FLEXIBLE PLATFORM FOR VOLUME CARD ISSUANCE OPERATOR MANUAL Revision 1.1 Copyright Important: the technical information contained in this manual is property of MATICA System S.r.l. and is secured by copyright. The terms of the license define and specify permitted uses and other limitations. Reproduction of any part of this manual, in any form, is forbidden without the explicit written permission of MATICA System S.r.l. Technical information contained in the present manual is subject to change without notice. If not otherwise specified, any reference to companies, names, dates and addresses is purely incidental and is only intended to illustrate the use of the MATICA System S.r.l. product. Every care has been taken in the collection and verification of the documentation inserted in this manual; nevertheless MATICA System S.r.l. cannot assume any responsibility deriving from its use. Copyright © 2011 MATICA System S.r.l. All rights reserved Published by MATICA System S.r.l. Printed in Italy Issue: March 2011 Revision 1.1 MATICA System S.r.l. via Guido Rossa, 4/6 20037 – Paderno Dugnano MILAN - ITALY Phone +39.02.92272501 Fax +39.02.91084372 E-mail: [email protected] Web: http://www.maticasystem.com System 7000 Operator Manual Rev. 1.1 Page 2/46 Contents Table of contents Chapter 1 – Introduction .......................................................... 4 1.1 1.2 1.3 1.4 Specifications ............................................................................. 4 Warnings ................................................................................... 6 Choice of site.............................................................................. 6 Removal of the package ............................................................... 7 Chapter 2 – Start up .................................................................. 9 2.1 Installation................................................................................. 9 2.2 Working cycle ............................................................................. 10 Chapter 3 – Consumables ......................................................... 21 3.1 3.2 3.3 3.4 3.5 Changing Changing Changing Changing Changing Thermal module cleaning tape ........................................ 21 Thermal module printing ribbon....................................... 22 Top Indent ribbon ......................................................... 25 Rear Indent ribbon ........................................................ 28 Tipper ribbon ................................................................ 31 Chapter 4 – Error List ................................................................ 35 Chapter 5 – Cleaning and maintenance ................................. 43 5.1 Thermal Printer cleaning .............................................................. 43 5.2 Preventive maintenance schedule .................................................. 46 System 7000 Operator Manual Rev. 1.1 Page 3/46 Chapter 1 - Introduction Chapter 1 – Introduction 1.1 Specifications Cabinet Size Single Feed/Unload Width: 15.6 cm (6.1”) Double Feed/Unload Width: 28.3 cm (11.1”) Standard Cabinet Width: 37.2 cm (14.6”) Height (incl. support): 150 cm (59.1”) Standard Cabinet Depth: 55 cm (21.7”) Double Feed Depth: 61 cm (24”) System 7000 Operator Manual Rev. 1.1 Page 4/46 Chapter 1 - Introduction Productivity Speed Printing Mode Card Format Hopper Capacity Comm. Interface depending on the system configuration Thermal Transfer and Sublimation 300 DPI Edge-to-edge printing ISO CR80 – ISO 7810 Input: 600 cards Output: 500 embossed cards (approx.) LAN The machine weight depends on the system configuration. Requirements Electrical 110V ÷ 120V, 60 Hz or 220V ÷ 240V, 50 Hz. Room electrical circuit with safety and emergency interlocks switch. AC voltage must be stable and constant. Environment Room temperature: 13 ÷ 35°C (55/95°F). Humidity: 20% to 80% non-condensing. Room no subject to dust, smog and filing. Place The machine must be disposed in closed place. At least 60 cm as free space around the machine must be guarantied. Pavement surface must be flat. If pavement is raised by floor like platform, be sure that it able to support the machine weight. Avoid that the machine is disposed near to: - heating sources - cooling sources - electromagnetic sources - water sources Power consuming Elements Power Modules Feeder & Stacker Encoder Multichip 5 Stations Thermo Embosser Tipper (1 Module) Laser System 7000 Operator Manual Machine state Standby Pick Working Current Current Current A A A 0.1 0.1 0.1 0.1 0.1 0.4 0.1 0.1 0.2 0.2 0.4 1.0 0.9 1.5 Rev. 1.1 0.1 0.2 0.2 0.4 1.0 0.4 1.5 Voltage V Power W Power BTUh 220 220 220 220 220 220 220 22 44 44 88 220 198 330 75 150 150 300 751 676 1,127 Page 5/46 Chapter 1 - Introduction 1.2 Warnings Respect these warnings and follow the indications labeled on the system. Power the system through the electrical power supply indicated on the related label. Connect the system to plugs-in provided with a grounding device. Avoid using plugs-in placed on the same circuit in connection with machines starting up and stopping periodically. Take care of the power supply cable, in order to avoid damaging or wearing out. The system has never to be installed near heat or cooling sources. When the cover is open the system automatically stops all the motors; this kind of safety is useful when cleanings and changing of consumables have to be performed. Only perform the adjustments reported in this manual: a wrong adjustment may cause serious damages. 