panel and hood assemblies and the front panels. Refer to page2-19 for instructions. Reconnect the panel hoods and reattach with the bracketscrews.

9. Reconnect power to the Controller and power on the system. The Controller

should automatically identify the new module.10. For safety reasons, make sure the interlock switch is working correctly by

using Diagnostics. Select Applications | Utilities | Diagnostics and click theSensors tab.

If the addition of the module requires that an auxiliary power kit be installedon the system, the kit must be installed after the module. Refer to the powerkit specification or Auxiliary AC Power Inlet on page 2-27 for moreinformation.

If your system includes a CardGard module, it is recommended that you

adjust the module after installation is complete. Refer to CardGard ModuleAdjustments on page 2-14 for instructions.

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2-14 Installation

CardGard Module AdjustmentsIf you installed a CardGard module as part of your system, perform the followingadjustments after installation is complete.

UV Lamp Housing Gasket and Latch Adjustment

The UV lamp housing assembly gasket prevents UV light from leaking out of thecure chamber. The latch holds the UV lamp housing assembly tightly to the curechamber to prevent light leakage.

This adjustment sets the compression of the gasket between the cure chamberand the UV lamp housing assembly and adjusts the tightness of the latch.

Adjustment Procedure

1. With the system up and running and the module in Service mode, lift thehood of the module.

2. After the high voltage indicator light (1 in the following figure) on the UVhousing assembly is off, release the latch (2) that secures the UV housing (3) tothe cure assembly. Pull the assembly back to open it.

3. Loosen (but do not remove) the screws (4) that secure the rear duct (5) to themodule base.

4. Set the UV lamp housing assembly gasket compression:

A. Loosen (but do not remove) the three screws (6) on the bottom of the UVhousing duct. There is one screw on each side and one in the center front.

B. Position each of the three screws in the center of each brackets slottedopening, and then partially tighten the screws to hold them in place.

Caution: Directly viewing UV light for extended periods can result inpermanent damage to the retinas. Do not proceed with the next step until thehigh voltage indicator light on the UV lamp housing assembly is off.

If the left front panel of the module is in the way of completely opening the

UV housing assembly, you may need to remove it. For more information,refer to the Module Front Panel on page 2-24 .

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C. Push the UV housing assembly against the cure chamber and check to seethat there is even compression of the housing gasket (7 in the figurebelow) against the face of the cure chamber (8) and of the UV assemblyagainst the rear duct (9) when compressing (25% to 75% of fullcompression).

D. Loosen and re-tighten the UV housing screws (6) as needed to adjust thegasket compression and angle.

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2-16 Installation

5. Adjust the tightness of the UV housing latch:

A. Release the latch (2 in the previous figure) that secures the UV housingassembly (3) to the cure assembly, and pull the assembly back to open it.

B. Loosen (but do not remove) the two screws that secure the latch (2) to the

side of the cure assembly (3).

C. Move the latch forward or backward in the slotted openings to adjust.Partially tighten the screws to hold the latch in place.

D. Close the UV assembly and secure the latch.E. Verify that the gasket (7) is compressed (25% to 75% of full compression)

on all sides of the face of the cure assembly (8).

F. Adjust the latch screws as needed to correct the tightness of the seal, andtighten the screws.

6. Adjust the tightness of the rear duct gasket compression:

A. Close the UV assembly (3) and secure the latch (2).

B. Align the rear duct (5) with the UV housing assembly, push the rear duct

against the UV housing, and partially tighten the screws (4) to hold it inplace.

C. Check the gasket compression; you want a 1 to 2-card thickness ofcompression against the housing (0.030 to 0.100 inch or 0.076 to 0.253 cm).

D. Once the compression is correct, tighten the screws (4) on the base of therear duct.

E. Unlatch the UV housing and re-latch it to ensure the gasket (9)compression is even and at the thickness described above.

7. Replace the panels and close the hood.

8. Run some test cards. Watch the first cards being processed by the module tobe sure no (or minimal) light escapes at the gasket area.

9. If there is still excessive leakage, repeat this procedure until leakage isminimized.

Caution: Make sure you do NOT remove the screws. They are attached toa small plate inside the assembly. It would require considerable time torepair the assembly if the screws were removed.

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UV Housing Interlock Activator Adjustment

In the UV lamp housing assembly, the UV housing closed interlock switch detectsthat the UV housing is in an operational position to prevent exposure toultraviolet (UV) light. This interlock switch needs to be closed to enable highvoltage power to be distributed to the housing for curing.

