3M MAXSecure Printer Module Maintenance Manual Manual No. 980286-001 Rev.
FOREWORD This manual contains service and repair information for 3M MAXSecure Printer Modules manufactured by the 3M Corporation,St. Paul, Minnesota. The contents include maintenance, diagnosis and repair information. TECHNICAL SUPPORT For technical support, users should first contact the distributor that originally sold the product—phone +1 (800) 344 4003 to locate the nearest 3M Distributor. COPYRIGHT NOTICE This document contains information proprietary to 3M Corporation.
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TABLE OF CONTENTS CHAPTER 1 GENERAL DESCRIPTION 1.1 PRINTER MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . 1-1 1.1.1 1.1.2 1.1.3 1.1.4 1.2 1.3 1.4 1.5 1.6 1.7 Clear Card Material Feed, Shear, and Flip-Over · Print Station · · · · · · · · · · · · · · · · · · White Card Feeder Station · · · · · · · · · · · Card Assembler Station· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · OPTIONS AND ACCESSORIES . . . . . . . . . ABOUT THIS MANUAL . . . . . . . . . . . .
CHAPTER 4 TROUBLESHOOTING 4.1 DIAGNOSING BASIC PRINTER PROBLEMS . . . . . . . . . . . . . . 4-2 4.2 DIAGNOSING COMPUTER INTERFACE PROBLEMS . . . . . . . . . 4-5 CHAPTER 5 REPLACEMENT PROCEDURES 5.1 REQUIRED TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 5.2 PART REPLACEMENTS . . . . . . . . . . . . . . . . . . . . . . . . 5-3 5.2.1 Case Removal · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 5-3 5.2.2 White Card Feeder Station Removal · · · · · · · · · · · · · · · · · · · 5-4 5.2.
APPENDIX A TEST SOFTWARE A.1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 A.2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 A.2.1 A.2.2 A.2.3 A.2.4 A.2.5 A.2.
Figure 5-18. Front Belt Removals. . . . . . . . . . . . . . . . . . . . . . 5-20 Figure 5-19. Printer Station Removal. . . . . . . . . . . . . . . . . . . . 5-21 Figure 5-20. Printer Station Rear Parts.. . . . . . . . . . . . . . . . . . . 5-23 Figure 5-21. Supply Spindle Assembly.. . . . . . . . . . . . . . . . . . . 5-25 Figure 5-22. Ribbon Take Up Spindle. . . . . . . . . . . . . . . . . . . . 5-27 Figure 5-23. Printer Station Card Sensor.. . . . . . . . . . . . . . . . . . 5-28 Figure 5-24. CPU Board..
CHAPTER 1 GENERAL DESCRIPTION 1.1 PRINTER MODULE DESCRIPTION 3M MAXSecure Printer Modules can operate as stand-alone card imaging devices or, as shown above, become part of a larger system that can also include a 3M Lamination and Die Cutter Module. 3M MAXSecure can also include a Magnetic Stripe Encoder Module (not shown). 3M MAXSecure can produce either two- or three-layer cards composed of either a Clear Card and a White Card or a white card sandwiched between two Clear Cards.
CHAPTER 1 GENERAL DESCRIPTION receive no image by the Printer Module. On the finished cards, however, these images underlie the Clear Card image. After imaging, the Printer Module assembles and delivers a Clear and White Card to the Laminator and Die Cutter Module. For three-layer cards, a second Clear Card follows. An attached Laminator and Die Cutter Module fuses the Clear and White Card material and die cuts the result to a standard credit/debit/etc card size.
CHAPTER 1 GENERAL DESCRIPTION 1.1.1 Clear Card Material Feed, Shear, and Flip-Over The upper part of this assembly contains a motor and a shear. The middle part has two sensors—one for signaling the shear point and another to sense splices. The lower part implements flip-overs of a second Clear Card. All three parts of the assembly have rollers that move the material, due either to a manual advance or by a motor powered drive roller.