1.3 Choice of site Follow the instructions reported below to choose the site where you want to place the 7000 System and to remove the package. Before starting the installation, choose a wide and functional area with the following requirements: - A level and rigid surface. Yielding surfaces, like pre-manufactured platforms or floors covered with a fitted carpet, don’t guarantee the right alignment of the modules making up the 7000 System. - A good accessibility. Leave free spaces all around the machinery, in order to allow access to inspection and maintenance areas, and a right ventilation of the system. Also leave at least one meter in front of the machine, so that the operator using the front panel has got a proper working area. - Favorable environment conditions. Install the 7000 System in a cool and dry place; avoid too cold or too warm temperatures; keep the machinery far from humidity, dust and smoke. Don’t directly expose to heat or sunlight. No electromagnetic interferences. - Proper electrical power supply. Connect the system and its devices with cables fit to your electrical power supply net. When using extensions or multiple plugs-in, be sure that the total absorption doesn’t exceed the maximum allowed value. System 7000 Operator Manual Rev. 1.1 Page 6/46 Chapter 1 - Introduction 1.4 Removal of the package The system is delivered in a wooden case. It’s necessary to pay attention to the size of the infrastructures (doors, hoists, etc.) through witch the machine must be passed to be definitively settled in its site. To dismantle the case, unscrew all the front cover and remove the cover; then remove the package crossbars by unscrewing the related fixing screws on each side panel. System 7000 Operator Manual Rev. 1.1 Page 7/46 Chapter 1 - Introduction Pull out the machine and its support crossbars using a fork lift. Remove the support crossbars under the machine. Remove the polystyrene protections and the film. It is advisable to keep the case and the protective materials for possible reuse. System 7000 Operator Manual Rev. 1.1 Page 8/46 Chapter 2 – Start up Chapter 2 – Start up 2.1 Installation The system specifications are written on the machine label; verify that the voltage marked on the label corresponds with your country voltage supply. Connect the power cord on the machine support to the wall socket, then connect the LAN interface cable on the back panel of the system. The service key on the machine back panel enable or disable the cover open safety. If the key can be removed, the cover open safety is enable so the machine stops if a cover is opened. Otherwise if the key can’t be removed, the cover open safety is disabled and the machine doesn’t stop even if a cover is opened. The emergency button on the machine front side bypass the service key; when this button is pushed the machine stops even if the service key is in the position that disables the cover open safety. Power on the machine turning the main switch clockwise. Now the system is ready to work. LAN System fuses Sevice key Power cord Main switch System 7000 Operator Manual Rev. 1.1 Page 9/46 Chapter 2 – Start up 2.2 Working Cycle To perform a working cycle you must introduce the plastic cards to be personalized into the automatic Input Hopper, with the magnetic stripe on the bottom right side of the card. Then you had to run the desired job with the Maticard Pro software. If the machine is equipped with a Double Input Hopper, insert the card in the desired one and it will be pushed into the Rotator module. This module simply pass the card to the next module if it comes from the Hopper on Xaxis or rotate the card 90° if it comes from the Hopper on the Y-axis. System 7000 Operator Manual Rev. 1.1 Page 10/46 Chapter 2 – Start up If the card it’s moved towards a Smart Station, this module can be equipped with a Chip contact, a Chip contactless, a Barcode reader and a OCR reader to personalize the card. System 7000 Operator Manual Rev. 1.1 Page 11/46 Chapter 2 – Start up If the card it’s moved towards a Transport, this module just passes the card to the next module. If the card it’s moved towards an Encoder, this module encodes (write & read) the magnetic stripe present on the card, with a capacity of reading and writing 3 tracks at high or low coercivity. System 7000 Operator Manual Rev. 1.1 Page 12/46 Chapter 2 – Start up If the card it’s moved towards a Multiple Smart Card personalization