This adjustment controls the pivot throw of the interlock activator to ensure theswitch is closed when the UV lamp housing is latched closed.

Adjustment Procedure

1. With the system up and running and the module in Service mode, lift thehood of the module.

2. Access the Diagnostics program by selecting Applications | Utilities |

Diagnostics.3. Select the CardGard Module and then display the Sensors tab. The UV

housing closed interlock switch is listed on the screen (High VoltageInterlock).

4. Make sure that the UV housing is closed and latched (1 in the followingfigure).

5. Loosen the two locking nuts (2) on either side of the interlock switch (3) on thecure bracket (4).

6. On the cure assembly base, manually adjust the bracket (4) position (forwardand back) until there is a transition on the computer screen of the interlockswitch changing states from Open to Closed.

7. Tighten the locking nuts (2). There can be a 0.020 to 0.030-inch (0.051 to 0.076-cm) overtravel when adjusting the locking nuts.

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2-18 Installation

T

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Removing Panels and HoodsPanels are the outside covers for all of the modules in the MX Series system.

Hoods are the see-through covers that protect the operator from the modulesmoving parts. All modules have hoods except for Card Input, Card Output, andthe Controller.

Each module has an independent interlock switch and only one hood interlock.For safety reasons, a module that is more than one module frame wide must haveeach of its hoods connected together or the interlock on that module will not befunctional on all the hoods.

Use the procedures in this section to remove the module panels and hoods.

Controller Rear Security Panel

A security panel covers the back of the Controller computer to prevent tamperingor unauthorized connections to the Controller computer.

Removal Procedure

1. Remove the screws from the Controllers two rear security panels (1 and 2 inthe following figure). Remove the screws from the Controllers rear securitypanel, and lean the panel against the back of the Controller.

2. As necessary, add or remove any cable connections to the Controllercomputer.

Be careful when removing and installing the security panel because thecomputers cables pass through the opening in the panel and can be pulledout of the computer or damaged.

Make sure that the security dongle is plugged back into the same USBport on the back of the computer. The system will not operate without thesecurity dongle. The dongle is attached to the Controller frame with asteel cable to prevent accidental loss.

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2-20 Installation

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Controller Front Panels

The front panels of the Controller module are different from the front panels ofother modules. Use the following procedure for removing either of the

Controllers two front panels.

Removal Procedure

1. Loosen, but do not remove, the three screws (1) across the top of the panel (2or 3).

2. Pull outward on the bottom corners of the panel to release the two latches onthe inside of the panel.

3. Pull the unlatched panel down and away from the module.

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2-22 Installation

Controller Side Panel

The Controller module has a side panel with a cutout for a fan filter. Use thisprocedure to remove the Controller side panel.

Removal Procedure

1. Loosen the three screws (1) on the front and the three screws (2) on the back ofthe side panel.

2. Remove the panel (3) from the side of the Controller module.

Replacement Note

Inspect and clean the filter (4) before replacing the panel.

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Hood Endcap Cover

A hood endcap cover is installed on two modules:

The module immediately downstream of the last Input module in the system.

The module immediately upstream of the first Output module in the system.

Removal Procedure

1. Remove the three screws (1) that attach the endcap cover (2) to the hoodassembly (3).

2. Carefully remove the endcap cover by pulling it down and away from thehood, making sure to detach the clip (4) from the hood assembly.

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2-24 Installation

Module Front Panel

Use this procedure to remove the front panel of any module, other than theController. This procedure can also be used to remove the rear panel of the CardInput or Card Output module, and the side panel of the Card Output module.

Removal Procedure

1. Raise the modules hood (1).

2. Loosen, but do not remove, the single retaining screw (6) at the bottom centerof the front panel. It is in a slotted opening.

3. Lift the front panel (7) up and forward until the two screws on the frame clearthe keyhole openings (8) in the panel.

Module Rear Panel and Hood Assembly

Each modules rear panel is attached to a hood assembly. The hoods are usuallyinterlocked so they can be opened as a unit. Use this procedure to remove the rearpanel and hood assembly of any module.

Removal Procedure

1. Raise the modules hood (1).

2. Disconnect the latching bar (3) from adjacent hoods by removing the twoscrews from the bar. Refer to Disconnecting Cover Latches on page 2-26 forfurther instructions.

3. Loosen, but do not remove, the two retaining screws (4) at the bottom of therear panel. These screws are in a slotted opening.