CHAPTER 1 GENERAL DESCRIPTION dithering creates a pixel (picture element) using a small dot matrix, reduced picture resolution results. This resin imaging process is called Thermal Transfer. In contrast, users can create 32 levels of gray using YMC blends without loosing any image resolution. By the time a card is fully imaged, a whole set of ribbon panels is used. Users can obtain ribbon media in several configurations, each offering a cost optimization for a particular set of card design requirements.
CHAPTER 1 GENERAL DESCRIPTION 1.1.4 Card Assembler Station After imaging, a Clear and a White Card come together in the Card Assembler. The card path deepens here, so that a White Card can rest on top of a Clear Card. The assembly includes a motor, a solenoid, and two sensors. After these card components come to rest in this assembly, as signaled by the lower of the two sensors, the solenoid-coupled roller raises to push the cards against the motor-powered drive roller.
CHAPTER 1 GENERAL DESCRIPTION 1.4 CAUTIONARY NOTES Exercise reasonable care when servicing the printer, as follows: Other than prescribed operator maintenance, only qualified personnel should remove the case or otherwise attempt to repair this equipment. 3M Products offers training to those wishing to service this equipment. Servicing personnel must avoid touching exposed circuitry. Inputs to the Power Supply operate at power line voltages.
CHAPTER 1 GENERAL DESCRIPTION Part Replacement Spares Recommended Quantity (Per 100 Printers) A/R 5 5 5 5 5 5 10 1 3 1 1 9 A/R A/R A/R A/R A/R 2 2 1 A/R 2 2 2 1 2 15 10 2 5 1 2 1 2 10 2 2 2 2 2 5 2 2 2 5 10 2 980286-001 Rev.
CHAPTER 1 GENERAL DESCRIPTION Spare Accessories Recommended Quantity (Per 100 Printers) A/R A/R A/R A/R A/R A/R A/R A/R A/R 10 A/R A/R A/R 1-8 Item Kit, Cleaning Core Interface Cable Power Cord (Domestic) Power Cord (Europe) Kit, Feeder, Weight Kit, Cleaning Card User’s Guide Windows Drivers (NT and 95) Kit, Cleaning Swab Kit, Ribbon Take Up Core Kit, Cleaning Core Spindle Assembly Kit, Foam and Box (Printer or Laminator) Kit, Maintenance Manual Part No.
CHAPTER 1 GENERAL DESCRIPTION 1.5 PACKAGING CONSIDERATIONS The factory cartons include a printer placed inside a protective ESD (Electrostatic Discharge) bag and suitable form-fitting foam cushions. Testing of this packaging has confirmed its ability to withstand the forces required by equipment transporters. If any other shipping materials are used, related shipping damage may not be covered by the warranty.
CHAPTER 1 GENERAL DESCRIPTION 1-10 980286-001 Rev.
CHAPTER 2 INSTALLATION AND OPERATION This chapter includes information on the following: • Unpacking • Attaching a Laminator and Die Cutter • Printer Module Cables • Printer Controls and Indicators • Ribbon Installation • Clear Card Installation • White Card Installation Similar descriptions also appear in the associated User’s Guide and other manuals shipped with the printer. The intent here is to make this manual as complete as possible for the targeted service provider.
CHAPTER 2 INSTALLATION AND OPERATION 2.1 INSTALLATION 2.1.1 Unpacking Figure 2-1 shows the packaging materials used to ship the Printer Module. Note that customers should keep these materials on hand for future shipping needs. The product warranty may not cover a printer damaged during shipment using other shipping materials. If necessary, users should order replacements before shipping the Printer Module. Figure 2-1. Packaging Materials 2-2 980286-001 Rev.
CHAPTER 2 INSTALLATION AND OPERATION 2.1.2 Location Concerns Users should avoid locations with heavy concentrations of airborne contaminates. Until ready to use, keep Clear Card material and White Cards in their cartons. Such care also applies to Cleaning Roller Sheaths. Handle all ribbon and card media in a way that avoids contamination. Fingerprints and other such contaminants can lower image quality. Select a location that offers easy access to all sides and unrestricted air flow for ventilation.
