Digital Identification Solutions EDI secure XID580i Service Manual

SERVICE MANUAL

SUBLIMATION TYPE RETRANSFER PRINTER

EDI secure XID580i

SPECIFICATIONS

Recording method : Sublimation type retransfer Feed format : Automatic feed Recording density : 300 dpi Expression gradation

Printing time : Approx. 29 seconds (for

Interface : USB2.0 (standard) Operating environment conditions

Storage environment conditions

Power supply : 100 — 120 V AC/

Current dissipation : 7.0A (for 100V system)/

Mass : Standard 22.0kg

: 256 gradations for each color

single-sided printing, excluding data transfer time)

Temperature: 15°C ~ 30°C Humidity: 35% ~ 70% (no condensation)

Temperature: -15°C ~ 55°C Humidity: 20% ~ 80%

220 — 240 VAC (allowance±10%)

5.0A (for 200V system)

Excluding the built-in magnetic encoder

Accessories : Power cable

The detached power cords and the Instruction manual vary according to model and country of purchase.

For 120 V AC x 1

Dark gray (North America) For 220 to 240 V AC x 1

(Europe) Instruction manual

English x 1

Card stacker ×1 Ink ribbon cassette ×1 Retransfer film cassette ×1 Jog lever (contained in the card tray) ×1

CX21ICL Series (Large-type IC unit) Power supply : Fed from the printer.

5V±5% DC, 12V±5% DC, 24V±5% DC

Current dissipation : 500mA, 300mA, 1A Mass : 3.5kg Dimension (mm) : 110(W) × 221(D) × 255(H) Accessories :Joint plate × 1

Inter-unit cable × 1

CX21ICS Series (Small-type IC unit) Power supply : Fed from the printer. Mass : 0.5kg Dimension (mm) : 50(W) × 152(D) × 115(H) Accessories : Screw (with washer) × 3

Screw (without washer) × 2

Products sold separately

: Ink ribon, retransfer film : Cleaning card

1,000 frames/set 10 card /set Model : CY-P340A Model : CX210-CC1

: Laminator Unit :

Model : ILU

: Card tray

When setting paper feeding feature on the right Model: CF-3NTR

: Hand gloves M Size (U105-M)

L Size (U105-L)

KAS-T099-002

May 2006

CONTENTS

 IMPORTANT SAFETY PRECAUTIONS

 INSTRUCTIONS

MODEL NAME ................................................................................. 1

1. Detailed specifications .................................................................... 1

HOW TO CONNECT SEPARATELY SOLD PARTS .................. 2

1. Connecting the Small IC Unit ..........................................................2

2. Connection of the Magnetic/Contact-type IC Encoder ....................3

3. Connecting card tray .......................................................................4

BLOCK DIAGRAM .......................................................................... 5

1. OVERALL BLOCK DIAGRAM .........................................................5

2. BLOCK DIAGRAM OF PRIMARY SIDE OF POWERUNIT .............6

3. INTERLOCK SW BLOCK DIAGRAM .............................................. 7

4. BLOCK DIAGRAM OF THE FPGA CIRCUMFERENCE

ON A CPU BOARD ................................................................... 8

WIRING DIAGRAM ....................................................................... 9

Main Parts Layout..........................................................................10

1. Sensor-related...............................................................................10

2. Related to Thermal Head and Rollers ........................................... 10

3. Motor-related ................................................................................. 11

4. Solenoid-RELATED ....................................................................... 11

5. Switch-related ............................................................................... 12

6. Related to Circuit Boards, Power Supply Unit, and Fans .............. 12

7. RF-ID .............................................................................................14

REMOVAL AND EXCHANGE OF THE MAIN PARTS ............ 15

1. CHECKING AT THE TIME OF SERVICING .................................. 15

1.1 REMOVE THE TOP COVER AND THE REAR PANEL. ..........15

1.2 REMOVE THE MG CIRCUIT BOARD. .................................... 15

1.3 SWING DOWN THE POWER SUPPLY UNIT. ........................ 16

2. REMOVAL AND EXCHANGE OF THE MAIN PARTS ...................16

2.1 REMOVAL OF THE HEAT ROLLER ....................................... 16

2.1.1 Removal of the Bend Remedy Roller ............................... 16

2.1.2 Removal of the Heat Roller .............................................. 16

2.2 REMOVAL OF THE CAM MOTOR .......................................... 17

2.2.1 Installation of the Cam Motor ........................................... 18

2.3 REMOVAL OF THE RETRANSFER FILM SUPPLY

MOTOR............................................................................18

2.3.1 Installation of the Retransfer Film Supply Motor...............19

2.4 REMOVAL OF THE RETRANSFER FILM TAKE UP

FILM WINDING MOTOR .................................................. 20

2.5 REMOVAL OF THE CARD FEED MOTOR .............................20

2.5.1 Installation of the Card Feed Motor .................................. 20

2.6 REMOVAL OF THE INK SUPPLY MOTOR AND

THE INK TAKE-UP MOTOR ............................................. 21

2.7 REMOVAL OF THE TURNOVER MOTOR AND

THE TURNOVER CARD FEED MOTOR.......................... 21

2.8 REMOVAL OF THE CARD PICKUP MOTOR ......................... 21

2.9 REMOVAL OF THE FRONT PANEL ....................................... 21

2.10 REMOVAL OF THE PLATEN SOLENOID ............................ 22

2.10.1 Installation of the Platen Solenoid .................................. 22

2.11 REMOVAL OF THE POWER SUPPLY UNIT ........................22

2.12 REMOVAL OF SENSORS AND SWITCHES .......................23

2.12.1 Removal of the Cam Sensor ..........................................23

2.12.2 Removal of the Card Outlet Sensor ............................... 23

2.12.3 Removal of the Ink Encoder Circuit Board ..................... 23

2.12.4 Removal of the External Unit Power Circuit Board ........ 23

2.12.5 Removal of the Turnover Initial Position sensor ............. 24

2.12.6 Removal of the Card Near-empty Sensor ......................24

2.12.7 Removal of the No Card Sensor .................................... 24

2.12.8 Removal of the Retransfer roller/

Remedial Roller Sensor ....................................... 24

2.12.9

Removal of the Retransfer Film Mark/Ink Start Position

Sensor Circuit Board and the Card Edge Sensor ...

2.12.10 Removal of the C.L. Interlock Circuit Board and

the Card Supply Sensor .......................................25

2.12.11 Removal of the Door Interlock Circuit Board .............. 26

2.12.12 Removal of the Cassette Interlock Circuit Board ....... 26

2.12.13 Removal of the Card Tray Interlock Circuit Board ...... 27

2.12.14 Removal of the Turnover Card Sensor

Circuit Board ........................................................27

2.13 REMOVAL OF THE TURNOVER UNIT ................................ 27

2.14 FAN REMOVAL .................................................................... 28

2.14.1 Removal of the Thermal Head Cooling Fan ................... 28

2.14.2 Removal of the Suction Fan ........................................... 28

2.14.3 Removal of the Card Cooling Fan .................................. 28

2.14.4 Removal of the Ventilation Fan.......................................29

2.15 ROLLER REMOVAL ............................................................. 30

2.15.1 Feed Roller Removal ..................................................... 30

2.15.2 Platen Roller Assy Removal .......................................... 31

2.16 CIRCUIT BOARD REMOVAL ............................................... 32

2.16.1 Removal of the Main Circuit Board ................................ 32

2.17 Thermal Head Exchange Method .........................................33

USE OF SERVICE MODE ........................................................... 35

1. Entry into Service Mode ................................................................35

2. Explanation of the Various Modes ................................................. 37

2.1 Download ................................................................................ 37

2.2 Maintenance ........................................................................... 37

2.2.1 Offset Prt Y Setting ........................................................... 37

2.2.2 Offset Prt X Setting ........................................................... 37

2.2.3 Offset Trf X Setting ........................................................... 38

2.2.4 Card Stop Position Setting (Offset Card X) ...................... 38

2.2.5 Default LUT Setting .......................................................... 38

2.2.6 Device Type Setting .......................................................... 38

2.2.7 Card Fan Setting .............................................................. 38

2.2.8 TUR Response Setting ..................................................... 38

2.2.9 Compatible Mode Setting ................................................. 38

2.2.10 Setting of the ink sensor level ........................................ 38

2.3 Off-line Test ............................................................................. 39

2.3.1 Pattern setting .................................................................. 39

2.3.2 Printing Side ..................................................................... 40

2.3.3 Times ................................................................................ 40

2.3.4 Test Select ........................................................................ 40

2.4 Diag. Test ................................................................................ 40

2.4.1 Sensor .............................................................................. 40

2.4.2 Actuator ............................................................................ 40

2.4.3 Memory ............................................................................ 41

2.4.4 SIO ................................................................................... 41

2.4.5 Display .............................................................................. 41

2.4.6 Back Color ........................................................................41

2.4.7 Buzzer .............................................................................. 41

2.4.8 Registers .......................................................................... 41

2.5 Information .............................................................................. 41

2.6 Parameter Push and Pop ........................................................ 41

OPERATION OF THE MECHANISM ......................................... 42

1. Single-side Printing ....................................................................... 42

2. Double-side Printing ...................................................................... 42

3. Initial Operation .............................................................................42

4. Card Supply and Card Feed.......................................................... 43

5. Printing Operation ......................................................................... 45

6. Retransfer Operation .....................................................................47

7. Operation in Case of Peeling with Return in Direction Towards

the Turnover Unit ..................................................................... 49

8. Operation of the Turnover Unit ...................................................... 50

9. Others ........................................................................................... 51

9.1 Position Relation with Ink Ribbon and Retransfer Film ...........51

9.2 Ink Ribbon and Retransfer Film End Treatment ...................... 51

TROUBLESHOOTING..................................................................52

1. LCD Error Code Correspondence ................................................. 52

2. Printing Defects and Countermeasures ........................................ 57

3. Power Supply Check ..................................................................... 61

LARGE IC UNIT ....................................................................73

1. Removal of Each Part ................................................................... 73

1.1 Removal of the Top Cover ....................................................... 73

1.2 Removal of the Front Panel .................................................... 73

1.3 Removal of the Mechanical Unit ............................................. 73

1.4 Removal of the IC Main Circuit Board ..................................... 73

1.5 Others ..................................................................................... 73

2. Block Diagram ............................................................................... 74

3. DIP Switch Specifications ............................................................. 75

3.1 Specifications .......................................................................... 75

3.2 IC Card Stop Position Adjustment .......................................... 75

4. Error Messages ............................................................................. 76

5. Specifications of Connector on the IC Main Board ....................... 77

EXPLODED VIEW AND ASSEMBLY LISTS ............................ 78

 HOPPER ASSEMBLY1/2 — 2/2 ................................................... 79

 FRAME ASSEMBLY1/7 — 7/7 ..................................................... 81

 PLATEN ASSEMBLY1/1 ............................................................... 88

 PICK UP MOTOR ASSEMBLY1/1 ................................................ 89

 FEED MOTOR ASSEMBLY1/1 ..................................................... 90

 MEDIA W MOTOR ASSEMBLY1/1 ............................................... 91

 MEDIA S MOTOR ASSEMBLY1/2 — 2/2 ..................................... 92

 INK S&W MOTOR ASSEMBLY1/1 ............................................... 94

 HEATER CAM MTR ASSEMBLY1/1 .............................................95

 TURN MOTOR ASSEMBLY1/1 .....................................................96

 TURN UNIT ASSEMBLY1/1 ......................................................... 97

 MECHANISM ASSEMBLY1/12 — 12/12 ...................................... 98

 FRONT PANEL ASSEMBLY1/2 — 2/2 ....................................... 109

 PR COMMON ASSEMBLY1/4 — 4/4 ......................................... 111

 FINAL ASSEMBLY1/14 — 14/14 ................................................ 115

MAINTENANCE INSPECTIONS ................................................62

1. Cleaning ........................................................................................62

2. Lubrication.....................................................................................62

3. Maintenance Inspections for Main Parts and

Execution Standard.................................................................62

4. Periodic Inspection Items .............................................................. 63

5. Trouble Diagnosis Sheet ............................................................... 64

ADJUSTMENT ............................................................................... 65

1. Layout of the adjustment elements ............................................... 65

2. Adjustment .................................................................................... 65

3. Caution Items for the Time of Exchange of

the CPU Circuit Board ............................................................ 65

MG ENCODING UNIT ..................................................................66

1. MG Encoding Specifications ......................................................... 66

1.1 Magnetic Encoder Specifications ............................................ 66

1.2 General Equipment Specifications .......................................... 66

2. Block Diagram ............................................................................... 67

2.1 MG Unit Block Diagram .......................................................... 67

2.2 Connection Diagram ............................................................... 68

3. MG Encoding Unit Exchange Method ...........................................69

3.1 Repair Classification ............................................................... 69

3.2 Exchange Method ................................................................... 69

3.3 DIP Switch Specifications ....................................................... 71

3.4 MG-related Error Messages ................................................... 72

Important Safety Precautions

1.25

2.0

5.5

Crimping tool

Prior to shipment from the factory, VDS products are strictly inspected to conform with the recognized product safety and electrical codes of the countries in which they are to be sold. However, in order to maintain such compliance, it is equally important to implement the following precautions when a set is being serviced.