4. While standing behind the system, grasp the open hood on both sides justabove the hinges, and then lift up slightly and pull back to remove the hood(1) and rear panel (5) assembly from the module.

5. Lay the hood assembly on its side on a piece of cardboard to preventscratching the clear plastic.

Warning: Removing the front panel from a module exposes high voltageelectrical components. Do not remove any panels when the system is pluggedinto facility power.

This procedure refers to the figure on the following page.

This procedure refers to the figure on the following page.

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2-26 Installation

Disconnecting Cover LatchesWhen you are adding modules to, moving them within, or removing them from asystem, disconnect and reconnect the latches between covers as needed.

1. Remove the two screws from the side of the latch (2) where the module is tobe disconnected.

2. Reattach the two screws when adjoining modules are again in position.

3. If the covers will not be reattached, fix them so the latch does not protrudewhen covers are lifted.

A. Remove the other two screws.

B. Rotate the latch.

C. Reaffix with the two screws.

Wider modules with more than one frame must have the cover latchesconnected or the module interlock will not function.

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Expansion KitsThe following kits may be needed on large systems. These kits are automaticallyincluded in the order if your configuration requires additional cooling fans or

power inlets.Additional Cooling Fans

Larger MX Series systems may require that an additional cooling fan be insertedinto a Card Output module. The cooling fan is available as an installation kit.Refer to the Card Output Module Illustrated Parts Manual for the part number ofthis kit. The kit is installed before shipping on new systems, supplied withexpansion systems as needed, or it can be ordered for a system. Refer to the kit forinstallation instructions.

Additional Ethernet Switches

Systems with more than 24 modules or with more than two cameras need anotherEthernet switch installed into the Controller. The switch is installed on any newsystems that require one. If additional modules/cameras make one necessary in afield system, the field kit is shipped with the modules.

Auxiliary AC Power Inlet

There will be times when a large system needs an auxiliary AC power inlet. Referto the System and Controller Module Illustrated Parts Manual for the part number ofthis kit. Refer to the kit for installation instructions and guidelines on determining

when a system needs an additional inlet. Kits are sent with expansion systemsthat exceed the power limit.

Optional KitsFor some modules, an optional kit can be ordered and installed to add morefunctionality to the module. Part numbers for these kits are provided in themodules Illustrated Parts Manual . Refer to the kit for installation instructions.

Magnetic Stripe Encoding ModuleMagnetic Head Lift KitWhen you are running a job that does not require magnetic encoding, thewrite/read head of the Magnetic Stripe Encoding module can be retracted bythe head lift kit so it is not subjected to unnecessary wear.

Each power inlet and power cord requires a dedicated power drop with a 15-amp breaker (U.S.) or 16-amp breaker (non-U.S.).

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2-28 Installation

Embossing ModuleIndent Printing Mechanism

With the Indent mechanism, the Embossing module has the option to printindent characters on the front, back, or both surfaces of cards.

Basic Topcoat ModuleHolographic Topcoat Registration Kit

This addition to the Basic Topcoat module enables a site to place a holographin a precise position on a card.

Topping ModuleFoil Slitter Assembly

The foil slitter assembly is an optional feature with the Topping module. Itmounts on the module base and splits the foil ribbon approximately down thecenter along its length. This provides a higher level of security whendisposing of used topping foil because the split halves of foil can be discardedin separate locations.

Input and Output ModulesLocking KitBoth Input and Output modules can be installed with locking covers so thatonly authorized personnel can insert or remove cards.

Input Module Thin Card Kit

To personalize cards thinner than the standard 30-mil cards on the MX2000Card Issuance system, an upgrade kit must be installed on the Input moduleso that only one card is picked at a time. The kit enables the Input module toprocess 24-mil or 18-mil cards. Thin card stocks must also be defined in StockManagement and selected in the Card Setup. If the system might resume

using 30-mil cards in the future, keep the standard upper pick guide toreplace the one in the kit.

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Installation TroubleshootingBefore the system left the factory, it was fully tested for proper operation. If thesystem fails to start properly after installation, use the following guidelines to

isolate the most likely cause. Some of these troubleshooting scenarios may requirea trained technician to isolate and correct the problem.

Controller Problems

If the Controller computer cannot be turned on:

Verify that the main power cord is connected to the system and the facilityoutlet.

Verify that the facility power is available and is of the correct voltage for thesystem. The system requires single-phase, grounded, 180-264-volt, AC power

at 47 to 63 Hz. Make sure the power cord on the back of the Controller computer is properly

connected.