CHAPTER 2 INSTALLATION AND OPERATION 2.1.4 Attaching Cables Figure 2-3 shows the Rear Panel of the Printer Module. This panel has the following: • Power ON-OFF Switch • Power Connector • Parallel Port DB-25 Connector (e.g., LPTx) With ferrites at each end. • Module Interconnect DB-9 Connector Figure 2-3 shows the cables to the host computer and the cable that interconnects the Printer Module to a Laminator and Die Cutter Module.
CHAPTER 2 INSTALLATION AND OPERATION 2.1.5 Cable Diagrams Figure 2-4 shows the cable wiring. HOST DB-25 Pin No. STROBE DATA 0 DATA 1 DATA 2 DATA 3 DATA 4 DATA 5 DATA 6 DATA 7 ACK/ BUSY PAPER ERR. READY INIT ERROR/ N/A N/A N/A SIG. GND SIG. GND SIG. GND SIG. GND SIG. GND SIG. GND SIG. GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 DB-25 PRINTER Pin No.
CHAPTER 2 INSTALLATION AND OPERATION 2.2 OPERATION 2.2.1 Controls and Indicators Figure 2-4 shows the Push Button and LCD (liquid crystal display) that appear on the front of the Printer Module as well as the rear-panel-mounted Power Switch. As shown, the LCD communicates operational status to users. After ribbon installation, users press and hold the Panel Button for about three seconds or until hearing the ribbon begin to advance. This initialization positions a yellow panel for subsequent printing.
CHAPTER 2 INSTALLATION AND OPERATION 2.2.
CHAPTER 2 INSTALLATION AND OPERATION 2.2.4 LCD Messages Related to Encoder Module LCD Message Description ENCODER BUSY Encoder is Busy; Printer Waiting to Send Card ENCODING ERR Error During Encoding WAIT ENCODER Error Reprint Wait–Encoder Finishing CARD ENCODER A Card is in the Encoder NO CARD ENCODER No Cards in Encoder MAGNETIC ERROR Communications Error Between Printer and Encoder CLEAN MAG HEAD Clean Magnetic Encoder 2.2.
CHAPTER 2 INSTALLATION AND OPERATION 2.2.7 Print Head Latch and Release Levers Figure 2-6 shows the Latch and Release levers for the Print Head. Users open the Cover and raise the Print Head for Cleaning Procedures and Ribbon Loading. The Print Head and Cover must both remain down for card imaging and other printer operations. Users should keep the cover closed as much as possible to reduce the exposure of internal components to airborne contaminants.
CHAPTER 2 INSTALLATION AND OPERATION 2.2.8 Ribbon Installation Refer to Figure 2-7, and proceed as follows: Step 1. Open the Cover, raise the Print Head, and remove any ribbon and ribbon core still remaining in the printer. Step 2. To prepare a new ribbon for installation, undo the tape keeping the ribbon from unraveling. Then, rest both the ribbon and an empty core on end, on a flat surface, and touching. Tape the loose ribbon end onto the empty core, and wind some ribbon onto the core.
CHAPTER 2 INSTALLATION AND OPERATION 2.2.9 Card Media 3M Products offers the following Card media: Description Part Number Kit containing Clear Card roll and White Cards for 2-Layers 104523-055 Kit containing Clear Card roll and White Cards for 3-Layers 104523-060 2.2.10 Clear Card Material Loads Refer to Figure 2-8, and proceed as follows: Step 1. Place a roll of Clear Card Material onto the holder such that the loose end feeds from the bottom of the roll. Step 2.