module, this one can manage the personalization of the chip present up to five cards in the same time. The mechanism works as an “elevator” by which the 5-station Smart Card module raises itself one station at the time until all 5 stations have been loaded, upon which the module descends to its initial position. At this point the first card, now fully personalized, is transferred to the next module and replaced by a new card, and the process described above is repeated. If there isn’t any chip personalization, the Multiple Smart Card module just passes the card to the next module. System 7000 Operator Manual Rev. 1.1 Page 13/46 Chapter 2 – Start up If the card it’s moved towards a Small Transport, this module just passes the card to the next module. System 7000 Operator Manual Rev. 1.1 Page 14/46 Chapter 2 – Start up If the card it’s moved towards a Flip Over, this module can simply pass the card to the next module, if the card has to be printed on the top side, or rotate it 180° if the card has to be personalized on the bottom side. System 7000 Operator Manual Rev. 1.1 Page 15/46 Chapter 2 – Start up If the card it’s moved towards a Thermal Printer, this module performs a 300 dpi graphic printing of the card in the desired position; the printing could be black, black with overlay protection, scratch off or full color with overlay protection, depending on the ribbon type. The module can support a ribbon length up to 500 meters and print the card from edge to edge. The Printer is equipped with a system which combines a cleaning tape and a cleaning roller called AdvanceClean®, and ensures that cards are free from dust and debris. Furthermore the Thermal module every 5000 cards automatically gives a warning, by blinking a red led on its console, to remember that the printing head has to be cleaned. System 7000 Operator Manual Rev. 1.1 Page 16/46 Chapter 2 – Start up If the card it’s moved towards a Laser, this module engraves the card in the desired position. The Laser Module needs a vacuum system to avoid the dispersion of harmful dust (please refer to the related documentation). System 7000 Operator Manual Rev. 1.1 Page 17/46 Chapter 2 – Start up If the card it’s moved towards an Embosser, this module emboss the characters present into its drum in the desired position on the card. This module can be equipped with two indent module, front and rear, to perform the indenting personalization of both sides of the card in a single pass. System 7000 Operator Manual Rev. 1.1 Page 18/46 Chapter 2 – Start up If the card it’s moved towards a Tipper, this module colors the embossed characters; the color depends on the kind of ribbon mounted. System 7000 Operator Manual Rev. 1.1 Page 19/46 Chapter 2 – Start up At the end of the cycle, the card is stored in the Output module; if the card is well personalized will be in the upper Output Hopper, while if the card is rejected or defective will be in the lower Reject Box. System 7000 Operator Manual Rev. 1.1 Page 20/46 Chapter 3 – Consumables Chapter 3 – Consumables 3.1 Changing Thermal module cleaning tape When the Thermal Printer cleaning tape is finished (fig. 1), you have to replace it, in order to avoiding plastic cards from dust before printing. First of all you must remove the used tape from its rolls (fig. 2). fig. 1 fig. 2 Now you need to insert the new tape in the two related rolls (fig. 3) with the full spool in the left roll, the empty spool in the right one and the ribbon over them. Be careful to put the tape under the shaft between the rolls (fig. 4). fig. 3 System 7000 Operator Manual fig. 4 Rev. 1.1 Page 21/46 Chapter 3 – Consumables 3.2 Changing Thermal module printing ribbon When the Thermal printing ribbon is finished (fig. 1), you must replace it. First of all you had to unhook the print head by pulling the related spring (fig. 2), in this way the head lifts up horizontally. fig. 1 fig. 2 Now it’s necessary to remove the used ribbon from its inserts (fig. 3). fig. 3 System 7000 Operator Manual Rev. 1.1 Page 22/46 Chapter 3 – Consumables Then you have to put the new ribbon over its inserts, with the full spool of the ribbon in the right inserts and the empty spool in the left ones (fig. 4). Be sure that the ribbon runs over its spools, and also that the large ends of the ribbon spools will be in the inner inserts and the narrow ends in the outer ones. fig. 4 The first spool to insert is the full one, then you must unwind the ribbon and pass it under the print head (fig. 5). fig. 5 System 7000 Operator Manual Rev. 1.1 Page 23/46 Chapter 3 – Consumables Now you can insert also the empty spool (fig. 6). fig. 6 Finally push down the print head (fig. 7) in order to hook the related pin to the module (fig. 8). fig. 7 System 7000 Operator Manual fig. 8 Rev. 1.1 Page 24/46 Chapter 3 – Consumables 3.3 Changing Top Indent ribbon To change the Top Indent ribbon, first of all you must unscrew the two cover disk knobs and remove the two disks (fig. 1). Cover disk Knob Knob Cover disk fig. 1 