If the Controller computer starts but does not properly boot up, follow thediagnostic procedures for Microsoft Windows .

Module Boot Problems

If none of the modules boot up:

Verify that the red module power switch on the front of the Controller is on. Verify that the power cable between the Controller and the first module

(Input module) is connected.

Verify that the Ethernet connection between the Controller computer and theEthernet switch is correct. Also verify that the Ethernet switch has power.

If all modules boot up except for one, the most likely cause is a bad Ethernetconnection.

If all modules downstream from a module fail to boot up, the most likely cause is

a disconnected power jumper between modules, or there may be an auxiliarypower cord on that module that is not plugged in to facility power.

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2-30 Installation

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Chapter 3: PreventiveMaintenanceThis chapter provides routine preventive maintenance schedulesand procedures for periodic cleaning and inspection of the system.

Overview____________________________________________________________ 3-2Cleaners, Tools, and Supplies _________________________________________ 3-2System Preventive Maintenance Tasks ________________________________ 3-3

Module-Specific Preventive Maintenance Tasks _______________________ 3-4Card Cleaning Module ____________________________________________ 3-4Card Output Module ______________________________________________ 3-4CardGard Topc oat Module ________________________________________ 3-4Single-Step C olor Printing Module __________________________________ 3-5Controller Module _________________________________________________ 3-7Graphics Printing Modules _________________________________________ 3-7Magnetic Stripe Encoding Module ________________________________ 3-11

Topper Module___________________________________________________ 3-13Smart Card Module_______________________________________________ 3-14Basic Topcoat Module ____________________________________________ 3-15

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3-2 Preventive Maintenance

OverviewMX Series systems require routine preventive maintenance to optimizeperformance and minimize downtime. Preventive maintenance procedures

should be performed either at specified time intervals or machine-cycle intervals,depending on the module in question. In addition, preventive maintenanceshould be performed after any of the following activities:

Replacing any module, assembly, sub-assembly or adjustable part

Performing any unscheduled maintenance

Some activities require that system power be off. Refer to the information on thefollowing pages for performing preventive maintenance activities.

Cleaners, Tools, and SuppliesThe cleaners, tools, and supplies required to maintain the MX Series system arelisted in the special Preventive Maintenance Tools and Supplies document on thisCD.

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System Preventive Maintenance TasksSite personnel need to perform the following preventive maintenance procedureson all modules in the system.

Procedure Frequency Comments

Clean all cardtracks

Once perweek or50,000 ca rds

Check for debris in both upper and lower cardguides.

Vacuum the area to remove dust and debris asnec essary.

Wipe the card trac k with a clean cloth dampenedwith isopropyl alcohol.

Clean reflectiveoptical sensors


Wipe the sensors with a soft, dry cloth. This includes all card entry and exit sensors.

This excludes all tabbed belt sensors and fiber opticsensors.

Clean c ard tracksensors


Vacuum clean card sensors (in card trac k only), or wipewith soft brush or cotton swab.

Clean transportrollers


Wipe the roller surfaces with a soft cloth dampened withisopropyl alcohol.

Vac uum theupper half of the

system

Once perweek or

50,000 ca rds

Vacuum dust and debris from the module platform area(above the frame only).

Do not vacuum near circuit boards or otherelectronic devices.

Clean Controllerair filter

Onc e everytwo weeks

Remove the filter (it is not necessary to remove the sidepanel) and vacuum it at least once every two weeks.

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Module-Specific Preventive Maintenance TasksSome modules have no specific operator maintenance tasks; others havepreventive maintenance tasks that should be performed by the operator. This

section describes those tasks.Card C leaning Module

Card Output Module

If the system has an extra cooling kit installed on the Card Output module,vacuum its air filter at least once every two weeks.

CardGard Topcoat Module


Clean a ll softrollers

Once per day Remove the c leaning rollers and wipe with asoapy wa ter solution.Note: Air dry the rollers after cleaning. Blow-drying c an damage the rollers.

The roller surface must remain intac t; if itbec omes damaged, the c ustomer engineer

must replace the roller.Clean the tapedrive rollers

As needed Inspect the drive rollers for accumulation ofadhesive.

If needed, clean the shafts with isopropylalcohol.


Inspec t and c leanthe c ard trac kand movingmechanismsurfaces

Daily Inspect the card track and a ll moving mechanismsurfaces. Clean off any card residue to avoid issues withdownstream modules.

Clean the film

guide pins

Weekly, or as

needed

When the film guides have material sticking to them,

clean them with isopropyl alcohol.Note: Never use sandpaper or other abrasive materialsthat could scratch the surfac e of the guides.