CHAPTER 2 INSTALLATION AND OPERATION 2.2.11 White Card Feeder Loading Refer to Figure 2-9, and proceed as follows: Step 1. Park the Card Weight at the top of the White Card Feeder. Step 2. Place cards in the Input Tray. Note that cards can stick together for various reasons, and users should effect a shuffle-like action on the stack prior to placing cards into the White Card Feeder. Note that Magnetic Stripes, if present, should face up and be nearer the back of the Feeder than the front.
CHAPTER 2 INSTALLATION AND OPERATION 2.2.12 Two- verses Three-Layer Selection Figure 2-10 shows the lever that sets the Printer Module for either two- or three-layer operation. Be sure that the lever setting matches with the card thickness selected for use, as follows: • 2-Layer Setting requires 0.022-inch card thicknesses. • 3-Layer Setting requires 0.015-inch card thicknesses. Figure 2-10. Card Layer Selection Lever. 980286-001 Rev.
CHAPTER 2 INSTALLATION AND OPERATION 2-14 980286-001 Rev.
CHAPTER 3 THEORY OF OPERATION This chapter includes three major topics: • Color Fundamentals • Printer Module Card Path Elements • Circuit Description 3.1 COLOR FUNDAMENTALS Color refers to the hues seen in the visual spectrum. This spectrum consists of all the colors seen in a rainbow or by the dispersal of white light through a prism. The extremes of this spectrum are red (the longest wavelength perceivable) and violet (the shortest wavelength perceivable). The remaining orange, yellow, green, etc.
CHAPTER 3 THEORY OF OPERATION When computers get involved in the color process such things as memory capacity and data compression become factors. Fifteen-bit color yields 32x103 shades and a requires 15-bits for each pixel in the desired image. Twenty-four bit color yields 16x106 shades. Thirty-two bit color yields 4x109 shades. Note that the memory required for images expands substantially with the number of shades. Compression attempts to reduce the memory requirements.
CHAPTER 3 THEORY OF OPERATION which can make individual dots more observable and subject to moiré pattern generation. With Dye Sublimation, users achieve essentially the continuous-tone quality of photographs. Moiré patterns can become a factor when users generate either print files or hard copy separations for offset printing. Users should ask the people that do their offset printing which separation angles best reduce these patterns before risking a distorted result.
CHAPTER 3 THEORY OF OPERATION When close concern for color is important in displaying prints, users should find a similar ambient setting for a color check. If a color is closely related to identifying a printed feature, users may find themselves dealing with this level of concern, with skin tones typically offering the greatest challenge. However, most applications tend to require a less critical evaluation.
CHAPTER 3 THEORY OF OPERATION 3.2 PRINTER INTRODUCTION 3M MAXSecure color imaging requires three passes of a Clear Card media across the Print Head. Clear Card media shuttles back and forth across the print head during this process. The ribbon feeds between the image head and the card media and during printing advances from its supply to its take-up reels in step with the advancing print media. Heat, when generated at an image head element, transfers ribbon dye in a measured quantity onto the print media.
CHAPTER 3 THEORY OF OPERATION Sensors During a print cycle, LED-Photo transistor sensors monitor the positions of the cards and the advance of the ribbon. Note that two types exist—a beam interrupt type and a beam reflection type. Switch sensors also exist that operate off of the cam that raises and lowers the Print Head. These switches sense completion of head-up and head-down transitions. Two ribbon sensors exist. One ribbon sensor can receive a beam reflection through the yellow ribbon panels.
Clear Card Feed Rollers Manual Advance Knob Ribbon Supply Clear Card Shear Card Path Select Solenoid Print Head Platen Roller Ribbon Take Up Cleaning Roller Clear Card Flip-Over Card Path Card Path Exit Solenoid CARD ASSEMBLER STATION Print Head Up/Down Cam Stepper-Driven Transport Rollers White Card Feeder Rollers PRINTER STATION CLEAR CARD FEED AND SHEAR STATION WHITE CARD FEED STATION Clear Card Material Sensor Flag Sensor Ribbon Sensor Input Sensor Cut Sensor Card at Output Sensor S
CHAPTER 3 THEORY OF OPERATION 3.3 CIRCUITRY As shown in Figure 3-2, the printer has the following circuits: • Print Head Circuitry • Motor Control Circuitry • Status Circuitry • Host and Module Interconnect Ports • Operator Panel Circuitry If possible, spend some time with this figure. The intent is to offer another perspective to descriptions given in other parts of the manual.