Now you can remove the used ribbon (fig. 2). fig. 2 System 7000 Operator Manual Rev. 1.1 Page 25/46 Chapter 3 – Consumables Then you can insert the empty spool on the left disk matching one of the spool hole with the related disk pin and full spool on the right disk matching one of the spool hole with the related disk pin; be sure that the ribbon unwinds on the left side of the full spool (fig. 3). Full spool Pin Pin Empty spool fig. 3 Be sure that the ribbon will pass trough this path: over the first roll, under the second and third rolls, between the rubber red roll and its pin, over the empty spool (fig. 4). Empty spool Rubber Roll Pin 1st Roll 2nd Roll 3rd Roll fig. 4 System 7000 Operator Manual Rev. 1.1 Page 26/46 Chapter 3 – Consumables Fasten the ribbon on the empty spool with a stick tape (fig. 5). Stick tape fig. 5 Match the hole on each of the two cover disks with the related ones on the ribbon disks and tighten the disks knobs into the aforesaid holes (fig. 6). Cover disk Knob Knob fig. 6 System 7000 Operator Manual Rev. 1.1 Page 27/46 Chapter 3 – Consumables 3.4 Changing Rear Indent ribbon To change the Rear Indent ribbon, first of all you must unhook the desired Indent cartridge by pulling the related lever on the right side (fig. 1). Lever fig. 1 Now you can pull out the lower cartridge (fig. 2). fig. 2 Then you have to put the lower cartridge on a plain surface (fig. 3) and pull the spring that releases the ribbon cover (fig. 4). Spring fig. 3 System 7000 Operator Manual fig. 4 Rev. 1.1 Page 28/46 Chapter 3 – Consumables At this point you need to lift up the ribbon cover (fig. 5) and remove the used ribbon from the cartridge (fig. 6). fig. 5 fig. 6 Now you can insert the new ribbon in the related pins with the full spool on the left pin and the empty spool on the two right pins (fig. 7), from the ribbon rolls point of view. fig. 7 You must be absolutely sure that the ribbon runs with the ink side opposite to the pin spools, trough this path: outside the two rolls near the full spool (fig. 8), outside the first roll and inside the second roll near the empty spool and finally outside the big red roll (fig. 9). fig. 8 System 7000 Operator Manual fig. 9 Rev. 1.1 Page 29/46 Chapter 3 – Consumables Now you have to put the side projections of the lower cartridge in the related left (fig. 10) and right (fig. 11) inserts on the module Insert fig. 10 Insert fig. 11 Finally you must push the cartridge in order to hook it, paying attention to pass the ribbon over the lower punches (fig. 12). fig. 12 System 7000 Operator Manual Rev. 1.1 Page 30/46 Chapter 3 – Consumables 3.5 Changing Tipper ribbon When the Tipper ribbon is finished (fig. 1) you have to unhook the ribbon cartridge, by pulling the black knob on the left of the module, in order to extract the cartridge itself (fig. 2). Knob Knob fig. 1 fig. 2 While you are holding the cartridge, you must remove the used ribbon from its spool (fig. 3) and pull the disk spring that holds the old carton core (fig. 4). fig. 3 System 7000 Operator Manual fig. 4 Rev. 1.1 Page 31/46 Chapter 3 – Consumables Then you can extract the old carton core (fig. 5) and insert in the same position the new ribbon by pulling the related disk spring (fig. 6). Be careful that the ribbon unwinds over the core. fig. 5 fig. 6 Now you must be absolutely sure that the ribbon follows this path: over the nearest first shaft, under the black shaft (fig. 7), between the third little shaft and the fourth one, over the fifth little shaft and finally under the farer shaft (fig. 8). fig. 7 System 7000 Operator Manual fig. 8 Rev. 1.1 Page 32/46 Chapter 3 – Consumables At this point you have to pull up the ribbon, pass it over the upper shaft, and put the cartridge in its beginning position on the module (fig. 9); then you can hook the cartridge by pushing it until the black knob clicks (fig. 10). fig. 9 fig. 10 Now you must insert the new carton core in the top spool (fig. 11) and fasten the ribbon on it with a stick tape (fig. 12). fig. 11 System 7000 Operator Manual fig.12 Rev. 1.1 Page 33/46 Chapter 3 – Consumables Finally you have to push the black button on the module (fig. 13) in order to tighten the ribbon and wind it on the top spool (fig. 14). fig. 13 System 7000 Operator Manual fig. 14 Rev. 1.1 Page 34/46 Chapter 4 – Error List Chapter 4 – Error List When an error occurred the PC will show the messages listed below. Apply the proper procedure to remove the error condition and read carefully the error comments. If there are more modules of the same kind in the system, in order to distinguish which module generated the error, the related module name is followed by a number that represents the order, in the working cycle, of one module compared to the other ones of that kind. ERROR CODE 0001 FEEDER x NOT CONNECTED 0002 FEEDER x NACK ANSWERED 0003 FEEDER x RESET (NACK-3!!) 3012 FEEDER x START LOAD ERROR 3013 FEEDER x END LOAD ERROR 3014 FEEDER x EMPTY 3015 FEEDER x JAM ERROR 0001 FLIP OVER x NOT CONNECTED 0002 FLIP OVER x NACK ANSWERED 0003 FLIP OVER x RESET (NACK-3!!) 