Precautions during Servicing

•

1. Locations requiring special caution are denoted by labels and inscriptions on the cabinet, chassis and certain parts of the product. When performing service, be sure to read and comply with these and other cautionary notices appearing in the operation and service manuals.

2. Parts identified by the ! symbol and shaded ( ) parts are critical for safety. Replace only with specified part numbers.

Note: Parts in this category also include those specified to com-

ply with X-ray emission standards for products using cathode ray tubes and those specified for compliance with various regulations regarding spurious radiation emission.

3. Fuse replacement caution notice. Caution for continued protection against fire hazard. Replace only with same type and rated fuse(s) as specified.

4. Use specified internal wiring. Note especially:

1) Wires covered with PVC tubing

2) Double insulated wires

3) High voltage leads

5. Use specified insulating materials for hazardous live parts. Note especially:

1) Insulation Tape 3) Spacers 5) Barrier

2) PVC tubing 4) Insulation sheets for transistors

6. When replacing AC primary side components (transformers, power cords, noise blocking capacitors, etc.) wrap ends of wires securely about the terminals before soldering.

12. Crimp type wire connector In such cases as when replacing the power transformer in sets where the connections between the power cord and power transformer primary lead wires are performed using crimp type connectors, if replacing the connectors is unavoidable, in order to prevent safety hazards, perform carefully and precisely according to the following steps.

1) Connector part number : E03830-001

2) Required tool : Connector crimping tool of the proper type which

will not damage insulated parts.

3) Replacement procedure

(1) Remove the old connector by cutting the wires at a point

close to the connector. Important : Do not reuse a connector (discard it).

cut close to connector

Fig.3

(2) Strip about 15 mm of the insulation from the ends of the

wires. If the wires are stranded, twist the strands to avoid frayed conductors.

15 mm

Fig.4

(3) Align the lengths of the wires to be connected. Insert the

wires fully into the connector.

Fig.1

7. Observe that wires do not contact heat producing parts (heatsinks, oxide metal film resistors, fusible resistors, etc.)

8. Check that replaced wires do not contact sharp edged or pointed parts.

9. When a power cord has been replaced, check that 10-15 kg of force in any direction will not loosen it.

Power cord

Fig.2

10. Also check areas surrounding repaired locations.

11. Products using cathode ray tubes (CRTs) In regard to such products, the cathode ray tubes themselves, the high voltage circuits, and related circuits are specified for compliance with recognized codes pertaining to X-ray emission. Consequently, when servicing these products, replace the cathode ray tubes and other parts with only the specified parts. Under no circumstances attempt to modify these circuits. Unauthorized modification can increase the high voltage value and cause X-ray emission from the cathode ray tube.

(4) As shown in Fig.6, use the crimping tool to crimp the metal

sleeve at the center position. Be sure to crimp fully to the complete closure of the tool.

(5) Check the four points noted in Fig.7.

Not easily pulled free

Wire insulation recessed

more than 4 mm

Metal sleeve

Connector

Fig.5

Fig.6

Crimped at approx. center

of metal sleeve

Conductors extended

Fig.7

S40888-01

Safety Check after Servicing

•

Examine the area surrounding the repaired location for damage or deterioration. Observe that screws, parts and wires have been returned to original positions, Afterwards, perform the following tests and confirm the specified values in order to verify compliance with safety standards.

1. Insulation resistance test

Confirm the specified insulation resistance or greater between power cord plug prongs and externally exposed parts of the set (RF terminals, antenna terminals, video and audio input and output terminals, microphone jacks, earphone jacks, etc.). See table 1 below.

2. Dielectric strength test

Confirm specified dielectric strength or greater between power cord plug prongs and exposed accessible parts of the set (RF terminals, antenna terminals, video and audio input and output terminals, microphone jacks, earphone jacks, etc.). See table 1 below.

3. Clearance distance

When replacing primary circuit components, confirm specified clearance distance (d), (d’) between soldered terminals, and between terminals and surrounding metallic parts. See table 1 below.

Fig. 8

4. Leakage current test

Confirm specified or lower leakage current between earth ground/power cord plug prongs and externally exposed accessible parts (RF terminals, antenna terminals, video and audio input and output terminals, microphone jacks, earphone jacks, etc.). Measuring Method : (Power ON) Insert load Z between earth ground/power cord plug prongs and externally exposed accessible parts. Use an AC voltmeter to measure across both terminals of load Z. See figure 9 and following table 2.

Externally exposed accessible part

Fig. 9

5. Grounding (Class 1 model only)

Confirm specified or lower grounding impedance between earth pin in AC inlet and externally exposed accessible parts (Video in, Video out, Audio in, Audio out or Fixing screw etc.).

Measuring Method:

Connect milli ohm meter between earth pin in AC inlet and exposed accessible parts. See figure 10 and grounding specifications.

Fig. 10

AC Line Voltage

100 V

100 to 240 V

110 to 130 V

200 to 240 V

Region

Japan

USA & Canada

Europe & Australia R 10 MΩ/500 V DC

Insulation Resistance (R)

≤

R 1 MΩ/500 V DC

≥≥

1 MΩ R 12 MΩ/500 V DC

≤

Tab le 1 Specifications for each region

Dielectric Strength

AC 1 kV 1 minute

AC 1.5 kV 1 miute

AC 1 kV 1 minute AC 3 kV 1 minute

AC 1.5 kV 1 minute

(Class 2)

(Class 1)

Clearance Distance (d), (d')

≤

d, d' 3 mm

≤

d, d' 4 mm

≤

d, d' 3.2 mm

≤

d 4 mm

≤

d' 8 mm (Power cord)

≤

d' 6 mm (Primary wire)

Table 2 Leakage current specifications for each region

Note: These tables are unofficial and for reference only. Be sure to confirm the precise values for your particular country and locality.

S40888-01

MODEL NAME

The letters and numbers following the model name are used to differentiate between destinations and specifications.

Model name: XID580i - #

1. Detailed specifications

# Portion – Internal option

Nil ......... No option (Standard model)

B...........Equipped with ISO magnetic encorder / IC contact

HOW TO CONNECT SEPARATELY SOLD PARTS

1. Connecting the Small-type IC Unit

Remove the cover on the side of the printer.

Remove the screw, and then raise the cover to remove it.

Connect the connector.

Please note that the connector has directionality.

Install the unit with three screws.

Install the screws so that the cable of the connector is not caught.

Install the cover with two screws.

Screw with washer (provided)

Pass the cable through the notch.

Screw (provided)

2. Connection of the Magnetic/Contact-type IC Encoder

When the separately sold magnetic/contact-type IC encoder is to be connected to a standard printer, connect it according to the following procedure.

For details in regard to the removal method for each part, refer to “Removal and exchange of the Main Parts”.

1) Remove the top cover.

2) Swing down the power supply.

3) Remove the front panel.

4) Install the magnetic unit. Fix with three black screws 8 at the front and four black screws 8 at the rear.

5) Install the bracket fixing the MG circuit board with four screws 6.

Pass the wires of power switch.

CN3

KWS0744-001

KWR18416-001

Clamp

(TFA0023)

J10

Explanation drawing 1

J14

(TSA0141)

G.NO.004

Make the cable routed away from the rail

MG PWB SA

Explanation drawing 1

J10

CLAMP

Explanation drawing 2

KWS0767-002

J14

J10

KWS0768-001

Clamp

Explanation drawing 2

J10

J14

3pin

CLAMP

Explanation drawing 1

CN12

KWR17110-001

Clamp

CLAMP

3. Connecting card tray

Upon issuing the card using paper feeding feature on the right, as the NG cards transported to the printer will be ejected, replace the standard hopper unit with an optional card tray.

Mount the card tray according to the following procedures:

1. Pull out the standard hopper unit diagonally upwards.

2. Insert the optional card tray diagonally downwards. (Note: The cleaning roller should be left as it is.)

3. Enter the service mode of the printer main unit, select “Card Loading” under the maintenance items and switch from “standard” to “Right Side”.

4. Settings other than this and operating procedures are dependent to the user system.

Note: If there are 10 cards accumulated continuously in the card tray, the printer will display “Card Tray Full”. Remove

the cards immediately.

5. Keep the removed hopper unit safely.

THERMAL HEAD

HEAD

CONN

PWB

EEPROM

32Kbit

HEAD BLOCK

MAIN PWB

FRONT PWB

POWER

SUPPLY

UNIT

CPU

XTAL

66.67MHz

EEPROM

32Kbit

SDRAM

64Mbit

FLASH ROM

16Mbit

TR THERMISTOR

THERMISTOR

DRIVE PWB

NO CARD

CARD IN

CARD (MG POSITION) (PWB)

(OPTION(MGIC))

CARD (TURN) (PWB)

TURN POSITION

EDJE (PWB)

CARD OUT (PWB)

FILM MARK (PWB)

CAM POSITION

TR POSITION

RR POSITION

INK FG (PWB)

CARD NEAR EMPTY

INK FG

(MOTOR built-in)

FILM F G (MOTOR built-in)

SENSORS

SDRAM

64Mbit

FLASH ROM

16Mbit

SENSORS

THERMISTOR &

CONNECTOR (PWB)

EXTERNAL UNIT

HEATER PROTECTOR PWB

USB

I/F

Q13

REGULATOR

(A+5V)

REGULATOR

(3.3V)

Q11

REGULATOR

(1.5V)

U10

REGULATOR

(1.8V)

DC-DC circuit

U11

FPGA

U12

SDRAM

64Mbit

DAConverter

LCD module

(16columX2line)

SWX6

COLOR

LED

LEDX2

BUZZER

U17

USB

chip

XTAL

48MHz

STEP MOTOR DRIVER

TRANSISTOR

STEP MOTOR DRIVER

U11

STEP MOTOR DRIVER

U13

DC MOTOR DRIVER

U14

DC MOTOR DRIVER

U15

DC MOTOR DRIVER

SOLENOID (PLATEN ROLLER)

SOLENOID (IC CONTACT(OPTION))

FAN (THERMAL HEAD)

FAN (CARD)

FAN (PRINTER)

CARD MOTOR

FILM MOTOR

CAM MOTOR

FILM MOTOR

INK MOTOR

TURN

MOTOR

CARD MOTOR (TURN)

CARD MOTOR (PICK UP )

STEP MOTOR DRIVER

U10

STEP MOTOR DRIVER

U16

DC MOTOR DRIVER

EXTERNAL

UNIT

EXTERNAL

UNIT

MG/IC UNIT(OPTION)

RF-ID UNIT

U14~16

BUFFER

U32,U33

COMPARATOR

U22,36~U39

BUFFER

Serial to Parallel

U19

INVERTER

CPU BUS

U13

ADConverter

RESET IC

(5V)

