Operator’s Guide Datacard Passport Issuance System PB8500 October 2021 528302-001, Rev.
Notice Please do not attempt to operate or repair this equipment without adequate training. Any use, operation or repair you perform that is not in accordance with the information contained in this documentation is at your own risk. Trademark Acknowledgments Entrust, Sigma and the hexagon design are trademarks, registered trademarks and/or service marks of the Entrust Corporation in the United States and other countries.
Revision Log Revision Date A October 2021 Description of Changes First release of this document.
Contents Chapter 1: Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Expansion Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Additional Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Process Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Run Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multi-Book Chip Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Laser 450G Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Secure Overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Buffer/Closer/QA Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 1: Introduction This chapter provides general information about the Datacard® PB8500™ Passport Issuance system. 1 System Overview The PB8500 passport issuance system has a series of modules that work together to complete the personalization of elements on a passport. Available modules are defined in the following table. A system may contain duplicate modules or none of certain modules.
Module Description System Controller The Controller contains the primary computer that controls the function of the individual modules in the system and is also the primary interface point for the operator. It includes the hardware necessary to power on and interact with the modules in the system. Each system has a dongle plugged into the Controller computer. The dongle needs to be in place for the system to work.
Module Description Single Passport Buffer This module is used to synchronize multiple Laser Engraving modules in one system to increase throughput when using teamed (ganged) engraving. Single Passport Buffer modules must be installed in pairs except when the module is directly before a Booklet Closing module. Drop On Demand (DoD) The Color Inkjet Printing module uses pigment to print 1200 dpi full-color, tonal, or black and white images and text on the paper pages of a passport booklet.
Expansion Kits The following kits are included in your shipment automatically if your configuration requires additional cooling fans or power inlets. Additional Cooling Fans Larger systems may require an additional cooling fan in the Output module. The cooling fan is available as an installation kit. This kit is shipped with a system or additional modules if one is required. Auxiliary AC Power Inlet The auxiliary AC power inlet is shipped with expansions that exceed the power limit.
Specifications and Requirements System specifications and site requirements are as follows. Electrical and Environmental Specifications Electrical, Operating, and Storage Refer to the PB8500 Passport Issuance System data sheet on the Datacard website (www.entrust.com). Power Consumption The power consumption of the system is the sum of the power consumption of the Controller and all of the modules in the system.
Physical Requirements The following section contains the physical site requirements needed for a PB8500 system. Floor Space The floor space required to install the system is dependent on the number and type of modules included. To determine how much floor space is required, calculate the following: 1. Controller width + [number of input and output modules x input/output width] + [number of inkjet modules x inkjet width)] + (number of standard modules x standard width) = Total width of system 2.
Weight To determine the system weight, calculate the sum of the weights for each module, the Controller, and any additional casters (11 lbs/5.0 kg). For the weight of the controller and each module, refer to the PB8500 Passport Issuance System data sheet on the Datacard website (www.entrust.com).
Module Interlocks Module interlocks are a safety feature that prevent operator injury. Lifting a 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 the adjoining modules finish processing passports and then sit idle with motors enabled. Most systems have connected hoods so that all or many modules lose power to the motors when hoods are opened. Wider modules have one interlock on the upstream side.
Module Status Lights Each module (except for the Input and Output modules) has a status light located 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 the Controller screen for more information. Flashing light—Module error or failure in normal operation; failure in module firmware. Light on, but not flashing— Supplies are low or the module is in a paused state.
Supplies Find the current supplies information on the Entrust website (www.entrust.com): Datacard Home > Product & Solutions > Supplies Related Documents The following documents provide additional information for the PB8500 system. Description Part No.
Chapter 2: System Power On and Power Off This chapter provides procedures for starting, stopping and pausing the Datacard® PB8500™ Passport Issuance system. 2 Power On the System The system has a button for starting the Controller computer and an E-Stop switch for powering on the system modules. Perform the following procedure to start the system.
Procedure 1. Plug the system into AC power. 2. Turn on the Controller PC by pressing the power button on the front of the computer. Allow the Controller PC to boot up completely. Do not use the keyboard or mouse during Windows start-up. 3. Log on to Windows. 4. Start the Controller software, and go to the Production screen. It displays the progress of the system during startup and, eventually, a diagram of the system. 5.
Power On Troubleshooting If the system fails to start properly, use the following guidelines to isolate the most likely cause. Some of these troubleshooting scenarios may require a 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 facility outlet. Verify that the facility power is available and is of the correct voltage for the system.
Power Off the System Remove AC power from the system any time service is being performed. 1. Wait until all production tasks are complete. 2. Select the Windows Shutdown command, and wait for the Controller PC to shut down. 3. Turn the E-Stop switch counterclockwise to OFF. The word OFF is then visible in the dial cutout. This removes power from the following: All modules The system fans Modules that are supplied by additional power cord inlets 4.