Clean the gritrollers

Daily Inspect the grit-coated rollers in the interstage and cureassemblies. Clean off any card residue from the rollerswith the wire bristle tool (or stiff bristle toothbrush).Vacuum away any debris or dust.

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Single-Step Color Printing ModuleThe preventive maintenance procedures done by the operator are described in thefollowing sections. Remove the ribbon supply from the Supply and Take-Upassemblies before cleaning the module.

Start of Shift

1. Remove the print ribbon from the module.

2. Vacuum the card track sensors or wipe them with a soft brush or cotton swab.See the locations of the track sensors in the following figure. Vacuum or wipethe sensors even if the module is operating in pass-through mode.

3. Clean debris from all rollers using a damp cloth.

4. Clean any debris from all upper and lower card tracks.

5. Use isopropyl alcohol to clean the guide pins that route the ribbon.

6. Rethread the print ribbon.

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Weekly

1. Clean the transport rollers weekly or after producing 50,000 cards. Wipe theroller surfaces with a soft cloth dampened with isopropyl alcohol.

2. Clean the print and capstan rollers with a cloth dampened with alcohol.

3. Vacuum the area to remove dust and debris as necessary.

4. Wipe the upper and lower card tracks, especially near the exit and entrance,with a clean cloth dampened with isopropyl alcohol.

Only As Needed

The print line or the printhead dot row on the printhead is indicated on thefollowing figure. It needs to be cleaned with lapping paper (Part No. 803359-003)as print quality declines. The dot row also needs to be cleaned with swabs dippedin alcohol to remove residue as part of routine maintenance.

If print quality declines, perform the following procedure:

1. Power off the system.

2. Open the cover of the module to access the printhead.

3. Put on the special gloves that are shipped with the printhead kit. (The glovescan be ordered as 810750-001 for a pair or 810750-002 for 50 pair).

4. Hold the supplied, colored lapping paper with the shiny side toward yourhand. Slide the lapping paper up and down the printhead dot row (see thefollowing figure) five to ten times, applying light pressure.

5. Moisten a swab in 90% (or greater) alcohol and remove any residue from theuse of the lapping papers.

6. Power on the machine and print a test card. Print quality should haveimproved significantly. If poor printing continues, replace the printhead.

Do not use lapping paper more frequently than once every 5,000 cards. Theresidue is easily removed with a few strokes, applying very light pressure.

Caution: Never touch the ceramic printhead surfaces or pins with yourfingers. Follow proper procedures to avoid electrostatic discharge.

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Controller Module

Graphics Printing ModulesStart of Shift

1. Remove the print ribbon from the module.

2. Vacuum clean the card track sensors or wipe them with a soft brush or cottonswab. See the locations of the track sensors in the following figure. Vacuum orwipe the sensors even if the module is operating in pass-through mode.


Clean the exteriorcomponents

As needed 1. Shut down the C ontroller and turn off the power.2. Clean the monitor with a soft cloth dampened with

water. Immediately wipe the monitor dry with aclean cloth.

3. Vacuum the keyboard. If necessary, wipe the keyswith a cloth dampened with water.

4. Remove the trac k ball from the mouse a nd wipe itwith a lint-free tissue.

5. Wipe the c abinet down with a c lean clothdampened in a mild detergent.

6. Remove the filter from the side of the C ontroller (it isnot nec essary to remove the side panel) andvac uum it at least onc e every two weeks.

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5. Use isopropyl alcohol to clean the guide pins that route the ribbon.

6. Rethread the ribbon using the path in the following figure (Back Graphicsmodule depicted).

Weekly


2. Clean the print and capstan rollers with a cloth dampened with alcohol.



Only As Needed

If print quality deteriorates, clean the printhead dot row as described below.

1. Power off the system and open the cover.

2. Release the printhead.

Caution: Never touch the ceramic surfaces, printhead face, or pins with yourfingers.

ESD

The thermal printhead assembly is a static sensitive device. Electrostatic

discharge precautions must be followed when handling, installing, orservicing the printhead to prevent damage. If you do not have an ESD kit,always touch the frame of the system before touching a printhead. Alwayswear special ESD-sensitive gloves when handling the printhead.

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3. Hold the very fine lapping paper (supplied with the printhead) with the shinyside toward your hand and lightly slide the paper up and down the dot rowfive to ten times. You can also use a cotton swab dipped in alcohol to clean thedot row. The dot row is visible at the left side of the print head. It is the shinyline above the green area.