CLEANING ROLLER INTERLOCK SW

DOOR INTERLOCK SW

CASSETTE INTERLOCK SW

CARD TRAY INTERLOCK SW

FAN (PRINTER)

CLK

DRIVER

XTAL

32MHz

BLOCK DIAGRAM

1. OVERALL BLOCK DIAGRAM

2. BLOCK DIAGRAM OF PRIMARY SIDE OF POWERUNIT

THERMOSTAT

HEATROLLER

(REMEDIAL)

t˚

THERMISTOR

(to DRIVE PWB)

THERMOSTAT

HEATROLLER

(RETRANSFER)

t˚

THERMISTOR

(to DRIVE PWB)

POWER

SUPPLY

UNIT

N(AC IN)

L(AC IN)

SSR2N

SSR2L

SSR1N

SSR1L

CN3

VTH

CN1

12V

CN2

24V

CN8

24V_RC

CN4

CONTROL

SIGNAL

N(AC OUT)

L(AC OUT)

(to ANALOG POWER PWB)

FAIL SIGNAL

(to DRIVE PWB)

HEATER PROTECTOR PWB

POWER

SWITCH

CN1

CN2

VOLTAGE

DETECT

PHOTO

COUPLER

ABNORMAL

CURRENT

DETECT

PHOTO

COUPLER

Primary

Secondary

SSR1L

SSR2L

ON/OFF

CN5

SSR

CN7

CN6

SSR

3. INTERLOCK SW BLOCK DIAGRAM

24V

TURN MOTOR DRIVER

U10

CARD MOTOR DRIVER

U16

PICK UP MOTOR DRIVER

Cleaning roller SW (PWB)

Card Tray SW (PWB)

24V_RC

POWER

SUPPLY

UNIT

DRIVE PWB

Cassette SW (PWB)

Door SW (PWB)

J16

J18

CN8

Door SW (PWB) OPEN

and

Cassette SW (PWB) OPEN

24V OFF

Cleaning roller SW (PWB) OPEN

Card Tray SW (PWB) OPEN

Turn Motor STOP

Card Motor STOP

Pick up Motor STOP

Specification of Interlock Switch

CN3

Vth

CN1

12V

CN2

24V

CN4

24V_RC

Vth_RC

MAIN PWB

BLOCK DIAGRAM OF THE FPGA CIRCUMFERENCE ON A MAIN BOARD

Motor Solenoid Control Signals

Sensor input

Retransfer Heater Temperature

Bend Remedial Heater Temperature

TPH Temperature

Retransfer Heater Control Signal

Bend Remedial Heater Control Signal

INK Sensor LED Driver

CPU

CPU I/F BLOCK

MOTOR CONTROL BLOCK

AD CONVERTER CONTROL BLOCK

HEATER CONTROL BLOCK

(The Heaters are controlled by each temperature.)

D/A Interface

16bit Data

PRINT BLOCK (Temperature correction, Outline emphasis, LUT)

Data Processor

Microcode Memory(*1) 512Word x 16bit

TPH I/F BLOCK

Line Buffer Memory

Flash Memory

INTERNAL CLOCK GENERATOR

SDRAM I/F BLOCK

x 2

32bit CPU BUS

SDRAM 4MWordx16bit

Step Motor Speed Up/Down Table (CPU generates the table data.)

Heater control Table(*2)

16bit Data

TPH Control Table(*2) (Strobe)

Tables for Print Data Correction(*2)

Work Memory for PRINT BLOCK

Plane Memory 2MByte

(*1)(*2)These data are copied

Print Data Strobe Lutch

Thermal Print Head

from Flash Memory.

*FPGA=

FieldPrgrambleGateArray

WIRING DIAGRAM

USB I/F

POWER SUPPLY

DRIVE PWB

Option1 I/FOption2 I/F Serial I/F

AC IN

DC5/12V

FRONT PWB

CTL1 V TH

HEAD PWB

MAIN PWB

CTL2ACAC

KWS0644-001

Step

Motor

Step

Motor

CN8 CN9

Step

Motor

DC Motor

Step

Motor

OPTION

(MG/IC Block)

Step

Motor

Pick up motor

Turn over motor

Turnover feed

motor

Ink takeup

motor

Ink supply motor

INK FG

sensor

card supply sensor

Platen

roller

solenoid

Card edge

sensor

HEATER

PROTECTOR

PWB

CN1 CN2

KWR16003-001

Turnover

card sensor

Retranfer

film mark

sensor

No card

sensor

Turnover

initial position

sensor

Card near

empty sensor

Thermal Head

cooling fan

Thermostat

Retransfer film

Take up motor

Cam motor

Card feed

motor

Retransfer film

supply motor

Remedial

Heat Roller

Thermistor

Card outlet

sencer

Retransfer

Heat Roller

Thermistor

Cam sensor Retransfer

Heatroller

Positionning sensor

Card tray

interlock

Thermal Head

Cleanning roller

interlock

Door interlock Cassette

interlock

Ink start

position

sensor

Cooling fan

POWER SWITCH

Remedial Heat roller

Retransfer Heat roller

Thermostat

DC24V

DC5/12V/24V

Step

Motor

MG Feed Motor

IC CONTACT

Solenoid For

Head position1

Card position

210Encode

75Encode

IC FLAG

5V 12V

IC R/W

MG HEAD

CONTACT

XID580i BLOCK DIAGRAM

Head position2

Head position3

Remedial

Heatroller

Positionning sensor

Card Cooling Fan

J13

J12

J11

J24

J23

J10

J9 J15

J21

J22

J18

J16

J17

J14

RF-ID PWB

J11

J12 J16

J14

J7 J6

CN1

CN2 CN3

to J13

J13 J15

J10

J12

J16

to J9

to J12

to J8

to J13

to J16

to J10

to J11

CN1

CN3

to J15

CN3

CN301

CN1

CN201

CN4 CN5

CN6

CN7

to J8

CN2

Main Parts Layout

1. Sensors

Retransfer film mark sensor (circuit board)

Retransfer roller sensor

Card outlet sensor

Bend remedial roller sensor

Ink FG sensor (encorder circuit board)

Ink start position sensor (circuit board)

Turnover card sensor (circuit board)

Turnover initial position sensor

Card supply sensor

Cam sensor Card near empty sensor

2. Thermal Head and Rollers

Platen roller

No card

Card edgesensor (Circuit board)

Bend remedial roller

Retransfer roller

Turnover unit

NG card outlet roller

Thermal head

Card supply roller

3. Motors

Ink take-up motor

Ink supply Motor

Retransfer film supply motor

Retransfer film take-up motor

Turn over motor

Turn over feed motor

4. Solenoid

Platen Solenoid

Cam motor

Card feed motor

Card pick up motor

Rear veiw

5. Switches

Door interlock switch

Card tray interlock switch

Cassette interlock switch

Cleanning roller interlock switch

6. Circuit Boards, Power Supply Unit, and Fans

Front PWB

Drive PWB

Power supply unit

Heater protector PWB

MAIN PWB

Thermal head cooling fan

Ventilation fan

Card cooling fan

7. RF-ID

RF-ID unit

Screw B

Screw A

REMOVAL AND EXCHANGE OF THE MAIN PARTS

1. CHECKING AT THE TIME OF SERVICING

When confirming the symptoms, swing the power supply unit down as shown in the following figure and check the inside.

1.1 REMOVE THE TOP COVER AND THE REAR PANEL.

1) Remove the filters on both sides of the top cover. Caution: If they are not removed, the filters will be damaged when the top cover is moved.

2) Remove the seven screws A and pull the top cover to the rear to remove it.

3) Remove the screw B and take off the rear panel.

Filter

ScrewB

1.2 REMOVE THE MG CIRCUIT BOARD.

1) Remove the three screws A and the screw B.

2) After the power supply unit has been swung down, use the screw B for provisional fixing, so that the MG circuit board does not move.

ScrewA

1.3 SWING DOWN THE POWER SUPPLY UNIT.

1) Remove the two screws B on both sides.

2) Loosen the four screws A on both sides.

3) Raise the power supply unit and swing it down.

4) Remove the thermostat cable from the clamper, raise the power supply unit once, and then swing it down.

Power supply unit

Screw B

Screw A

2. REMOVAL AND EXCHANGE OF THE MAIN PARTS

2.1 REMOVAL OF THE HEAT ROLLER

CAUTION:

Immediately after the power has been switched OFF, the retransfer roller and the bend remedial roller are still hot. Please perform the work after these rollers have cooled down sufficiently, as otherwise burns may be caused.

Screw A Thermostat wire

Thermistor wirePower connector

2.1.2 Removal of the Retransfer Roller

1) Disconnect the right side of the spring.

2) Remove the screw A and bring the sensor bracket to free condition.

For installation, match the notches so that they engage.

3) Disconnect the junction connectors of the thermistor and the thermostat of the retransfer roller.

Remove the power connector.

4) Remove the two screws B and remove the roller by pulling it slowly to the front.

Notch Spring

Screw A

1) Refer to section 2.2 and remove the cam motor.

2) Remove each roller individually.

2.1.1 Removal of the Bend Remedial Roller

1) Disconnect the junction connectors of the thermistor and the thermostat of the bend remedial roller.

Remove the power connector.

2) Remove the two screws A.

3) The bend remedial roller can be removed when the roller is turned upwards and slowly pulled to the front.

Screw BPower connector

CAUTIONS FOR INSTALLATION AND CLEANING OF BOTH ROLLERS

1) The oil bearing % is on the tip of the roller assembly. Do not forget it at the time of installation and removal.

2) When installing a new roller, take care that it will not hit the bracket.

3) AC 100 V is impressed to this heater. Use sufficient care for the wire processing.

4) Do not turn the roller by hand. The thermistor may become damaged when the roller is turned by hand.

Accordingly, when a roller is to be turned for cleaning etc., do the turning while the bracket on which the thermistor is installed has been raised a little.

2.2 REMOVAL OF THE CAM MOTOR

1) Remove the two screws A. Please use a long screwdriver for the lower screw. If the power supply unit is in the way, raise it once

and use the gap underneath to perform the work.

2) Remove the screw B from front side. Refer to section 2.9 to remove the front panel.

3) Insert the screwdriver to the hole fixing the card cooling fan, and remove another screw B.

(Refer to section 2.14.3)

4) Disconnect the flat wire and the other cables.

5) Raise the bend remedial roller and pull out the motor, taking care that the motor bracket will not hit circuit boards etc.

Screw B

(Front side)

QYSPSPD 4008N

Bearing

Thermistor bracket

Pass the wires behind the lever

(-010)

screw B

(TSS0181)

Clamp

(-010)

Retransfer roller

KJJ46271-003

Bend remedial roller

(TSS0182)

KJJ46271

-003x2

KJJ46271

-003x2

KJJ46271-003

Clamp

(T2,H2)

(FD M.MOTOR ASY)

Screw A

Clamp

(F1)

Cam motor

(TSS0189)

Clamp

(P4)

KJJ46271

-003x2

Screw A

2.2.1 Installation of the Cam Motor

1) The gear of the cam motor has a phase. When it is removed at the time of roller cleaning, exchange, etc., it can be installed again in the same condition, but setting in the following way should be done when the cam gear is exchanged.

Apply grease to this side also

Apply sufficient grease to the hole for the shaft.

Please use care, as the installation orientation can be mistaken easily.

Apply a sufficient quantity of grease to the two holes for the shaft.

Install so that the slit of the cam gear comes to the gear edge of the double gear when seen from above.

Gear setting method

Apply grease to a small gear by one grain of rice.

QYSPSPD3006Nx2

Cam gear

Slit

Double gear

Apply grease to this side also

QYREE4000X

Engage with

the cam gear.

Upper side

Lower side

2.3 REMOVAL OF THE RETRANSFER FILM SUPPLY MOTOR

1) Remove the ink ribbon and the retransfer film cassette.

2) Remove the bobbin holder 7 on the film supply side. Perform the work while using your hand to prevent that the E-ring drops down.