3004 FLIP OVER x CARD ALREADY INSIDE 3005 FLIP OVER x 2 SENSORS ARE BUSY 3006 FLIP OVER x ROTATE ERROR 3007 FLIP OVER x CARD-IN ERROR 3008 FLIP OVER x CARD-OUT ERROR 3009 FLIP OVER x UNABLE TO ROTATE 3010 FLIP OVER x UNABLE TO MOVE System 7000 Operator Manual POSSIBLE CAUSES Communication error with the Feeder board. System error; please contact the technical support. System error; please contact the technical support The card can’t be loaded; check if: a) Card jam; b) Card in sensor damaged; c) Loading motor damaged. The card can’t be loaded; check if: a) Card jam; b) Card out sensor damaged; c) Loading motor damaged. If the hopper is empty add cards; while if the hopper isn't empty, check if: a) Cards are stuck together or bowed; b) Mechanical impediments; c) Alignment between modules; d) The Loading motor moves correctly. Card Jam. Remove the card Communication error with the Flip Over board. System error; please contact the technical support. System error; please contact the technical support Card already present inside the module while expected free. Card jam. Remove the card. Movement error when searching the 180° sensor. Error on module card input. Check if: a) Card jam; b) Card-in sensor damaged; c) Motor damaged. Error on module card output. Check if: a) Card jam; b) Card-out sensor damaged; c) Motor damaged. The Flip Over can’t rotate because of a card not positioned in the middle of the module (but under the card in or the card out sensor). The Flip Over is in a incorrect position. Check the motor. Rev. 1.1 Page 35/46 Chapter 4 – Error List ERROR CODE POSSIBLE CAUSES 0001 ENCODER x NOT CONNECTED 0002 ENCODER x NACK ANSWERED 0003 ENCODER x RESET (NACK-3!!) 3004 ENCODER x CARD ALREADY INSIDE 3005 ENCODER x 2 SENSORS ARE BUSY 3016 ENCODER x CARD JAM 3007 ENCODER x CARD-IN ERROR 3008 ENCODER x CARD-OUT ERROR 3018 ENCODER DATA ERROR 5019 ENCODER TRACK 1 EMPTY 5020 ENCODER TRACK 2 EMPTY 5021 ENCODER TRACK 3 EMPTY x x x x 5022 ENCODER x TRACK 1 ERROR 5023 ENCODER x TRACK 2 ERROR 5024 ENCODER x TRACK 3 ERROR 5025 ENCODER x TRACK 1 STX ERROR 5026 ENCODER x TRACK 2 STX ERROR 5027 ENCODER x TRACK 3 STX ERROR 5028 ENCODER x CHIP ERROR 5059 ENCODER x VERIFY ERROR TRACK 1 5060 ENCODER x VERIFY ERROR TRACK 2 5061 ENCODER x VERIFY ERROR TRACK 3 System 7000 Operator Manual Communication error with the Encoder board. System error; please contact the technical support. System error; please contact the technical support Card already present inside the module while expected free. Card Jam. Remove the card. If there is one card in the Encoder check if: a) The card is slipping on rollers, if so clean them; b) Check if pulleys are fixed correctly on their shaft; c) Check if the Encoder motor is damaged; If there isn’t any card in the Encoder check if: a) Check if one of the three card movement sensors is damaged or dirty. Error on module card input. Check if: a) Card jam; b) Card-in sensor damaged; c) Motor damaged. Error on module card output. Check if: a) Card jam; b) Card-out sensor damaged; c) Motor damaged. Invalid data. a) Check if the cards are up side down; b) Check if the encoder head is connected correctly. a) Check if the cards are up side down; b) Check if the encoder head is connected correctly. a) Check if the cards are up side down; b) Check if the encoder head is connected correctly. a) Check if the magstripe is scratched or dirty on track 1; b) Check if the Encoder head is dirty; c) Check for timing belt tension. a) Check if the magstripe is scratched or dirty on track 2; b) Check if the Encoder head is dirty; c) Check for timing belt tension. a) Check if the magstripe is scratched or dirty on track 3; b) Check if the Encoder head is dirty; c) Check for timing belt tension. Error on the track 1 Start Sentinel. Error on the track 2 Start Sentinel. Error on the track 3 Start Sentinel. Smart card reading / writing error Error during the track 1 verification. Error during the track 2 verification. Error during the track 3 verification. Rev. 1.1 Page 36/46 Chapter 4 – Error List ERROR CODE 0001 TRANSPORT x NOT CONNECTED 0002 TRANSPORT x NACK ANSWERED 0003 TRANSPORT x RESET (NACK-3!!) 3004 TRANSPORT x CARD ALREADY INSIDE 3005 TRANSPORT x 2 SENSORS ARE BUSY 3007 TRANSPORT x CARD-IN ERROR 3008 TRANSPORT x CARD-OUT ERROR 0001 MCHIP x NOT CONNECTED 0002 MCHIP x NACK ANSWERED 0003 MCHIP x RESET (NACK-3!!) 