Pause and Resume the System You can pause the system with the Controller software, or by pressing the Pause/Resume button on the Output module. The Pause/Resume button has a built-in light that shows the following system states: Green flashing light—System is paused. Green light on, but not flashing— System is in the normal running or idle state. No light—System is temporarily between the pause and running state.
16 System Power On and Power Off
Chapter 3: Load Supplies This chapter provides procedures for loading supplies in the Datacard® PB8500™ Passport Issuance system. 3 Booklets Use the following instructions to load booklets into the Passport Input Module. If the booklets are different stock, adjust for booklet thickness as described in “Adjust for Change of Booklet Thickness” on page 18. If booklets are jammed in a module, refer to instructions on page 18.
Adjust for Change of Booklet Thickness When you load thicker or thinner booklet stock, you may need to adjust the Input Module so that the booklet separator picks only one booklet at a time. Adjustment Procedure 1. Place two booklets into the stacker and move them forward until they both line up with the edge of the booklet separator. 2. Loosen the adjustment knob (2). 3. Move the booklet adjuster (1) forward or back until it is in the center of the second booklet.
Printheads for Inkjet Modules Printheads must be replaced by trained service personnel. This procedure is documented in the Drop On Demand Module Service Manual (Part No. 528211-001).
Overlay Material When the supply roll is empty, replace it with a new roll, as described below. Replacement Procedure 1. Load the thin film overlay so that the registration mark is at the top of the roll.
2. Use the following figure as a guide to thread the thin film overlay through the standard Secure Overlay Module.
22 Load Supplies
Chapter 4: Production This chapter informs the user how to use the Production application of the Controller software to monitor the system and process jobs. 4 Monitor the System The Production application in the Controller software allows you to process and monitor jobs. You also can see the status of modules and whether supplies need to be replaced. To customize elements of the production interface, refer to “Production Preferences” on page 47.
Blue indicates normal operating status. Yellow indicates a cautionary condition (low supplies, input passport tray approaching empty, and so forth). Red indicates an error condition or an opened interlock. If an interlock is opened, the module, controller, and both neighboring modules on the topology turn red. When you close the interlock, the color changes to blue. You may right-click on a module to see a menu for resetting it.
Job Status You can monitor the status of individual passports within a job from the Job Details tab. The Job Details tab has information about each passport in the selected job. For more information, refer to “View Job Information” on page 29. Other Status Reporting Use the following for additional status information. Status Bar The status bar on the main interface has load status, production status, and machine monitors that give visual indicators of job and machine states.
Event Log The system administrator can use the Event Log tools to query and view system events for administration and troubleshooting. The Event Log is described in detail in the Controller software online help and the Administrator’s Guide. Process Jobs The following sections describe how to use the Production application to process passports. Load Jobs Follow the steps below to load job files into the database. 1. In the Production Station tab (Applications > Production), click Load on the status bar.
2. To select the job file, click Browse, navigate to the file location, and click Open. The file path displays in the File Name text box.
3. Perform one of the following steps. Select the Job Setup file (click Browse, navigate to the file location, and click Open). or If selection criteria are set up, select the Use Selection Criteria check box to let the program search through existing Job Setups (which contain the selection criteria) to find a name that matches the job file. Job Setups specify which Data Setups, Production Options Setups, Audit Setups, and Passport Setups the job uses.
User Input Needed Dialog If you have the Vision Verification or Quality Assurance module, the User Input Needed dialog box displays if a quality issue is detected by one of these modules. The message prompts you to take some action to make sure that the job completes successfully. Production does not continue until you take action. You can click the Override check box to continue for this production run if needed.
Preview Products Print preview from the Job Details tab allows you to proof a passport before it is produced. The preview shows printable graphics information such as image, text, and bar code elements. You can view non-printable information such as chip data in the Job Details screen. Print Preview is not available when data is encrypted. Perform the following procedure to access Print Preview from Job Details. 1. Open the Production window (Applications > Production). 2.
5. Use one of the following to open the print preview window. Right-click on the selected records and then select Print Preview. or Click the Print Preview button. If more than one record is selected in the table to preview, the row is highlighted in light blue to correspond with the record being previewed in the Print Preview window. If the Passport Setup is changed after loading the job or running the job, the preview might not match the printed passport.
The following table describes the print preview properties on the Front, Back, and Both Sides tabs. Front/Back/Both Sides Tabs Properties 32 The “Virtual Passport” View the passport as designed in Passport Setup. Only image, text, and bar code elements display. Zoom Select the zoom level to view greater or less detail. Rotation Select Rotation to turn the passport clockwise in increments of 90 degrees. Show Background Select the check box to display the background image (if any).