QYREE4000X

Bobbin holder

Cam motor

Before installing the gear, install it on the bracket.

Stepping motor SA

2) When installing the cam motor, first insert the longest shaft into the hole while raising the bend remedial roller a little.

Next, insert the second shaft into its hole while turning the motor bracket a little. The bend remedial roller will move down.

Finally, confirm that the projecting part is in the heater lever hole.

At this time, raise the bend remedial roller by hand, confirm that it is locked, and tighten the screws.

3) Check the cam movement as described in Service mode "Diag. TEST cam motor".

3) Remove the drive circuit board. Disengage the clampers and the connector. Disengage the two clampers fixing the circuit board and remove the circuit board by pulling it in diagonal direction.

DRIVE PWB is attached after checking that the wire passes along 3set in EDGE SADDLE

(Front sensor)

J11

(KWS0751-002)

(Tray interlock)

Clamp

Clampx3

(KWS0757-002)

(Door interlockSA)

DRIVE PWB SA

The relay connector confirms and connects with number as which the connector number is same.

J11

4) Remove the tensioning spring @ . (Refer to the figure on the lower part of next page.)

5) When the five screws

are removed, the film

&, (

supply motor assembly can be removed.

(Refer to the figure on the lower part of next page.)

2.3.1 Installation of the Retransfer Film Supply Motor

(TSS0187)

QYSPSPD4008Nx2

(-007)

QYSPSPD4008Nx3

Retransfer film supply motor

Tighten provisionally.

KJJ46271

-003x2

Clanp

Retransfer film take up motor

1) When the motor has been disassembled or exchanged, first the belt @ tension must be adjusted.

2) After assembly has been performed, leave the screw

tightened provisionally.

3) Turn the motor all the way in arrow direction and tighten the screw # securely.

Tighten the screw B securely to turn the motor in arrow direction to tighten the belt, and then tighten the screw A securely.

Tighten provisionally.

F689ZZ

4) When installing the motor assembly, the tension adjustment of another belt % is required.

5) Install the two screws &.

6) Tighten the four screws

7) Hook the tension spring @.

8) Tighten the four screws securely.

9) Install the bobbin holder.

(, )

provisionally.

QYSPSPD3006Nx2

80S2M224

F689ZZ

QYSBST3006Nx2

80S2M224

2.4 REMOVAL OF THE RETRANSFER FILM TAKE UP FILM WINDING MOTOR

With the drive circuit board removed, the Retransfer film take up motor can be removed after the screw * in the above figure has been removed. (Refer to a front page.)

Ink supply motor

Ink take-up motor

KJJ46271-001x2

2.5 REMOVAL OF THE CARD FEED MOTOR

1) Remove the tensioning spring

2) Remove the two screws (. Disengage the belt from the roller.

3) The card feed motor can be removed by pulling it to the front.

2.5.1 Installation of the Card Feed Motor

1) When the motor has been disassembled or exchanged, first the belt tension must be adjusted.

2) After assembly has been performed, leave the screw

tightened provisionally.

3) Turn the motor all the way in arrow direction and tighten the screw 8 securely.

4) Engage the belt and tighten the screw ( provisionally.

5) Apply the tensioning spring %.

6) Securely tighten the screws ( which have been tightened provisionally.

QYSBST3006Zx2

P1 P2

D1 D2

Turnover card feed motor

Turnover motor

KJJ46271

-001x3

Clamp

Set the belt to the pulley.

Card feed motor

Tighten provisionally

DPSP4008Nx2

Set the springs to tighten the belt, and then tighten securely.

(-006)

(M180)

(M224)

Tighten the screw B securely to turn the motor in arrow direction to tighten

Tighten provisionally

DPSP3006Nx2

Motor SA

the belt, and then tighten the screw A securely.

2.6 REMOVAL OF THE INK SUPPLY MOTOR AND THE INK TAKE-UP MOTOR

2.9 REMOVAL OF THE FRONT PANEL

1) When there is an MG circuit board, remove the circuit board screws and move the circuit board to the side.

2) Disengage the hook on the left side of the drive circuit board. Disengage the wire clamp.

3) The ink motor assembly can be removed after the two screws * have been removed. (Refer to a front page.)

2.7 REMOVAL OF THE TURNOVER MOTOR AND THE TURNOVER CARD FEED MOTOR

1) The turn over motor and the turn over card feed motor assembly can be removed after the three screws ) have been removed. (Refer to a front page.) Remove the spring, as one of the screws is hidden by the spring.

2.8 REMOVAL OF THE CARD PICKUP MOTOR

1) Remove the retransfer film and the ink ribbon cassette.

2) Remove the card tray.

3) Remove the cleaning unit.

4) When the six screws

and the screw 5 for earth

wire have been removed, the front panel can be removed.

Installation of the Front Panel

1) There are two claws at the rear of the front panel. Insert into the frame by lightly hitting on the claws. And then secure the six screws 4.

Front Panel

1) The card pickup motor assembly can be removed after the two screws * have been removed.

Insert the gear shaft

Card pikup motor

KJJ46271

-001x2

Insert the front panel into the frame by lightly hitting on the claws.

G IS

SDSP4008Nx6

2.10 REMOVAL OF THE PLATEN SOLENOID

100V/200VCommon

CN8

CN4

CN5

CN6

CN7

CN8

CN4

CN2

CN1

CN3

KWS0639-001

POWER SUPPLY SA

KJJ46271-003x2

H1=Retransfer heater H2=Bend Remedial heater

1) Remove the drive circuit board.

2) Disengage the wire from the clamp. (2 places)

3) Remove the two screws

and then remove the so-

(

lenoid support @ and #.

4) Remove the two screws

, raise the solenoid body

once, and pull it to the rear.

5) Be careful not to damage the disk of ink encoder located above when removing the screw

(

2.10.1 Installation of the Platen Solenoid

1) Insert the plunger by itself into the cutout.

2) Fix the solenoid body with two screws

3) Fix the solenoid support with two screws (. At this time, Pay attention to the following item.

4) Before tightening the screws, adjust the gap uniformly so that there will be no interference with the platen lever and the solenoid support when the plunger moves in and out.

5) Be careful not to damage the disk of ink encoder located above when securing the screw (.

2.11

REMOVAL OF THE POWER SUPPLY UNIT

1) Disconnect the wires and the connectors.

2) Remove the two screws

3) When ordering a power supply unit, also order the wire clamps around it at the same time.

Gap

Platen lever

Before tightening the screws, adjust the gap uniformly so that there will be no interference with the platen lever and the solenoid support when the plunger moves in and out.

Explanation drawing 1

Caution for the time of installation of the solenoid support

Solenoid support

Explanation drawing 1

Platen solenoid

(TSS0179)

QYSPSPD4008Nx2

QYSPSPD

4008Nx2

Clamp

Plunger

Engage the bearing with the rear frame.

Lead the wire along the bracket so that it does not become an obstacle on the inside of the bracket.

2.12 REMOVAL OF SENSORS AND SWITCHES

2.12.1 Removal of the Cam Sensor

Function

This sensor decides the origin position for pressurizing the retransfer roller and the bend remedial roller.

1) Refer to section 2.2 and remove the cam motor.

2) The sensor can be removed after the screw * has been removed.

2.12.2 Removal of the Card Outlet Sensor

Function

This sensor detects card jams. An error will be caused when no card passes the sensor within a fixed time after completion of retransfer.

1) The sensor can be removed after the screw ( has been removed.

2.12.3 Removal of the Ink Encoder Circuit Board

Function

The ink feed quantity is decided by the pulses of this encoder. Start position is decided by the ink start position sensor.

1) The bracket can be removed after the two screws have been removed.

2.12.4 Removal of the External Unit Power Circuit Board

Function

When a small external IC unit is connected, power is supplied from this power supply. The thermistor detecting the environment temperature is installed on this board.

1) Refer to section 2.2 and remove the cam motor.

2) The circuit board can be removed after the screw has been removed.

)

⁄

EXT. unit power

KJJ46271-003

KJJ46271

-003x2

Ink Encoder

Cam sensor

KJJ46271

-003

KJJ46271-003

Card outlet sensor

Yellow

2.12.5 Removal of the Turnover Initial Position

sensor

2.12.8 Removal of the Retransfer roller/Remedial Roller Sensor

Function

This sensor decides the origin position for the turn unit.

1) Refer to section 2.7 and remove the turnover and card feed motor.

2) The sensor can be removed after the screw

been removed.

2.12.6 Removal of the Card Near-empty Sensor

Function

When the number of remaining cards drops to about 20 cards (for the card 0,76mm thick) , the electronic buzzer sounds.

1) Refer to section 2.16.1 and remove the Main circuit board.

2) Remove the card tray.

3) The sensor can be removed after the screw ( has been removed with a long screwdriver from the hole in which the Main circuit board is located.

2.12.7 Removal of the No Card Sensor

This sensor checks whether there are remaining cards or not. An error is caused when the remaining quantity becomes zero.

1) Refer to section 2.7 and remove the turnover and card feed motor.

2) The sensor can be removed after the screw * has been removed.

has

Function

This sensor detects the origin of the retransfer roller and the bend remedial roller.

Energization is performed only when a roller is in this position.

1) Remove the screw &.

2) Slide the sensor to the side, as the lever is inserted into the sensor.

DR PCB BKT SA

TSS0239-V

(-010)

TSS0239-U

HEATER SENSOR SA

(-010)

(TSS0181)

(TSS0182)

CLAMP (T2,H2)

(FD M.MOTOR ASY)

CLAMP (F1)

(TSS0189)

CLAMP (P4)

Head cooling fan

Turnover initial position sensor

KWS0757-002

KJJ46271

-003

No Card sensor

Card near-empty

sensor

KJJ46271

-003

KJJ46271-003

2.12.9 Removal of the Retransfer Film Mark/Ink Start Position Sensor Circuit Board and the Card Edge Sensor

Function

Card edge sensor

•

This sensor decides the card position at the time of card retransfer.

Retransfer Film mark sensor

•

This sensor detects the black bar on the film and selects the panel for printing.

Ink start position sensor

•

This sensor detects the boundary between magenta and cyan ink. Next, the pulses of the rotary encoder are detected and movement is made to yellow.

1) When a magnetic encoder is built-in, refer to "Connection of optional parts" and remove the encoder.

2.12.10 Removal of the C.L. Interlock Circuit Board and the Card Supply Sensor

Function

C.L. interlock switch

•

This sensor detects the presence or absence of the cleaning unit. When the switch is OFF, no power is supplied to the driver IC for the card supply motor and the turnover motor.

Card supply sensor

•

This sensor checks whether cards are being supplied or not.

1) Refer to section 2.9 and remove the front panel.

2) The sensor bracket holding these two sensors can be removed when the screw 6 has been removed.

2) Remove the feed roller marked with* in the lower

drawing of section 2.15.1 “feed roller removal”.

3) The sensor bracket holding the sensor can be removed when the screw # has been removed.

Ink start position sensor

Explanation drawing 4

Route the edge sensor wire underneath the film mark sensor between the circuit boards.

Card edge sensor

Retransfer film mark sensor

( side)

Explanation drawing 4

Pass the wire through the notch in the bracket.

REAR PLATE SA

Card supply sensor

C. LInterlock switch

2.12.11 Removal of the Door Interlock Circuit Board

KJJ46271-001x2

Cassette interlock

2.12.12

Removal of the Cassette Interlock Circuit Board

Function

This circuit board detects opening of the front door. The DC 24 V power put out from the power supply unit is cut off when the door interlock switch and the cassette interlock switch are not both ON.

1) Refer to section 2.9 and remove the front panel.

2) The door interlock circuit board can be removed after the screw

KJJ46271-003

has been removed.

(15)

Door interlock

RED

Function

This circuit board detects the presence or absence of the retransfer film and the ink ribbon cassette. The DC 24 V power put out from the power supply unit is cut off when the door interlock switch and the cassette interlock switch are not both ON.