4. Power on the system and print a test pattern. If print quality is still poor,replace the printhead using instructions supplied with the replacement part.

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Magnetic Stripe Encoding Module

Start of Shift

1. Vacuum clean the card track sensors or wipe them with a soft brush or cotton

swab. See the locations of the track sensors in the following figure. Vacuumthe sensors even if the module is operating in pass-through mode.


3. Clean any debris from all upper and lower card tracks.4. Check the first card produced using an analyzer to detect proper placement of

data.

Weekly



3. Wipe the upper and lower card tracks, especially near the exit and entrance,

with a clean cloth dampened with isopropyl alcohol.Clean Heads Only As Needed

When the module requires excessive retries, use a magnetic stripe cleaning cardto clean the read/write heads.

1. Place a drop of cleaning solution in the center of the cloth patch on thecleaning card (Part No. 589248-001).

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2. Place the cleaning card into the card guide in the exit area of the upstreammodule, and feed it into the entrance of the Magnetic Stripe module.

3. Turn the Transport motor drive plate to move the card back and forth underthe heads until they are clean. The number of times to move the card back and

forth depends on the degree of accumulation.

4. Remove the card from the module.

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Topper Module

Start of Shift

1. Vacuum the card track sensors or wipe them with a soft brush or cotton swab.

See the locations of the track sensors in the following figure. Vacuum thesensors even if the module is operating in pass-through mode.

2. Use a damp cloth to clean debris from all rollers.


Weekly

1. Clean the transport rollers weekly or after producing 50,000 cards. Wipe the

roller surfaces with a soft cloth dampened with isopropyl alcohol.2. Vacuum the area to remove dust and debris as necessary.


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Smart Card Module

Start of Shift

1. Vacuum the card track sensors or wipe them with a soft brush or cotton swab.

See the locations of the track sensors (exit and entry sensors in red) in thefollowing figure. Vacuum these sensors even if the module is operating inpass-through mode.

2. Use a damp cloth to clean debris from all rollers.


Weekly




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Basic Topc oat Module


Clean the transportrollers

Weekly, or as needed Dampen a cloth with alcohol androtate the rollers as you wipe.

Clean the guide pins Weekly, or as needed Dampen a cloth with alcohol androtate the rollers as you wipe.

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Chapter 4: Loading Supplies

This chapter provides procedures for loading supplies in variousmodules.

Introduction _________________________________________________________ 4-2Card Cleaning Module _______________________________________________ 4-2Card Input Module ___________________________________________________ 4-4

CardGard Topcoat Module ___________________________________________ 4-6Replac ing C ardGard Supply Film ___________________________________ 4-6Repa iring Broken CardGard Film ___________________________________ 4-8

Embossing and Indent Module________________________________________ 4-9Label Affixing Module _______________________________________________ 4-11Graphics Printing Modules___________________________________________ 4-13Topping Module ____________________________________________________ 4-14Basic Topcoat Module_______________________________________________ 4-16Single-Step Color Module____________________________________________ 4-17

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4-2 Loading Supplies

IntroductionSome of the modules have supplies that must be periodically loaded or changed.This section describes the procedures for loading or replacing the supplies.

Card Cleaning ModuleDatacard cleaning tape is supplied on a disposable core. When the modulecleaning tape supply core is empty, replace the tape using the followingprocedure. An animated version of this procedure is available from the UserAnimations option on the CD.

Cleaning Tape Replacement Procedure

1. Remove the full take-up roll and discard.

2. Move the empty supply core to the take-up spindle.

3. Place the new cleaning tape roll onto the supply spindle so it rotatescounterclockwise as the tape unrolls.

4. Thread the new tape. (If re-threading broken tape, start from wherever thetape broke.)

A. Peel off the edge of the cleaning tape (1 in the following figure) and wrapit around the idler roller (2) with the adhesive side away from the roller.

B. Wrap the tape around the gold drive roller (3) and then around the

backup roller (4).C. Wrap the tape around the black drive roller (5) and then onto the empty

take-up core (6). Use the small piece of tape on the end of the roll to fastenthe cleaning tape to the core.

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Card Input ModuleUse the following procedure to load cards into the card tray. An animatedversion of this procedure is available from the User Animations option on the

CD.