Remake a Job Use the following procedure to remake passports that were rejected. 1. In the Production window (Applications > Production) under the All Jobs tab, select the job from the list. 2. Select the Job Details tab. The Job Details screen contains a list of all passports in a selected job. 3. If any passports have been rejected, click Remake in the status bar to remake those passports. You can click and drag using your mouse and use Alt+Click or Shift+Click to select multiple passports. 4.
Split Jobs Use the following procedure to create multiple jobs from a single job. For example, if a job contains 1000 passports, you can split it into smaller jobs. You can split a job into two jobs at a specific passport or form, or you can split a job into multiple jobs of equal size. You also can select individual passports to split into a different job. Refer to “Advanced Split” on page 35. 1.
c. Click OK. The new job is created and added to the job lists. The new job has the same name as the current job with “[001]” appended. 4. To split a job into multiple jobs: a. Click Split into jobs of passport quantity. b. Enter the number of jobs that you want. The passports are split equally between jobs. If the number of passports is not evenly divisible by the number of jobs, the resulting jobs contain an equal number, except for the final job, which contains the remaining passports. c. Click OK.
36 Production
Search for Jobs Perform the following steps to search for jobs within the database: 1. In the Production window (Applications > Production), select the All Jobs tab. 2. In the left pane, select the check box next to the parameters on the jobs list that you want to use in your search. The more you select, the narrower the scope of the search. Name - Enter the name of the job in the text box. State - Select the state from the list.
Hold/Reject Passports from a Job Perform one of the following procedures to hold, reject, or remove a product from a job. 1. In the Production window (Applications > Production) under the All Jobs tab, select a job from the list. 2. Select the Job Details tab. The Job Details screen contains a list of all passports in the selected job. 3. To reject a passport or passports from the job: Select a passport or passports from the list. Click Set Reject on the upper bar to reject the passport manually.
Production Station Reference The Production interface includes bars and tabs that display information job screens. Production Station Status Bar The status bar is viewable regardless of the tab displayed. To customize elements of the Production interface, refer to “Production Preferences” on page 47. Each operator can customize fonts and font sizes for tool bars, tables, and other elements. You also can activate FIR data views and tooltips to display at the bottom of job screens.
Indicator Description Hood status The Hood status indicates whether opening the hood is allowed (OK to Open Hood or Do Not Open Hood). The hood status is red when it is NOT OK to open the hood. Audit On or Off Audit ON is green when audit data is being collected. Open Applications Bar The lower bar has program tabs on the left side that display all open applications. Click a tab to bring that application window to the top.
The information that displays in the Ready Jobs tab depends on the fields defined in Data Setup and the columns selected. Following is an example. Refer to “Choose Columns to Be Displayed” on page 45.
Column Description Status The job status Input File The Input file used for this job Filtering Tool The All Jobs tab includes a filtering tool for quickly locating jobs based on their parameters. Use the filtering tool to define specific criteria to speed up the search. Follow these steps to search for jobs: 1. In the left pane, select the check box next to the parameters to use in the search. The search filter parameters are listed in the following table.
Search Filter Parameter Description Last Worked On Enter a number in the text box and select Hours or Days from the list. Example: If you enter 8 in the text box and select Hours from the list, the program displays only jobs worked on during the past eight hours. Job Setup Select Browse, and then select a Job Setup from the dialog box. The program displays only jobs that use the selected Job Setup. Input File Enter the Input File name into the text box.
Print Preview Select one or more records in the Job Details tab and select the Print Preview option to preview the selected records (print preview is also available from the right-click menu). Refer to “Preview Products” on page 30 for more information. Sort and Filter Records in the Job Details Tab In the Job Details tab, you can sort the records by column heading and filter the records shown in the list. Filtering categories (record number, state, status, etc.) are defined in the Data Setup.
Sort by Table Heading To enable records to be sorted by column head, click Allow Table Sorting in the Job Details tab. This setting is saved in the user preference file. Do not sort tables during a production run with a large number of passports, as this causes delays in production times. Filter by Production Counts Click a Production Count folder to view only the passports in that folder. For example, to view only the rejected passports from a specific job, click the Reject folder.
2. Click Choose Columns. 3. Add or remove column types from the Selected Columns box by using the arrow buttons. To select multiple column types, use Shift+Click or Alt+Click.
4. Click Set to Default to return to the default setting. 5. Click OK when finished, or Cancel to exit without making changes. Group Jobs The Ready Jobs and All Jobs tabs can group jobs by group name or input file (jobs that have been loaded from the same input file) into a single display item. Select an option from the Group by list. The job group becomes a separate row in the table. You can expand and collapse the job group to show or hide the jobs contained in the group.