1) Refer to section 2.10 and remove the platen solenoid.

2) The cassette interlock circuit board can be removed after the screw

has been removed.

(16)

2.12.13 Removal of the Card Tray Interlock Circuit Board

Function

This circuit board detects whether the card tray is presence or absence. When the tray is absence, the power is not supplied to the driver IC for the card pickup motor.

1) Remove the card tray.

2) Remove the three screws 9 and the rail on the left side of the card tray.

3) When the screw is removed with a small screwdriver, the cassette interlock circuit board can be removed.

QYREE4000X

KJJ46271-003

2.13 REMOVAL OF THE TURNOVER UNIT

1) Refer to section 2.9 and remove the front panel.

2) Refer to section 2.8 and remove the turnover motor and the turnover card feed Motor.

3) Remove the E-rings

4) The turnover unit can be removed after the oil bearing # has been removed by sliding it along the shaft.

Installation

1) Install the front E-ring and the oil bearing first.

2) As the gears 5 and 6 are not fixed, hold them by hand while installing the oil bearing and the E-ring.

3) Turn the turnover unit by hand and check that the wire does not get caught.

Attachment position of the serial number

and %.

Install so that the bracket of the turn unit goes under the plate of the rear frame.

QYREE5000X

QYREE4000X

KWR

10303-010

KJJ46271-003

Card tray interlock

L. FRAME SA

Pass the wire underneath the sumi tube.

Pay attention to the wire passing direction.

Explanation drawing 2

QYREE5000X

2.12.14 Removal of the Turnover Card Sensor Circuit Board

Explanation drawing 2

Connect the connector.

(-002)

Q03093-836

Tu r nover Card Sensor Board

Install the gear, holding it so that it will not drop down.

Explanation drawing 1

(-002)

QYREE5000X

(-002)

Function

This sensor checks for correct card storage at the time of card supply and card turning.

1) Refer to section 2.9 and remove the front panel.

2) Turn the turn unit so that the sensor circuit board comes to the top.

3) The sensor circuit board can be removed after the two screws

have been removed.

2.14 FAN REMOVAL

2.14.1 Removal of the Thermal Head Cooling Fan

1) Remove the two screws and the air duct

2) The thermal head cooling fan can be removed after the two screws $ have been removed.

2.14.2 Removal of the Suction Fan

1) The Suction fan can be removed after the two screws

have been removed.

Insert the red wire first, so that the wires will be arranged nicely after connector insertion.

Red

Clamp the wire of suction fan.

Pass the fan wire through the notch.

Loosen the two screws of the duct frame for joint tightening.

QYSPSPD

3012Nx2

2.14.3 Removal of the Card Cooling Fan

1) Refer to section 2.9 and remove the front panel.

2) The card cooling fan can be removed after the two screws 6 have been removed.

Card cooling fan

KJJ46271-003x2

QYSDSP 3030Rx2

Suction fan

Thermal head cooling fan

2.14.4 Removal of the Ventilaion Fan

1) Remove the rear panel and the junction connector.

2) Remove the two screws for the fan.

Remove the clump

Remove the junction connctor

QYSDSP

4008N

Rear Panel SA

QYSPSPD3030N X2

Rear Panel SA

2.15 ROLLER REMOVAL

2.15.1 Feed Roller Removal

1) Refer to section 2.9 and remove the front panel.

2) Remove the card feed motor and the retransfer roller as required.

3) Tension adjustment is required for the belt at the front. Please refer to the following figure.

(M132)

(Use for 5 only)

(M266)

QYYASPW4004F

(-012)

A side with the stage

QYYASPW4004F

(-011)

MAIN ROLLER SA

Please (Insert from the front.)

ANTI BEND ROLLER SA (EPDM)

QYREE5000X

(-002)

CARD OUT ROLLER SA

QYYASPW4004F

(-011)

Hardness : 77

At the time of installing the main roller SA, also engage the front belt.

QYREE5000X

A side with the stage

(-011)

QYREE5000X

ANTI BEND ROLLER SA

QYREE5000X

Hardness : 60

MAIN ROLLER SA

Belt setting

Tension the belt and tighten the screw securely.

QYREE5000X

(-002)

QYYASPW4004Fx3

(-011)

(-002)

(M118)

AL ROLLER SA

JOG DIAL SA

(-002)

REE5000

Engage the bearing with the frame, pull it to the front, and fix it with an E-ring.

QYYASPW4004F

KJJ46271

-003 x2

(-002)

Explanation drawing 1

JOG DIAL SA

(M116)

(50S2M192)

Belt setting

Tension the belt and tighten the screw securely.

QYREE5000X

(-002)

CARD OUT ROLLER SA (EPDM)

AL ROLLER SA

QYREE5000X

MAIN ROLLER SA

2.15.2 Platen Roller Assy Removal

1) Remove the thermal head to prevent damage to it.

2) After removing the thermal head, remove the front panel , E-ring

and the worm screw *, then the

platen roller can be removed. Be careful not to damage the platen roller, other-

wise print quality may be affected.

3) After assembling, remove the protection sheet.

Platen roller (With protection sheet)

long

(-007)

QYREE5000X

short

QYSPSPD

4008N x2

(-007)

QYYASPW3004F

PLATEN ARM SA(F)

PLATEN ARM SA

(F)

(-003)

PLATEN ARM SA

(R)

PLATEN ARM SA(R)

(-003)

Projected side

(-010)

QYREE7000X

QYSPSPD4008N

2.16 CIRCUIT BOARD REMOVAL

2.16.1 Removal of the Main Circuit Board

1) When the three screws

are removed and the cir-

cuit boards are pulled out.

Caution at the time of exchange of the Main circuit board

1) Values set in user mode and service mode are stored on the Main circuit board.Accordingly, when the circuit board has been replaced by a new one, these set values must be stored. For details, refer to Service Mode “Parameter Push and Pop”.

From power supply unit

MAIN PWB SA

TPS0242-001

J23,J24through the inner part of the cable

2) The connectors tend to break in performing removal and attachment of a Main circuit board, please work carefully enough.

J18

J22

KJJ46271-003x3

J15

J21

J17

J22

J18

J23

MAIN PWB SA

J23

J11

J24

J11

J24

2.17 Thermal Head Exchange Method

Head exchange cover

1) Remove the ink ribbon and the retranster film cassette.

2) When the locking claws on both sides of the head are spread, the connector can be disconnected. Remove the connector by pulling it.

3) Remove the screw

. Pull the thermal head to the front to remove it.

Installation method

1) Install a new thermal head.

2) Tighten the screw.

3) Press the connector near its center and insert it. The claws will lock.

When a part of the connector is difficult to see at this time, the work can be facilitated by removing the head exchange cover of the enclosure.

The head exchange cover can be removed by removing the screw and sliding the cover to the rear.

*Notes:

1) When the connector at the time of installation is inserted with the pins not correctly aligned, the connector will be damaged. Please insert it after aligning it correctly.

2) When the heater element on the thermal head is hit at the time of exchange, it can become scratched white streaks etc. can be caused for the printing results. Please handle the thermal head with sufficient care.

3) When the thermal head is touched by someone with an electrostatic charge, it may be damaged. Please touch the frame of the unit before the start of work.

Locking claw

Thermal head

QYSDSP4008N

The check after head exchange

After thermal head is exchanged, a printing position may move in the direction of Y. In this case, please adjust in the following procedures.

Enter into “Service mode”, “Maintenance” and “Offset Prt Y”. See the next page.

1) Determines the displacement amount according to the print results (those owned by the user). Every step corresponds to a displacement of about 0.17 mm. The step can be varied in the range between -15 and +15.

2) Press ENTER to save the setting.

3) Print and check the result.

4) To adjust to the standard setting: In the service mode, print color patterns on single sides of 4 to 5 sheets. Adjust so that the distance from the card edge to the box enclosing the line (A) is about 2.15 mm. (Check the third to fifth cards.)

A=2.15mm

Printing startCard shifting direction

(+)

(-)

USE OF SERVICE MODE

At the time of operation by the user, the "User mode" is used, while the "Service mode" is used at the time of servicing. Refer to the instruction manual for the user mode.

1) Fine adjustment of the printing position

2) Printing of the built-in test pattern

3) Individual operation of motors

1. Entry into Service Mode

In ready condition, in preheating condition, or in error condition, press the buttons button [MENU] is released first, the printer will enter into the following service mode.

[EXIT]

Power off

[MENU]

Lo-Co

[MENU]

Completion

Downloading.. Keep Power On

Start

The new firmware becomes eflective after power off. [EXIT] End of Service mode.

Setting of the printing position Y

[-15(Front) – -1(Front),0,+1(Back) - +15(Back)] Select with [↑][↓] and save with [ENTER].

Setting of the printing position X

[-7(Left) – -1(Left),0,+1(Right) – +7(Right)] Select with [↑][↓] and save with [ENTER].

Setting of the retransfer position X

[-7(Left) – -1(Left),0,+1(Right) – +7(Right)] Select with [↑][↓] and save with [ENTER].

Setting of the card stop position X

[-7(Left) – -1(Left),0,+1(Right) – +7(Right)] Select with [↑][↓] and save with [ENTER].

Setting of the Vth gain (Supplementary function for the future : Always set to 8. )

[0 - +15] Select with [↑][↓] and save with [ENTER].

Setting of the printing density

[Standard Density,Low Density, High Density,User's LUT] Select with [↑][↓] and save with [ENTER].

Card cooling fan ON/OFF

[On, Off] Select with [↑][↓] and save with [ENTER].

Different type of JIS magnetic encoding

[Lo-Co, Hi-Co] Select with [↑][↓] and save with [ENTER].

Card supplying direction

[Standard, Right Side] Select with [↑][↓] and save with [ENTER].

Ajust the threshold level of the ink-Sensor

Select with [↑][↓] and save with [ENTER]. Answered On or Off. [off:transmission,on:interruption.]

Start of the firmware download function The new firmware becomes effective after power OFF or rebooting.

Service Mode

After 1 sec

Download

Maintenance

OK?

[MENU]

[ENTER]

[EXIT]

[ENTER]

Download Ready

Offset Prt Y

Offset Prt X

Offset Trf X

Offset Card X

VGAIN

Default LUT

Standard Density

Card Fan

MG JIS TYPE

Card Loading

Standard

Ink Sensor OFF

107

and simultaneously. When the

The positions where the setting value of –15 was actually setup by the version of a firmware differ.

Under user mode, when the “IC Antenna Pos.” is “Ext. Unit/Ad.on” or the “IC Contact Pos.” is “Ext. Unit”, the “Right Side” cannot be selected.

[EXIT]

Off-line Test

Diag. Test

[MENU]

[ENTER]

[EXIT]

[ENTER]

Pattern

Color

[MENU]

Printing Side

Single

[MENU]

Times

Test Select

Sensor

1000010101010110

Actuator

[MENU]

> >>>

[MENU]

[EXIT]

[ENTER]

[EXIT]

[ENTER]

Test pattern setting

[Step,Vth,Registration,Addres,Color,Black,Gray,All,(YMCK+K),(K+YMCK)] Select with [↑][↓] and set with [ENTER].

Switching between printing single side and both sides

[Single, Both] Select with [↑][↓] and set with [ENTER].

Setting of the number of times for testing

[1,2,3,4,5,6,7,8,9,10,20,30,40,50,100,200,300,400,500,Endless] Select with [↑][↓] and set with [ENTER].

Test Select

OK?

Ink TUP Mo.

OK?

[MENU]

>>>

Ink SPY Mo.

OK?

[MENU]

>>>

Media TUP Mo.

OK?

[MENU]

>>>

Media SPY Mo.

OK?

[MENU]

[ENTER]

Testing

>>>

Ink TUP Mo.

Testing..

>>>

Ink SPY Mo.

Testing..

>>>

Media TUP Mo.

Testing..

>>>

Media SPY Mo.

Testing..

...

Setting the test type

[Print,Feed,IC(Contact),IC(Antenna),MG(JIS), MG(ISO),] Select with [↑][↓] and set with [ENTER].