1. Open the transport cover.

2. Press and hold the release lever on the stack pusher, and pull the stack pusherall the way to the back of the tray.

3. Release the lever to lock the stack pusher in place.

4.Load cards into the card tray, working from front to back. Cards are usuallyinserted with the magnetic stripe facing to the back and on top; some jobsmay require a different position. See the following figure for placement ofvarious types of cards.

Wear lint free gloves to load cards. Finger oils interfere with graphicsprinting.

All cards in the tray should be the same thickness.

Visually inspect the card grippers for cracked or damaged plastic. Ifdamaged, they should be replaced before loading cards in the tray.

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5. When the tray is full, press the lever on the stack pusher again to release thecatch, and gently guide the pusher until it is resting against the last card in thestack.

6. Straighten the cards by aligning them evenly along the top and on one side ofthe tray.

The following figure shows how to load various types of cards into the CardInput module.

Caution: To avoid injury, never manually force the stack (card) pusher into

operating position and keep your free hand away as you release the lever.

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CardGard Topcoat ModuleThe CardGard topcoat material is a clear, plastic film that includes both a (tacky)carrier layer and a cover layer. The beginning length of the film contains a leader,

which is a plastic strip for easy threading. The leader should be long enough tothread around the supply guide pins to the carrier take-up spindle.

Replacing C ardGard Supply Film

When the supply is empty, replace it with a new roll as described below.

Procedure

1. Remove the cover and weight over the empty supply roll.

2. Turn the carrier and cover knobs clockwise and lift to remove them.

3. Remove any remaining film, carrier, and cover material.

4. Pull about 10 inches of tape leader from the new supply roll.

5. Place the new roll (1 in the following figure) on the supply spindle so itunwinds counterclockwise.

6. Unwind the carrier leader from the roll and thread it around the film guidepins (2 and 3) and capstan roller (4) separating the cover layer before thesecond pin guide (2).

Wear lint-free and powder-free gloves while removing and loadingCardGard film.

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7. Wrap the film a full turn around the carrier take-up spindle (5). Replace thecarrier take-up knob so that the film is enclosed by the pin. Turn the knob toseat it on the spindle.

8. Pull the tab on the cover layer to separate it from the carrier layer. Wind the

carrier around the guide pins (6 and 7) and onto the carrier spindle (8).9. Wrap the carrier a full turn around the spindle (just enough to keep it in

place).

10. Simultaneously turn the carrier take up knob (5) and cover take up knob (8)counterclockwise to continue winding the cover and carrier around theirspindles and remove any slack in the film. Turning only the cover or carrierspindle will cause slack in the material.

Supply

Carrier Cover

Capstan

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Repairing Broken C ardGard Film

If the CardGard film breaks during operation, use this procedure to re-threadfilm without leader tape.

Procedure

1. Identify where the film break occurred and remove the threaded film fromthe point of the break to both the carrier and cover spindles.

2. Place a piece of tape on each side of the broken edge of the film.

3. Pull the two pieces of tape apart, separating the cover and carrier layers of thefilm.

4. Fold back the carrier end over the sticky coating material to form a new tapeleader of about 10 inches (25.4 cm).

5. Using the previous threading diagram, thread the tacky carrier layer of thefilm around the supply film guides (3) and capstan roller (4), and then wind itaround the carrier take-up spindle (5). Thread the cover layer around theguide pins (6 and 7) and then wind it around the cover take-up spindle (8).

6. Turn the capstan, take-up, and cover knobs as needed to continue wrappingthe film around the spindles until there is no slack.

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Embossing and Indent ModuleIndent mechanisms use a colored supply ribbon to transfer pigment to theindented characters on the cards surface for readability. When the indent ribbon

supply roll is empty, replace it with a new roll as described below.

Indent Ribbon Replacement Procedure

The following instructions are for a rear indent mechanism.

1. On the Controller screen, right-click the Embossing module and select accessribbon to raise the card transport, or manually raise the assembly by liftingthe lever marked with a green up-arrow label.

2. Tip the indent mechanism back for access to the ribbon.

3. Turn the green t-handle counterclockwise to remove it.

4. Remove the full take-up core and discard.

5. Remove the empty core on the supply hub and place it on the take-up hub.

6. Replace the green t-handle.

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7. Place the new supply roll on the supply hub (1 in the following figure) so itunwinds clockwise and pull the end of the ribbon from the roll.

8. Unwind the ribbon from the roll and thread it under the ribbon guides (2 and3).

9. Thread the ribbon past the ribbon guide (3). Twist the ribbon so the dull sidewith pigment faces the cards, and thread the ribbon across the two ribbonguide arms (4).