3004 MCHIP x CARD ALREADY INSIDE 3005 MCHIP x 2 SENSORS ARE BUSY 3007 MCHIP x CARD-IN ERROR 3008 MCHIP x CARD-OUT ERROR 3030 MCHIP x RESTORE ERROR 3031 MCHIP x CASTLE-IN ERROR 3032 MCHIP x CASTLE-OUT ERROR 3033 MCHIP x CONTACTS MOVEMENT ERROR 5025 MCHIP x CHIP ERROR ! System 7000 Operator Manual POSSIBLE CAUSES Communication error with the Transport board. System error; please contact the technical support. System error; please contact the technical support Card already present inside the module while expected free. Card jam. Remove the card. Error on module card input. Check if: a) Card jam; b) Card-in sensor damaged; c) Motor damaged. Error on module card output. Check if: a) Card jam; b) Card-out sensor damaged; c) Motor damaged. Communication error with the Multichip board. System error; please contact the technical support. System error; please contact the technical support Card already present inside the module while expected free. Card Jam. Remove the card. Error on module card input. Check if: a) Card jam; b) Card-in sensor damaged; c) Motor damaged. Error on module card output. Check if: a) Card jam; b) Card-out sensor damaged; c) Motor damaged. Lift module error; check if: a) Card jam; b) Home sensor damaged; c) Castle motor damaged; d) Castle belt broken. Card transport input error.; check if: a) Card jam; b) Castle-in sensor damaged; c) Castle motor damaged; d) Castle belt broken. Card transport output error.; check if: a) Card jam; b) Castle-out sensor damaged; c) Castle motor damaged; d) Castle belt broken. The chip contacts remain opened/closed. Check the contacts motor. Smart card reading / writing error Rev. 1.1 Page 37/46 Chapter 4 – Error List ERROR CODE 0001 ROTATOR x NOT CONNECTED 0002 ROTATOR x NACK ANSWERED 0003 ROTATOR x RESET (NACK-3!!) 3004 ROTATOR x CARD ALREADY INSIDE 3005 ROTATOR x 2 SENSORS ARE BUSY 3006 ROTATOR x ROTATE ERROR 3007 ROTATOR x CARD-IN ERROR 3008 ROTATOR x CARD-OUT ERROR 3009 ROTATOR x UNABLE TO ROTATE 3010 ROTATOR x UNABLE TO MOVE 0001 UNLOAD x NOT CONNECTED 0002 UNLOAD x NACK ANSWERED 0003 UNLOAD x RESET (NACK-3!!) POSSIBLE CAUSES Communication error with the Rotator board. System error; please contact the technical support. System error; please contact the technical support Card already present inside the module while expected free. Card jam. Remove the card. Movement error; check the motor. Error on module card input. Check if: a) Card jam; b) Card-in sensor damaged; c) Motor damaged. Error on module card output. Check if: a) Card jam; b) Card-out sensor damaged; c) Motor damaged. The Rotator can’t rotate because of a card not positioned in the middle of the module (but under the card in or the card out sensor). The Rotator is in a incorrect position. Check the motor. Communication error with the Unloader board. System error; please contact the technical support. System error; please contact the technical support 3007 UNLOAD x CARD-IN ERROR Error on module card input. Check if: a) Card jam; b) Card-in sensor damaged; c) Motor damaged. 3010 UNLOAD x UNABLE TO MOVE The module can’t move. Check the motor. 3035 UNLOAD x HOME POSITION ERROR 3036 UNLOAD x UP POSITION ERROR 3037 UNLOAD x STACKER FULL 3038 UNLOAD x UNABLE TO LOAD System 7000 Operator Manual During a reset operation or if the card has been ejected: a) Check if the motor is damaged; b) Check if the home sensor is damaged or dirty; If the card hasn’t been ejected: a) Check for mechanical impediments. Card Jam. Remove the card. If the stacker is full unload it. If the stacker isn’t full check if the full sensor is damaged. The card can’t be loaded; check if: a) Card jam; b) Loading sensor damaged; c) Loading motor damaged. Rev. 1.1 Page 38/46 Chapter 4 – Error List ERROR CODE 0001 TIPPER x NOT CONNECTED 0002 TIPPER x NACK ANSWERED 0003 TIPPER x RESET (NACK-3!!) 3004 TIPPER x CARD ALREADY INSIDE 3005 TIPPER x 2 SENSORS ARE BUSY 3007 TIPPER x CARD-IN ERROR 3008 TIPPER x CARD-OUT ERROR 3050 TIPPER x RIBBON ERROR 3057 TIPPER x TIPPER TEMPERATURE LOW 3058 TIPPER x TIPPER TEMPERATURE HIGH 5051 TIPPER x TIPPER ERROR 5055 TIPPER x TIPPER PRESSURE ERROR 5056 TIPPER x TIPPER TEMPERATURE ERROR System 7000 Operator Manual POSSIBLE CAUSES Communication error with the Tipper board. System error; please contact the technical support. System error; please contact the technical support Card already present inside the module while expected free. Card jam. Remove the card. Error on module card input. Check if: a) Card jam; b) Card-in sensor damaged; c) Transport Motor damaged. Error on module card output. Check if: a) Card jam; b) Card-out sensor damaged; c) Transport Motor damaged. Tipper ribbon finished or broken. Tipper temperature too low Tipper temperature too high The Tipper can’t reach or leave its home position; check if: a) Home sensor damaged; b) Pad motor damaged. The Tipper pad has not enough pressure. Check the pad motor. Tipper temperature out of range Rev. 1.1 Page 39/46 Chapter 4 – Error List ERROR CODE 0001 THERMO x NOT CONNECTED 0002 THERMO x NACK ANSWERED 0003 THERMO x RESET (NACK-3!!) 