Ink take-up motor

Ink supply motor

Retransfer Film take-up motor

Retransfer Film supply motor

Memory

Informations

[MENU]

Parameter Push

[MENU]

Parameter Pop

[MENU]

Assistance 12345678

[MENU]

OK?

SIO

OK?

Display

OK?

Back Color

OK?

Buzzer

OK?

Registers

[EXIT]

[ENTER]

[EXIT]

[ENTER]

[EXIT]

[ENTER]

Ancillary data, 8-digit display (read only)

Firmware

Version

FPGA Config.

Version

FPGA Table

Version

Thermal Head

12345678/ 24.00

MG Firmware

Version

Laminator

Version

Ext. Unit

Version

HR PwrOn Time

HR POT Reset

Parameter Push

Parameter Pop

[MENU]

123

[MENU]

1234

[MENU]

___

[MENU]

1234/5 [MENU]

[MENU]

OK?

[ENTER]

[EXIT]

[ENTER]

>>>

Card Feed Mo.

OK?

>>>

urn Over Mo.

OK?

>>>

Turn Feed Mo.

OK?

>>>

Heat Cam Mo.

OK?

>>>

Pick Up Mo.

OK?

>>>

Platen Sol.

OK?

>>>

Ink TUP Enc.

OK?

>>>

Ink SPY Enc.

OK?

>>>

Media TUP Enc.

OK?

Memory

Testing..

SIO

Testing..

Display for 5 sec

The buzzer sounds

[EXIT]

ADPORT0

ADPORT1

Firmware version

FPGA config version

FPGA table version

Thermal Head serial No. and Vth

MG encoder firmware version

Firmware version of laminator when connected

External unit firmware version

[EXIT]

>>>

Retransfer

>>>

Bend Remedy

>>>

Retransfer

>>>

Bend Remedy

Parameter Push

Running..

Parameter Pop

Running..

[ENTER]

[MENU]

[ENTER]

[MENU]

[ENTER]

[MENU]

[ENTER]

[MENU]

[ENTER]

[MENU]

[ENTER]

[MENU]

[ENTER]

[MENU]

[ENTER]

[MENU]

[ENTER]

[MENU]

In case of an error, the buzzer sounds and the LED lights. When there is no error, the indication just returns to the initial indication.

C277

[MENU]

Value obtained by A/D conversion of the thermistor value of the heater or head

FCFC

Displayed the total lighting time of the heat roller

Cleared the total lighting time of the heat roller

Parameter settings save in the head EEP-ROM. * The buzzer beeps in case of an error.

Loading the parameter settings from the head EEP-ROM. * If the correct data is not stored by the head EEP-ROM, "No Data" is displayed and the buzzer beeps.

>>>

Card Feed Mo.

Testing..

>>>

Tur n Over Mo.

Testing..

>>>

Turn Feed Mo.

Testing..

>>>

Heat Cam Mo.

Testing..

>>>

Pick Up Mo.

Testing..

>>>

Platen Sol.

Testing..

>>>

Ink TUP Enc.

Testing..

>>>

Ink SPY Enc.

Testing..

>>>

Media TUP Enc.

Testing..

Display for 3 secDisplay for 3 sec

Card feed motor

Turnover motor

Turnover card feed motor

Cam motor

Card pikup motor

Platen solenoid

Ink take-up encoder In case of an error, the buzzer sounds and the red LED lights. When there is no error, the indication just returns to the initial indication.

Ink supply encoder In case of an error, the buzzer sounds and the red LED lights. When there is no error, the indication just returns to the initial indication.

Retransfer Film take-up encoder In case of an error, the buzzer sounds and the red LED lights. When there is no error, the indication just returns to the initial indication.

Display for 3 sec

Explanation of the Various Modes

2.1 Download

When changing the version of firmware inside the printer, FPGA table or FPGA firmware, refer to the “XID580i maintenance CD-ROM” distributed separately.

2.2 Maintenance

2.2.1 Offset Prt Y Setting

For example, when printing with this printer is to be done on preprinted cards and the position relation is not correct, the entire screen can be shifted. The print position can be varied using the four items listed below. Changing any of the following items varies the print position. However, do not touch the Card X because this is the standard for the X-direction. Use items (3) and (4) for fine adjustments.

BACK

FRONT

LEFT RIGHT

2.2.2 Offset Prt X Setting

B=2.07mm

A=2.15mm

Printing startCard shifting direction

* Items for varying the print position in the latitudinal

direction of the card:

(1) 2.2.4, Offset Card X: Adjusts the card feed amount

from the card edge sensor.

(2) 2.2.2, Offset Print X: Adjusts the feed amount from

the black marker to the start of printing.

(3) 2.2.3, Offset Trf X: Adjusts the feed amount to the

start of a retransfer.

* Item varying the print position in the longitudinal di-

rection of the card:

(4) 2.2.1, Offset Print Y: Adjusts the start position among

the 1152 head heater elements.

(1) Determines the displacement amount according to the

print results (those owned by the user). Every step corresponds to a displacement of about 0.17 mm. The

step can be varied in the range between -15 and +15. (2) Press ENTER to save the setting. (3) Print and check the result. (4) To adjust to the standard setting:

In the service mode, print color patterns on single sides

of 4 to 5 cards.

Adjust so that the distance from the card edge to the

box enclosing the line (A) is about 2.15 mm. (Check

the third to fifth cards.)

1) Determine the displacement amount according to the print results (those owned by the user). Every step corresponds to a displacement of about 0.17 mm. The step can be varied in the range between 7 and +7. (The displacement amount of one step changes with versions of a firmware.)

2) Press ENTER to save the setting.

3) Print and check the result.

4) To adjust to the standard setting: In the service mode, print color patterns on single

sides of 4 to 5 cards. And then remove the film cassette.

Adjust so that the distance from the black marker on the film to the remaining vertical line (P) is about

8.5 mm. (Check the third to fifth cards.)

Take-up side

Supply side

2.2.3 Offset Trf X Setting

1) Determine the displacement amount according to the print results (those owned by the user). Every step corresponds to a displacement of about 0.17 mm. The step can be varied in the range between -

7 and +7.

2) Press ENTER to save the setting.

3) Print and check the result.

4) To adjust to the standard setting: In the service mode, print color patterns on single sides of 4 to 5 cards. Adjust so that the distance from the card edge to the box enclosing the line (A) is about 2.07 mm. (Check the third to fifth cards.)

2.2.4 Card Stop Position Setting (Offset Card X)

This adjustment is made when special cards are used. In the same way as in the preceding item, the card stop position is adjusted and the transfer position is changed. When standard cards are used, the cards may be flicked out. Accordingly, this setting normally should not be changed.

2.2.5 Default LUT Setting

When printing data with a high density are to be printed over the entire area, wrinkles may be caused. In such a case, switch the setting to “Standard” or “Low”.

2.2.6 Device Type Setting

The device type of SCSI Standerd is switched. Normally "Printer" is used.

2.2.7 Card Fan Setting

At the time of separating the card and the retransfer film, the card is cooled with a fan. Depending on the card, the transfer may be better when there is no cooling. In such a case, change this setting.

2.2.8 TUR Response Setting

This mode selects the response that the printer returns to the "Test unit ready" command from the host computer while the printer is executing printing. Normally the setting is changed according to the application software on the side of the host computer.

2.2.9 Compatible Mode Setting

This mode is set when application software created for the model CX710 is to be used with the XID580i. However, care is required as the compatibility is not perfect.

2.2.10 Setting of the ink-sensor level

Set the threshold level of the ink sensor so that the ink sensor defect the ink color “yellow” and “magenta” as transmission, and “cyan” and “Bk”as interruption. Select threshold value by using “↑” and “↓” buttons, and press the “ENTER” button to save the select Value.

[High] [Standard] [Low]

Output

When black omitted characters are to be put out with high density

Y.M.C O.D. = 2.1

Input

Output

Setting at the time of shipping from the factory

Y.M.C O.D. = 1.9

Input

Select “User’s LUT” when the print density similar to that of CX710 is needed.

Output

When changed to close to the hue of a CRT

Input

C M

2.3 Off-line Test

Step Vth Registration

Address

Gray

Color Black

This is used to print the built-in test pattern of this printer and for execution of an MG self-test.

2.3.1 Pattern setting

This printer has seven types of built-in printing patterns. Select a pattern and press the "ENTER" button to store it. Return to the initial pattern is made when the power is cut.

1) Step This is for confirmation of uniform gradation.

2) Vth A and B are printed with the same data values. This is used to confirm that the power supply voltage compensation (Vth) has been done correctly (same density).

3) Registration This is used to confirm that each color overlaps correctly.

4) Address The head has 1152 heater elements. This is used to confirm the uniformity of the density for each heater element.

5) Color

6) Black

7) Gray

8) ALL

This is a pattern for overall evaluation

For checking of black ink blurring, drop-outs, etc.

For checking of feed irregularities caused by mechanical trouble etc.

The above patterns 1) to 7) are printed in sequence. (Each pattern is printed on separate card.)

2.3.2 Printing Side

Selection whether test printing is to be done on one side or both sides.

2.3.3 Times

The number of cards for the test contents selected by "Test select" of the following item is selected.

2.3.4 Test Select

The test to be executed is selected.

1) Print Select this for printing and press "ENTER" twice to

start.

2) Feed Select this to test only the card feed.

3) IC (contact) The cards are fed and the contact for clip card is

lowered. There is no data communication.

4) IC (Antenna) The card is fed and stops under the antenna for con-

tact-free clip card.

5) MG (JIS), MG (ISO) Data actually are written to and read from magnetic

stripe cards. An error is displayed on the LCD panel in case of abnormalities.

2.4 Diag. Test

2.4.1 Sensor

Correct operation of the sensor is checked. Confirm the valve is changed, when the sensor is interrupted or reflected.

Sensor

1000010101010110

D15 D0

D0: NOCD (no card) ................................................. Reflection: 0

D1: CDIN (card supply) ............................................ Interruption: 0

D2: MGCDPOS (MG card position) ......................... Reflection: 0

D3: TURNCD (turnover card) ................................... Interruption: 0

D4: TURNPOS (turnove initial position) ................... Interruption: 0

D5: EDGE (card edge) ............................................. Interruption: 0

D6: CDOUT (card outlet) .......................................... Interruption: 0

D7: CDNE (card near empty) ................................... Reflection: 0

D8: INK (ink start position)

.................... Transmission (yellow,magenta):0,Interruption: 1

D9: MEDIA (retransfer film mark) ............................. Interruption: 0

D10: CAM (cam position) ......................................... Interruption: 0

D11: HR0POS (retransfer heat roller position) ......... Interruption: 0

D12: HR1POS (bend remedial heat roller position) . Interruption: 0 D13: Not used D14: Not used D15: Not used

2.4.2 Actuator

It is possible to operate each motor individually and to check for motor defects and to check the operation of the mechanisms. When two cassettes or a door are open, the power supply to the motor is cut, it will not operate, and inspection should be performed.

1) Ink TUP Mo. (ink take-up motor) ** Remove the inkribbon cassette.

When “OK?” is displayed, press the “ENTER” button to perform take-up operation.

2) Ink SPY Mo. (ink supply motor) ** Remove the inkribbon cassette .

When “OK?” is displayed, press the “ENTER” button to perform supply operation.

3) Media TUP Mo. (retransfer film take-up motor) **

Remove the retransfer film

cassette

. When “OK?” is displayed, press the “ENTER” button to perform film take-up operation.

4) Media SPY Mo. (retransfer film supply motor) Remove the retransfer film

cassette

. When “OK?” is displayed, press the “ENTER” button to perform film supply operation.

5) Card Feed Mo. (card feed motor) The card feed motor operates and the roller rotates.

6) Turn Over Mo. (turnover motor) The turnover motor operates and the turn unit moves through one cycle.

7) Turn Feed Mo. (turnover card feed motor) The turnover card feed motor operates and the roller in the turnover unit rotates.