Each tab in the tool has options for customizing Production interface elements (font, font size, FIR data, and tool tip views). Each tab has the following buttons: OK - Applies changes, Saves, and closes the dialog. Cancel - Closes the dialog, no changes are applied. Apply - Applies changes, Saves, and the dialog box continues to display. Use Defaults - Resets all settings to the default.
Use the General tab to set the font and font size for interface elements including: the text of the Production tabs (1 in the following figure), Production Statistics (2), Display Fields (3), and Extended help titles and text (4). You also can enable and customize Table Tool Tips (5) that display when the pointer hovers over a cell in a table.
Toolbars Tab Use the toolbar tab to select the font and font size for the toolbar buttons on the Production interface tabs and View Accounts dialog. You can use common settings for all toolbars or set the toolbars individually.
Tables Tab Use the Tables tab to set the font and font size for the tables on the Production interface tabs and View Accounts dialog. The font and font size changes apply to the table column headings and table values. You can use common settings for all tables or set the tables individually.
FIR Record Tab Use the FIR Record tab to enable FIR data to display at the bottom of the Production interface tabs with customized sizing and the tool tip option. You can set the font and font size for the FIR data view as well as the tool tip. You can set common preferences for all tabs, or set the tabs individually.
Chapter 5: Preventive Maintenance This chapter provides routine preventive maintenance schedules and procedures for periodic cleaning and inspection of the Datacard® PB8500™ Passport Issuance system. 5 Overview PB8500 systems require routine preventive maintenance to optimize performance and minimize downtime. Perform preventive maintenance procedures either at specified time intervals or machine-cycle intervals, depending on the module.
System Preventive Maintenance Tasks Site personnel need to perform the following preventive maintenance tasks. Warning: Before performing maintenance, power off the Controller and remove the AC power cords. Refer to “Power Off the System” on page 14. Procedure Frequency Vacuum all booklet tracks Once per week or every 25,000 books Clean track sensors Once per week or every 25,000 books Comments Check for debris in both upper and lower guides. Vacuum the area to remove dust and debris as necessary.
Procedure Frequency Comments Clean the exterior components of the Controller As needed 1. Clean the monitor with a soft cloth Clean the Controller module filter (also the air filter on the Output module, if present) Monthly Clean the filter over the fans on the side of the Controller whenever it gets dirty, and at least once per month. Pull the flexible filter away from the Controller and vacuum it on both sides. Operator’s Giude dampened with water.
56 Preventive Maintenance
Chapter 6: Troubleshooting This chapter provides troubleshooting procedures that the operator can perform. 6 Reset the Controller or a Module To reset only the Controller or a specific module, use the following procedure. 1. Make sure that there are no jobs are running and that the system is idle. 2. In the Production tab of the Controller software, right-click the Controller or module and select Reset.
Remove Jammed Booklets The PB8500 system is designed to recover automatically from booklet jams. However, if automatic recovery is unsuccessful, use the following procedures to remove the booklets. You can remove a jammed booklet directly from a module without affecting other modules. Be careful to avoid damaging the belt’s tab when you move the booklet back into a module. Move the belt by rotating the pulley. Do not push back against the tab itself.
Page Turning Module If the booklet is still closed when it gets jammed in the Paging module, use the following procedure to remove it. 1. Lift the module hood. 2. Push the back plate down and remove the booklet from the rear. Caution: Be careful not to wrinkle or rip the booklet when removing. 3. Rehome the back plate. Booklet Opener Module 1. Lift the module hood. 2. Use your hand to pull back the horizontal guide and pull the booklet out towards you. 3.
Laser 450G Module Use the following procedure to extract a jammed booklet from the Laser module. 1. Lift the module hood. 2. Lift the laser chamber cover. 3. Rotate the upper booklet guide assembly (1) for clearance to remove the booklet. 4.
Secure Overlay Use the following procedure to extract a jammed booklet from the Secure Overlay module. 1. Lift the module hood. 2. If necessary, manually push the platen carriage away from the booklet jam. Warning: Always allow the platen assembly to cool or wear protective gloves before handling the platen shoe or internal components. Press on the sides of the perforated guard shield when moving the platen carriage. 3. Use your hand to dislodge the jammed booklet.
Buffer/Closer/QA Module Use the following procedure to extract a jammed booklet from the Closer or Verification module. 1. Lift the module hood. 2. Use your hand to dislodge the jammed booklet. Move the booklet near the closing area of the booklet track. Refer to (1) in the figure below. 3. Lift the hinged track guide to release the horizontal opened cover of the booklet (2).
4. Pull the horizontal cover of the booklet down and toward the front of the module (3). Slide the vertical cover out of the upper retaining clip. Caution: Always remove booklets from the bottom, or binding edge. Pulling the booklet from the top can damage the booklet retaining clip. 5. Remove the jammed booklet from the module.
64 Troubleshooting