3004 THERMO x CARD ALREADY INSIDE 3005 THERMO x 2 SENSORS ARE BUSY 3007 THERMO x CARD-IN ERROR 3008 THERMO x CARD-OUT ERROR 3050 THERMO x RIBBON ERROR 5062 THERMO x COMMAND ERROR 5063 THERMO x PARAMETER ERROR 5064 THERMO x TIMEOUT 5065 THERMO x COVER OPEN 5069 THERMO x INVALID DOWNLOAD 5070 THERMO x BAD SECURITY CODE 5071 THERMO x CLEANING (GOLD) RIBBON ERR 5072 THERMO x ERROR: EXIT SENSOR BUSY 5073 THERMO x UNKOWN ERROR! System 7000 Operator Manual POSSIBLE CAUSES Communication error with the Thermo board. System error; please contact the technical support. System error; please contact the technical support Card already present inside the module while expected free. Card jam. Remove the card. Error on module card input. Check if: a) Card jam; b) Card-in sensor damaged; c) Motor damaged. Error on module card output. Check if: a) Card jam; b) Card-out sensor damaged; c) Motor damaged. Ribbon finished or not present. Thermal printer command error. Parameter error in the buffer sent to Thermal printer. Timeout expired. Printer head up. Wrong data format downloaded. Mismatch between Thermal printer ID card in buffer and ID card present under the printing head. Cleaning cycle error. The card already printed is still inside the module. Unknown error. Rev. 1.1 Page 40/46 Chapter 4 – Error List ERROR CODE AND DESCRIPTION 0001 EMBOSSER x NOT CONNECTED 0002 EMBOSSER x NACK ANSWERED 0003 EMBOSSER x RESET (NACK-3!!) 3039 EMBOSSER x X HOME ERROR SYMPTOM AND CORRECTIVE ACTION Communication error with the Embosser board. System error; please contact the technical support. System error; please contact the technical support Check for X home sensor: a) X home sensor is dirty: clean it with compressed air or lint free cloth; b) X home sensor isn’t connected correctly on the board. Check that all pulleys are fixed on the shaft. Check X motor connection. Check the belt’s state. Card is picked by embossing clamp and is taken to the embosser’s exit. 3040 EMBOSSER x X END ERROR 3041 EMBOSSER x Y HOME ERROR 3042 EMBOSSER x Z HOME ERROR Check for X end sensor: a) X end sensor is dirty: clean it with compressed air or lint free cloth; b) X end sensor isn’t connected correctly on the board; c) Remove any impediments along the X embossing travel; d) Check that all pulleys are fixed on the shaft; e) Check X motor connection; f) Check the belt’s state. Card is embossed in a wrong way. Remove any impediments along the embossing Y travel. The card can even be picked or not by the embosser’s clamp and the embossing sequence isn’t completed correctly. If the clamp picks the card but doesn’t start punching and the drum keeps on moving: a) Check drum motor home sensor; b) Drum motor home sensor is dirty: clean it with compressed air or lint free cloth; c) Drum motor home sensor isn’t connected correctly on the board. If the card is picked, but it is embossed in a wrong way check: a) Belt tension; b) If pulleys are fixed on the shafts; c) If the motor is moving correctly or it stalls. If the card is picked by the clamp but the drum doesn’t move check: a) Drum motor connection on the board. 3046 EMBOSSER x COVER OPEN 3008 EMBOSSER x CARD-OUT ERROR 3053 EMBOSSER x CARD LOST System 7000 Operator Manual Machine cover open Check the output sensor or card jam. Card correctly loaded and then lost by the Embosser card guide. Rev. 1.1 Page 41/46 Chapter 4 – Error List ERROR CODE AND DESCRIPTION 3054 EMBOSSER x CARD MISFEED 5043 EMBOSSER x X EMBOSS ERROR 5044 EMBOSSER x Y EMBOSS ERROR 5045 EMBOSSER x Z EMBOSS ERROR 5047 EMBOSSER x PUNCH ERROR SYMPTOM AND CORRECTIVE ACTION The clamp holds the card, but the embossing cycle doesn’t start. Check the entry sensor: a) Entry sensor is dirty: clean it with compressed air or lint free cloth; b) Entry sensor isn’t connected correctly on the board. The clamp moves straight to embossing area without a card or after having made a bad noise: a) Check for Y home sensor; b) Y home sensor is dirty: clean it with compressed air or lint free cloth; c) Y home sensor isn’t connected correctly on the board; d) Check Y motor electrical connections; e) Check if the pulley is fixed on Y motor shaft; f) Check belt state. X-axis card movement error; reject the card. See ERROR 3039 Y-axis card movement error; reject the card. See ERROR 3041 Z-axis card movement error; reject the card. See ERROR 3042 The embossing clamp picks the card but the embossing sequence isn’t completed correctly. Check for any mechanical impediments along the embossing leverage. If the card is picked by the embosser’s clamp but just one character is embossed: a) Check punch motor home sensor; b) Punch motor home sensor is dirty: clean it with compressed air or lint free cloth; c) Punch motor home sensor isn’t connected correctly on the board. If the card data aren’t embossed correctly check: a) Belt status; b) All pulleys are fixed on the shaft correctly. The card is picked correctly by the embosser’s clamp and it is placed correctly under the drum, but the embosser mechanism doesn’t start, check: a) If the embossing motor is connected correctly on the board; b) replace the motor. Card not punched in infill way. 5048 EMBOSSER x INFILLER ERROR If ribbon is finished replace it. If ribbon isn’t finished: a) Check if ribbon is installed correctly; b) check if ribbon advance sensor is working correctly. 5049 EMBOSSER x CASSETTA ERROR Infiller cartridge movement error. 0001 SERVICE-BOARD NOT CONNECTED Communication error with the Service board. 