8) Heat Cam Mo. (cam motor) The cam motor operates and the retransfer roller and the bend remedial roller move through one cycle.

9) Pick Up Mo. (card pickup motor) ** The card pickup motor does not rotate when there

is no cleaning roller unit. The card pickup motor operates and the card supply roller rotates.

10) Platen solenoid The solenoid becomes ON (plunger pulled) once and pushes the platen against the thermal head.

11) Ink TUP Enc. (ink take-up encoder) ** Remove the ink ribbon cassette .

The ink FG sensor is checked. The buzzer sounds in case of an abnormality.

12) Ink SPY Enc. (ink supply encoder) **

Remove the ink ribbon

cassette

. The ink supply encoder (inside the motor) is checked. The buzzer sounds in case of an abnormality.

13) Media TUP Enc. (retransfer film take-up encoder) **

Remove the retransfer film

cassette

. The film take-up (inside the motor) is checked. The buzzer sounds in case of an abnormality.

2.4.3 Memory

Heat roller thermistors

0 20 50 80

100 130 140 150 160 170 180 190 200 210 220

93 82 72 64 56

3F 36

Ambient temperature

thermistor

Thermal head

thermistor

-5 0

10 15 20 25 30 35 40 45 50 55 60 65 75

98 86 76 68

50 46

5 10 15 20 25 30 35 40 45 50 55 60 65 70

E8 E2

D3 C9 BF

B4 A8

90 83 77

61 57

Indicated

Value

Temperature

(°C)

Indicated

Value

Temperature

(°C)

Indicated

Value

Temperature

(°C)

The picture memory SDRAM on the Main PWB is tested. The buzzer sounds in case of an error. The error LED also will light.

2.4.4 SIO

A special jig is connected and the terminals OPTION 1 and 2 are tested. Normally this is used for inspection at the time of shipping from the factory.

2.4.5 Display

All the dots of LCD are displayed black. Conferm that there is no missing dot.

2.4.6 Back Color

The back colors red, green, and blue are displayed for 3 seconds and correct display of the back colors is tested.

2.4.7 Buzzer

Correct sounding of the electronic buzzer is tested.

The following table shows reference values.

2.4.8 Registers

This printer has four temperature-detecting thermistors:

1) Retransfer heat roller thermistor

2) Bend remedial heat roller thermistor

3) Thermal head thermistor

4) Ambient temperature thermistor

These thermistors output analog signals, which are applied to the circuits for four channel 8bit A/D converter IC. Each of these converted value in a hex decimal number as shown below. Note that the following values are the values at the moment the ENTER button is pressed.

>>ADPORT0

C277

Ambient temperature

Thermal head

>>ADPORT1

FCFC

Retransfer heat roller

Bend remedial heat roller

2.5 Information

The information for the various firmware versions can be confirmed. For the thermal head, the serial No. and the head supply voltage (Vth) are displayed. And the total lighting time of the heaters (retransfer and bend remedy) can be displayed. And it is possible to clear the total lighting time to zero after replacing those heaters.

2.6 Parameter Push and Pop

This printer has two EEPROMs for storage of data for the thermal head and for user and service mode. When the Main PWB is exchanged, the settings for user and service mode must be done over again. The Parameter Push/Pop function is provided to shorten this operation. When initially Push is selected and the [ENTER] button is pressed, the set values (including head, total countor) in the EEPROM on the Main PWB are written to the EEPROM in the head. When then “Pop” is selected after the Main PWB has been exchanged and the [ENTER] button is pressed, these set values are copied to the EEPROM on the Main PWB.

OPERATION OF THE MECHANISM

The operation from card supply via card transport and printing to retransfer will be explained using a timing chart. The entire timing chart is shown below. The individual tasks (programs) operate independently.

1. Single-side Printing

Printing task

Ink task

Transport task

2. Double-side Printing

Printing task

Ink task

Printing Printing

Printing

Rewinding

Printing

(front)

Rewinding Rewinding

Retransfer

(front)

Positioning

to the start

Retransfer

Positioning

to the start

Retransfer

Printing

(back)

1Card supply

Retransfer

(back)

Positioning

to the start

Transport task

Card supply Turn

Retransfer

3. Initial Operation

At the time of power ON, the mechanism is initialized.

1) The platen solenoid is pulled once.

2) The turnover unit is returned to the initial position.

3) The cam motor is returned to the initial position.

4) The card feed motor is run to discharge any intermediate cards.

5) Ink ribbon and retransfer film are positioned to the start position. Error stop is performed in case of an abnormality.

Retransfer

4. Card Supply and Card Feed

Period 2: The turnover motor operates and the turno-

ver unit is moved to the card supply position. (Vertical position)

Period 3: The card pick-up motor operates and a card

is supplied from the hopper. The turnover card feed motor also operates at the same time. At this time, the cleaning roller and the roller in the turnover unit also rotates and the card is stored in the turnover unit.

Period 4: The turnover unit turns once from the card

supply position to the printing position.

Period 5: The card is fed from the turnover unit to the

card edge sensor.

Period 6: The card feed to the retransfer standby po-

sition and waits for complation of printing operation.

Turnover card sensor

Card supply sensor

Turnover card feed motor

Cleaning roller

Card

feed motor

Card edge sensor

Card

Card supply roller

pickup motor

Turnover unit (printing position)

NG card outlet roller

Card supply roller

5. Printing Operation

Platen solenoid

12345

OFF

Retransfer film supply motor

Retransfer film take-up motor

Ink take-up motor

Ink supply motor

OFF

CCW

OFF

CCW

OFF

CCW

OFF

CCW

Period 1: The thermal head energization ON signal is

sent to the power supply unit. Head voltage (Vth) is put out from the power supply unit.

Period 2: The retransfer film take-up motor runs to take

up film slack.

Period 3: The platen is pushed against the thermal

head. Then thermal head is energized and printing is start.

Period 4: Delay time for separation of ink ribbon and

film

Period 5:After printing, the ink ribbon and the film stick

to each other, and during this period the ink take-up motor operates to separate them.

87.6 1036dot

56X

664dot

Card size

85.6 x 54

*Notes:

The printing position is shown in the figure on the right. The value of X and Y are adjustment items.

67 3

Retransfer film supply motor

Ink take-up motor

Retransfer film take-up motor

Platen roller

Ink supply motor

Thermal head

Retransfer film

Platen roller

Ink ribbon

Thermal head

6. Retransfer Operation

FWD

123456 7 8 9

Card feed motor

Retransfer film supply motor

Retransfer film take-up motor

Cam motor

Card edge sensor

Card outlet sensor

Retransfer film mark sensor

OFF

N1 N 2

REV

OFF

CCW

OFF

CCW

Rep

OFF

Fix

Period 1: The printed panel on the film and the card

are transported to the retransfer position. Also, the cam motor operates and the retransfer roller is moved to the standby position.

Period 2: The cam motor operates, the retransfer roller

is lowered, and the film and the card are pressed against each other.

Period 3: The card feed motor operates and retransfer

starts.

Period 4: The cam motor operates and the bend re-

medial roller is moved to the standby position.

Period 5: The user mode has the item “Cooling time

setting”, and during this period, the operation is stopped for the set time of 1 to 15 seconds.

** There is no card feed roller between the

retransfer roller and the bend remedial roller. Card movement in this interval is done sticking to the film.

Period 6: The film is moved to the peeling start posi-

tion. (At this time, the card is close to directly under the bend remedial roller.) Also, the cam motor operates and the bend remedial roller is pushed down.

Period 7: Film peeling and card bend remedial are per-

formed.

Period 8:After the card has been discharged, the cam

returns to the stand-by position. Also, one screen is taken up looking at the film mark sensor.

Period 9: The film is returned for another screen for

the next printing.

Retransfer film take-up motor

Platen roller

Card outlet sensor

Retransfer film supply motor

Retransfer film mark sensor

Card feed motorCam motor

FRONT VIEW CAM MODE

Card edge sensor

INITIAL MODE RETRANSFER MODE BEND REMEDIAL MODE

7. Operation in Case of Peeling with Return in Direction Towards the Turnover Unit

In case of printing on both sides, separation of card and film is done in the opposite direction. Up to retransfer, the operation is the same as in the above items. Then the operation becomes as shown below.

12 3 4 5

FWD

Card feed motor

Retransfer film supply motor

Retransfer f

ilm take-up motor

Cam motor

Retransfer f

ilm mark sensor

OFF

REV

OFF

CCW

OFF

CCW

Rep

OF F

Fix

Period 1: The cam is returned to the intial position.

Period 2: In the same way as for the preceding item, a

card cooling period exists.

Period 3: The card is fed in the direction towards the

turnover unit to separate card and film, and peeling is performed.

Periods 4 and

: Searches a start position of the next panel

and becomes to the standby mode.

8. Operation of the Turnover Unit

In case of printing on both sides, the card is turned. The card which has been printed to front side is fed to the turnover unit.

Turnover motor

Turnover card feed motor

Card feed motor

OFF

CCW

FWD

OFF

REV

FWD

OFF

Period

: The card feed motor and the turnover card

feed motor operate and the card is fed.

Period 2: The turnover motor operates and the turno-

ver unit is turned 180°.

Period

: The card is fed to the retransfer standby po-

sition.

Period 4: The turnover unit is initialized.

1234

n 3

n 1

n 2

REV

Turnover card sensor

Card edge sensor

Period 1: The turnover motor operates to the position

sensor detection.

Period 2: The turnover motor is reversed and the po-

sition of turnover unit is fine adjusted.

Turnover motor

OFF

CCW

Turnover intial position sensor

9. Others

9.1 Position Relation with Ink Ribbon and Retransfer Film

Film supply

Film take-up

C’

B’

Platen

Film mark sensor

Retransfer roller

A A

Cartridge shaft

Head

Ink start position

sensor

Ink take-up

B’

Ink supply

C’

Cartridge shaft

Bend remedial roller

9.2 Ink Ribbon and Retransfer Film End Treatment

End marks as shown below are provided near the end of the ink ribbon and the retransfer film. The respective sensor detects the mark and “RUN OUT” is displayed.

Ink start position sensor

Ink FG sensor

∗

LLHHL

KCMY YK

Ink ribbon transport direction

§§§§§§§

In case of positioning the ink ribbon to the start position The boundary between magenta and cyan is detected by the sensor for the ink ribbon start position. The output pulse of the ink feed quantity sensor is counted, and the start position of yellow is decided.

.............

End mark

2.5cm

TROUBLESHOOTING

1. LCD Error Code Correspondence

No.

Error item

Please Power off

Please Remove Media Cassette

HR is too hot!

Jam (Hopper) Card jam (hopper part)

Error detection contents

When recovery is not possible even when the RESET button is pressed. When the feed rollers are is to be cleaned, cleaning mode is not entered as the transfer film cassette is present. In the same way as above, this message is displayed when the heat roller temperature is 50˚C or more at the time of entry into cleaning mode. An error will be caused when the card supply sensor is not passed within a fixed time after start of card supply.

This display appears for example when there is hardware trouble, as with the following trouble of No. 18-26.

Remove the retransfer film cassette. This prevents sticking of the cleaning card to the film.

1) Switch off the power and wait for the temperature to

2) When the retransfer film is in the unit, the heat roller is

1) Check for sticking of the cards in the card tray because of

Check that the cards are aligned.

2) Is the card push Plate of the card tray in the lock position? Check the force with which this Plate presses onto the cards. If

3) In the case of 0.25 mm cards, the number of cards which can

4) Clean the card supply roller with alcohol. Touch the surface to

5) Check the thickness of the thickness adjustment plate and the

6) Perform the diagnostic test in service mode and check for

7) When this message appears at the time of power ON, the

8) Check for contamination of the cleaning roller. Clean the roller

The life of the cleaning roller is about one year. The adhesive

It is also possible that the roller becomes worn and no longer

9) After the cleaning roller, the cards are transported by the

Perform the diagnostic test of the service mode and check the

drop.

heated even in this mode. Always remove the retransfer film first.

static electricity. Try to separate the cards from each other.

it is weak, check for spring elongation etc.

be set in the tray is limited according to the used cards. Test by trying to set about 50 cards into the tray.

check if it is slippery.

card. Also check for correct thickness adjustment in case of special card thickness (turn the gear of the card supply roller and check for individual card supply).

operation of the card pickup motor. Also confirm correct operation of intermediate gears.

sensor is broken. Use the sensor check of service mode for confirmation.

if it is dirty.

power gets lost with use for many years.

can feed the cards correctly.

turnover card feed motor.

operation of the turnover card feed motor.