10. Thread the ribbon down to lay underneath the ribbon guide roller (5), andtwist the ribbon again so the shiny side is facing up.

11. Thread the ribbon into the take-up hub from the bottom and pull it throughthe slot (6) in the hub. Turn the t-handle to wrap the ribbon several turns untilit is secure. Tape the end of the ribbon to the side of the take-up plate.

12. Place the Indent mechanism back in position; let the system lower the cardtransport assembly as it does a reset.

When properly loaded, the shiny (non-pigment) side of the ribbon contactsthe roller and guides (2, 3, 4, and 5).

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Label Affixing ModuleThe Label supply material consists of a paper or polyester liner with adhesivelabels to affix to card surfaces. When the Label supply roll is empty, replace it

with a new roll as described below.

Label Replacement Procedure

1. Pull out on the knob to remove the supply retainer (1 in the following figure).

2. Lift the shoe mechanism (2) to lock the assembly in the load position.

3. Push the knob (3) forward and then release it to lock the supply and take-upassemblies in the load position.

4. Pull the retainer plate (4) out of the take-up spindle to open the two halves ofthe spindle, and remove any remaining label supply material from themodule.

5. Pull the label material away from the supply and peel labels offapproximately 24 inches (60 cm) of the material to form a leader (5).

6. Place the roll on the supply spindle and thread the leader up and over thesupply roller, then down under the shoe, and finally up and over the take-uproller as shown.

7. Insert the label material between the spindle halves and push the retainerplate (5) back in to close the take-up spindle (the smooth side of the plateshould face the label material).

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8. Wind the label material around the take-up spindle to secure it. Wind upenough material so the leading label is between the supply roller and the peeledge.

9. Simultaneously push the knob (3) forward and the latch lever (7) down to

engage the supply and take-up roller assemblies.10. Push the release lever (6) forward to place the shoe mechanism back into

position for production.

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Graphics Printing ModulesDatacard print ribbon is supplied on a disposable core. Load or replace the ribbonusing the following procedure. An animated version of this procedure is available

from the User Animations option on the CD.

Printing Ribbon Replacement Procedure


2. Move the empty supply core from the supply spindle to the take-up spindle.

3. Load the new tape by placing the new print ribbon roll onto the supplyspindle (1) so it will rotate clockwise as the ribbon unwinds.

4. Rotate the knob (2) to move the printhead away from the assembly.

5. Thread the print ribbon in the following manner.A. Peel the edge of the print ribbon from the spool.

B. Route the ribbon through the ribbon sensor (3), around the first guidepost, and then around guides (4 and 5) and the printhead (6) as shown inthe following figure.

C. Wrap the ribbon onto the empty take-up core (7) and use a piece of tape tosecure it to the core.

D. Wind the knob on the roller (8) to remove slack.

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Topping ModuleThe Topping supply material is a colored foil ribbon whose pigment istransferred to the top of the cards embossed characters for readability. When the

supply roll is empty, replace it with a new roll as described below.

Topping Foil Replacement Procedure

1. Remove the take-up roll with core from the module and discard.

2. Move the empty core from the supply spindle to the take-up spindle.

3. Pull off the end of the new supply roll and place the roll on the supply spindle(1 in the following figures) so that it unwinds in a clockwise direction.

4. Unwind the foil from the spindle and unroll it down the ramp under the cardtrack (2).

5. Thread the foil under the lower foil guide roller (3) and over the lift arm.

6. Raise the lift arm (4) to pull the foil up through the opening in the upper cardguide assembly and around its upper guide shaft (5).

7. If you have a foil slitter assembly installed:

A. Thread the foil through the assembly and around its foil guide shaft (7)before threading it around the take-up core.

B. Pull the operator knob on the slitter assembly downward to thread the foilthrough.

8. Thread the material around the take-up core (6) from the bottom and tape theleading edge to the core.

Light pressure is required to unseat the cores from the retainers on thespindles.

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Topping Module Without Foil Slitter Assembly

Topping Module with Foil Slitter Assembly

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Basic Topcoat ModuleUse the following figure as a guide to threading the supply roll through themodule.


2. Move the empty supply core from the supply spindle to the take-up spindle.

3. Load the new roll onto the supply spindle to unwind in a clockwise direction.

4. Thread the supply in the following manner.

A. Peel the edge of the roll from the spool.

B. Wrap the supply around the spindles, guides, and heated area.

C. Wrap the supply onto the empty take-up core and use a piece of tape to

secure it to the core.

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Single-Step Color Module

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