CHAPTER 3 THEORY OF OPERATION Operator Control and Display MICROCONTROLLER LCD Messages Initialize and Error Clear Data Bus (16-bits) Control Signals Clock (32 MHz) Address Bus DB-9 (Encod.) DB-9 (Lam.
CHAPTER 3 THEORY OF OPERATION A Parallel cable extends the data bus of the Main CPU board to the Extension board. Centronics™ (i.e., LPTx) port signals from the Main CPU board serve as a Host I/O. A serial (RS-232C) port interconnects the Printer Module with a Laminator and Die Cutter Module. Another serial port interconnects the Printer Module with the Encoder Module. An associated Receiver/Transmitter IC contains a charge pump, so that serial signals can have ±10-volt swings.
CHAPTER 4 TROUBLESHOOTING Typically, troubleshooting begins with an attempt to relate a problem to an associated component or system function. In this phase, servicing personnel may attempt to duplicate the problem and then use various means to test for a malfunction or improper system setup. This chapter hopes to aid in this process by presenting Flow diagrams that lead to some areas related to an observed problem.
CHAPTER 4 TROUBLESHOOTING 4.1 DIAGNOSING BASIC PRINTER PROBLEMS Figure 4-1 shows a diagnostic flow diagram designed to reproduce problems related to card images and card transports. Two tables follow that offer associated details and section references. Diagnosing Basic Printer Step 1 Turn Power On LCD Message Appears? No Check Power, Fuse, Cord, etc.
CHAPTER 4 TROUBLESHOOTING Problems Associated with Print Anomalies References Symptom Possible Causes Adjustment or Cleaning 5.2.20 5.2.16 5.2.16 No Image CPU Board Head Up/Dn Motor Switch Sensors Faint Image Low Print Head Voltage Dirty Print Head 6.2.1 Artifacts Particles on Feed or Transport Rollers 6.2.3 Horizontal Lines Dirty or Damaged Print Head Element 6.2.1 Multiple Evenly-Spaced Horizontal Lines CPU Board Print Head Registers Vertical Lines Stepper Transport Belts Too Tight 6.3.
CHAPTER 4 TROUBLESHOOTING Problems Associated with Card Transport Failures References Symptom No Clear Card Feed Possible Causes Clear Card Material Not Below Shear LED Indicates SPLICE Clear Card Feed Station Rollers Dirty Clear Card Feed Motor, Belt, or pulleys Clear Station PCBA or IC Adjustment or Cleaning 2.2.10 2.2.2 6.2.3 5.2.6, 5.2.7 5.2.
CHAPTER 4 TROUBLESHOOTING 4.2 DIAGNOSING COMPUTER INTERFACE PROBLEMS Figure 4-2 shows a flow diagram that checks the interface to the computer. For additional information, see: • Cabling— • Theory— • Replacements— Diagnosing Interface Connect Printer to PC, Prepare Printer with Ribbon and Cards, and Turn Power On Issue Commands Using Either: · WindCard · Windows Driver · Test Software Printer Responds? Yes Interface Is OK No Repair/Replace: · I/O Cable · CPU Bd. Cable Ÿ CPU Bd. Figure 4-2.
CHAPTER 4 TROUBLESHOOTING 4-6 980286-001 Rev.
CHAPTER 5 REPLACEMENT PROCEDURES This chapter consists of part replacement procedures for those items either found or suspected of malfunctioning. These procedures cover the items checked during the troubleshooting presented in the previous chapter. However, this manual does not cover all components and only represents an attempt toward identifying a potential set of components. As a result, servicing personal may discover additional items that warrant procedures.