0002 SERVICE-BOARD NACK ANSWERED System error; please contact the technical support. 0003 SERVICE-BOARD RESET (NACK-3!!) System error; please contact the technical support System 7000 Operator Manual Rev. 1.1 Page 42/46 Chapter 5 – Cleaning and maintenance Chapter 5 – Cleaning and maintenance To ensure that the system operates correctly, it is necessary to carry out periodic cleaning of some of the components that otherwise could cause problems in cards production. To clean all the transport rolls of the system and the Encoder module head, you must absolutely use isopropyl alcohol; at this purpose you can ® ®. use an apposite cleaning card supplied by MATICA® It is recommended to use the aforesaid products only for the indicated components, in order to avoid damaging the system. It is also useful to carry out a periodic general cleaning of the system, by using a vacuum cleaner every week or 10,000 cards performed. 5.1 Thermal Printer cleaning Warning: The Print Head must be cleaned every 5000 cards to satisfy the warranty conditions. To check the cleaning status press on the keyboard ALT + F12 and then the up arrow key two times. The system display will show two counters and a message. The first counter is the number of card passed. The second counter indicates when to perform the cleaning cycle. The message could be: THERMO x COUNTER if the cleaning cycle has been performed or Tx : CLEANING NEEDED if the cleaning cycle has not been performed (in both messages the digit x represents the position in the working cycle of the displayed Thermo Module, regarding other modules of the same kind present in the whole Card Issuance System). System 7000 Operator Manual Rev. 1.1 Page 43/46 Chapter 5 – Cleaning and maintenance When the Thermal Printer module has to be cleaned, every 5,000 cards, the right led on its own console starts to blink a red light (fig. 1). fig. 1 To clean the print head you must use a PVC printer cleaning kit (fig. 2) provided with a cleaning card (fig. 3). fig. 2 fig. 3 Remove the printing ribbon as shown in paragraph 3.2, being sure that the print head is down. Then insert the cleaning card into the first Flip Over (fig. 4) and push it until the Thermal module (fig. 5). fig. 4 System 7000 Operator Manual fig. 5 Rev. 1.1 Page 44/46 Chapter 5 – Cleaning and maintenance Push and hold the right button on the module console (fig. 6). fig. 6 Now the card passes under the print head (fig. 7). fig. 7 At the end of the cleaning cycle, it goes into the second Flip Over (fig. 8) where you can take the card away. Finally you must insert again the printing ribbon as shown in paragraph 3.2. fig. 8 System 7000 Operator Manual Rev. 1.1 Page 45/46 Chapter 5 – Cleaning and maintenance 5.2 Preventive maintenance schedule The S7000 Card Personalization Systems have been designed and manufactured using high quality and high technologies materials guaranteeing so, reliability, performance and long life. Nevertheless to have always the best performances of the system it’s advisable to make periodical inspections and preventive maintenances taking under control the parts listed in the “Preventive Maintenance Schedule”. The “Preventive Maintenance Schedule” includes all the operations and actions fundamental for the reliability of the system and must be performed by qualified technical personnel. The non correct or missing maintenance execution can carry out the decay of the warranty in every form and type. PREVENTIVE MAINTENANCE SCHEDULE Time Cleaning and Lubrication Controls and inspections Daily or 5.000 cards - Cleanliness of all machine rubber rolls - Cleanliness of encoding head - Cleanliness of thermal print head Weekly or 25.000 cards - Cleanliness and removal of dust and dirty from the machine - General Visual Inspection Monthly or 100.000 cards - Cleanliness and removal of dust and dirty from the machine - General Visual Inspection - Cleanliness and lubrication of all machine moving axis. - Embossing X Axis Belt (tension and integrity) Note: only PTFE oil must be used and few drops must be put - Lubrication/greasing of Embossing Pins Striker - Embossing Y Axis Belt (tension and integrity) - Multichip Elevator belt (tension and integrity) Replacement - Embossed character height - Drum Home Position Six months or 500.000 cards - Cleanliness of sensors - Tipper Pad (pressure and integrity) - Encoding head - Machine bearings - All machine belts - No play on mechanical axis Yearly or 1.000.000 cards - Power Supply output voltages - All machine springs - Embossing punch cycle - All machine offset - Drum wheel & Drum Motor Pulley for joining - All machine belts - All machine rolls - Embossing Arm Bearing - Tipper Pad The above schedule is referred to a working cycle of 8 hours having 500 cards per hour as throughput. NOTE: Belts, Rubber Rolls, Springs, Gears & Pulley, Encoding Heads and Thermal Printer Heads (except the electrical part) are considered worn out parts and not covered by machine warranty. System 7000 Operator Manual Rev. 1.1 Page 46/46