)Does the turn over unit come to the card supply position

(vertical position) at the time of card supply? The pulses of the turnover motor are counted and rotation to the card supply position is done. When the turnover unit is not pointing straight down, the card will not enter the rail and an error will be caused. Perform the diagnostic test in service mode and check the operation of the turnover unit.

)Check for correct rotation of the roller in the turnover unit. Clean

the roller in case of rotation. Perform the diagnostic test in service mode and check the operation of the turnover card feed motor.

Treatment contents

Exchange parts

* Card

Card supply roller

* Adjustment

Motor, Drive circuit board Main circuit board *

Sensor,

Main circuit board

* Cleaning roller

Motor, Drive

circuit board,

Main circuit board

Motor, Drive

circuit board,

Main circuit board

Motor, Drive

circuit board, Main

circuit board, roller

No.

Error item Jam (TurnOver) Card jam (turnover unit)

Jam (MG) Card jam (encoder)

Jam (Retransfer) Card jam (retransfer section)

Jam (Discharge) Card jam (discharge)

Media Broken Torn retransfer film

Media Search Retransfer film detection error

Error detection contents When the card does not

enter to or depart from the sensor inside the turnover unit within a specified time.

When the card does not arrive at the card edge sensor within a specified time after leaving the turnover unit. Also, in case of magnetic encoding, when detection by the start position sensor of the MG unit is not possible. When the card outlet sensor is not reached within a specified time after leaving the card edge sensor.

In case of stopping at the card outlet sensor.

Detection of the retransfer motor rotation condition, pulses, marks, etc.

Treatment contents

1) When this message appears at the time of power ON, the sensor is broken. Use the sensor check of service mode for confirmation.

2) Confirm the operation of the turnover unit until the card reaches the sensor.

Perform the diagnostic test in service mode and check

the operation of the turnover unit.

3) Check for correct rotation of the roller in the turnover unit. Clean the roller with alcohol in case of rotation.

Perform the diagnostic test in service mode and check

the operation of the turnover card feed motor.

4) Check that card feed is OK when the turnover unit is oriented in the print mode direction.

Perform the diagnostic test in service mode and check

the operation of the card feed motor.

1) When this message appears at the time of power ON, the sensor is broken. Use the sensor check of service mode for confirmation.

2) Check the operation until the card enters to the sensor.

Perform the diagnostic test in service mode and check

the operation of the card feed motor.

Check belts, gears, and rollers for wear. Clean the

rollers with alcohol.

1) Check if the card sticks to the film.

* If the card sticks to the film, check for correct operation of the card cooling fan (rotates only at the time of

retransfer).

* If the card sticks to the film, replace the film by a different film and try printing.

2) Check the condition of the rubber on the retransfer roller surface.

3) Perform the diagnostic test in service mode and check the operation of the card feed motor.

Check belts, gears, etc.

1) When this message appears at the time of power ON, the sensor is broken. Use the sensor check of service mode for confirmation.

2) Check the condition of the rubber on the bend remedial roller.

3) Perform the diagnostic test in service mode and check the operation of the card feed motor.

Check belts, gears, out roller, etc.

4) For bend remedy at the time of one-sided printing, there is the temperature setting for the bend remedial roller. Is double-sided printing being done with this temperature setting too high? In this case, the cards may become deformed and jams may be caused,

1) Perform the diagnostic test in service mode and check the operation of the retransfer film supply motor.

2) Perform the diagnostic test in service mode and check the operation of the retransfer film take-up motor.

Exchange parts

* Sensor, Main circuit board

* Motor, Drive circuit board, Main circuit board

Motor, Drive

* circuit board, Main

circuit board, roller

* Motor, Drive circuit board,

Main circuit board

*Sensor x 2,Main circuit board MG circuit board

Motor, drive

circuit board,

Main circuit board * Belts, gears, rollers

* Film

* Retrnsfer roller

* Motor, Drive circuit board,

Main circuit board * Belts, gears * Sensor, Drive circuit board * Bend remedial roller

Motor, Drive

* circuit board,

circuit board

Main * Belt, gear, roller

* Motor, Drive circuit board,

Main circuit board * Motor, Drive circuit board,

Main circuit board

No.

Error item Media Run Out End of the retransfer film

Ink Broken Torn ink ribbon

Ink Search Ink ribbon detection error

Ink Run Out End of the ink ribbon

Turn Over Unit Defective operation of the turn-over mechanism

Error detection contents

Detection of ink motor rotation condition, pulses, marks, etc.

Detection of the motor rotation condition and operation of the turnover initicl position sensor.

Treatment contents

3) The retransfer film take-up motor has a encoder for output of pulses when the motor operates.

Perform the diagnostic test in service mode and check

the output of the encoder of the retransfer film take-up motor.

4) When this message appears at the time of power ON, the sensor is broken. Use the sensor check of service mode for confirmation.

5) Remove the cassette and confirm the retransfer film installation condition. Confirm that there is no winding deviation or similar to prevent error of the sensor,

In case of winding deviation, check the shaft, the bobbin

holder, etc. of the retransfer film cassette.

6) If winding eleviation is serious,then replace the retransfer film with a new one.

1) Perform the diagnostic test in service mode and check the operation of the ink supply motor.

2) Perform the diagnostic test in service mode and check the operation of the ink take-up motor.

Perform the diagnostic test in service mode and check

the output of the encoder coupled with the ink take-up gear.

3) The ink supply motor has a encoder for output of pulses when the motor operates.Perform the diagnostic test in service mode and confirm the output of the encoder of the ink supply motor. (Ink SPY Enc) When this message appears at the time of power ON, the sensor

4) is broken. Use the sensor check of service mode for confirmation.

5) Remove the cassette and confirm the ink installation condition. Confirm that there is no winding deviation or similar to prevent error of the sensor,

In case of winding deviation, check the shaft, the bobbin

holder, etc. of the ink cassette.

6) If winding eleviation is serious,then replace the ink ribbon with a new one.

1) Perform the diagnostic test in service mode and confirm the operation of the turn over motor.

2) When this message appears at the time of power ON, the sensor is broken. Use the sensor check of service mode for confirmation.

Exchange parts

* Motor, Drive

circuit board, Main circuit board

* Sensor, Main circuit board

* Retransfer film, cassette

* Motor, Drive circuit board,

Main circuit board * Motor, Drive circuit board,

Main circuit board, INK FG circuit board * Motor, Drive circuit board,

circuit board

Main * Sensor, Main circuit board

* Ink ribbon, Cassette

* Motor, Drive circuit board,

Main circuit board * Sensor, drive circuit board

Heater Cam

Defective heat roller operation

No Card

There is no card, the tray is empty.

Detection of the motor rotation condition and the cam sensor operation.

Card presence is detected by a reflection sensor.

1) Perform the diagnostic test in service mode and confirm the cam motor operation.

2) When this message appears at the time of power ON, the sensor is broken. Use the sensor check of service mode for confirmation of the cam sensor retransfer roller sensor, and remedial roller sensor.

3) Check the cam mechanism etc.

4) Check the installation and the wire routing for retransfer roller and bend remedial roller.

1) When this message appears at the time of power ON, the sensor is broken. Use the sensor check of service mode for confirmation of the no card sensor.

* Motor, drive circuit board,

Main circuit board * Sensor, drive circuit board

* Cam * Roller, wire * Sensor, Main circuit board

No. 14

Error item Door open The printer door is open.

No Cleaning Ro. There is no cleaning roller.

No Cassette There is no cassette.

Hardware

TR Overheat Retransfer roller overheat

TR Broken Defective retransfer roller

Error detection contents The door interlock

switch is detected.

The cleaning roller interlock switch is detected.

The cassette interlock switch is detected. Ink and retransfer

cassette switch are connected in series. Vth (Voltage supplied to the thermal head ) is not determined. Circuit trouble is detected. The temperature of the retransfer roller is detected with a thermistor, and an error is caused when this temperature exceeds about 240°C. When this temperature is exceeded, the thermostat operates and the circuit is cut.

When the temperature does not rise even after about 30 sec. have passed since heater ON.

When the temperature at the time of READY is about 40°C lower than the set temperature.

Treatment contents

1) Check that the door interlock switch is pressed normally. When it is pressed normally, the cooling fan on the left

side of the printer operates.

2) Check the mechanism pressing the switch.

1) Check that the cleaning roller interlock switch is pressed normally.

2) Check the mechanism pressing the switch.

1) Check that the cassette interlock switches for ink and retransfer film both are pressed correctly.

2) Check the mechanism pressing the switch.

Check that the connector is connected correctly to the thermal head.

When Vth power can not be put out from the power supply unit.

When

the A/D circuit of the analog power circuit board is

defective.

This is a defect of the heater control system.

1) Analog power circuit board: Defect of the circuit performing A/D conversion for the thermistor.

2) Heater protector circuit board.

3) Heat roller unit: Defective thermistor etc.

This is a defect of the heater control system.

1) Analog power circuit board: Defect of the circuit performing A/D conversion for the thermistor.

2) Heater protector circuit board.

3) Retranser roller unit: Defective thermistor etc.

Thermistor: Measure with a tester - about 220 kΩ at

normal temperature and about 1 kΩ at 200°C.

4) Measure the thermostat with a tester and confirm a value of about 2 or 3 Ω. The resistance is infinite in case of abnormalities.

5) Defective power supply unit.

Exchange parts

Door interlock

switch, Main circuit board * Door

Cleaning roller

* interlock switch, Main circuit board

Cleaning roller unit *

Cassette interlock

switch, Main circuit board * Ink cassette, Retransfer cassette * Thermal head

Power supply unit

* * Main circuit board

* Main circuit

board

* Heater protector

circuit board

* Heat roller unit

* Main

circuit board

* Heater protector

circuit board

* Heat roller unit

*Heat roller unit

Power supply unit

TR Sensor Broken Defective retransfer roller thermistor

The retransfer roller temperature is detected with a thermistor. When the temperature has dropped about 10°C from READY.

Check for a wire break of the thermistor.

1) Thermistor: Measure with a tester - about 220 kΩ at normal temperature and about 1 kΩ at 200°C.

2) When the thermistor is normal: Defective analog power circuit board, CPU circuit board.

* Heat roller unit * Main circuit board

No. 21

27 28 29 30 31 32 33 34 35 36 37

Error item RR Overheat Bend remedial roller overheat

RR Broken Defective bend remedial roller

RR Sensor Broken Defective bend remedial roller thermistor

Overcool Overcooling

Head Overheat Head overheat

EEPROM Broken Defective EEPROM

Printer CFG Err MG Unconnected MG Mechanical MG Hardware MG Write MG Read MG Communicate EXT.Unconnected EXT.SW Setting EXT.Jam EXT.Communicate

Error detection contents

The temperature of the bend remedial roller is detected with a thermistor, and an error is caused when this temperature exceeds about 220°C. When this temperature is exceeded, the thermostat operates and the circuit is cut.

1) When the temperature does not rise even after about 30 sec. have passed since heater ON.

2) When the temperature at the time of READY is about 40°C lower than the set temperature.

The bend remedial roller temperature is detected with a thermistor. When the temperature has dropped about 10°C from READY. The TPS0220-001-H circuit board has a sensor for detection of the ambient temperature. When detection by this sensor has become impossible. The thermal head has a built-in thermistor, and the density is kept constant according to the temperature of the head. When head temperature exceeds 70°C This unit has two EEPROMs.

Refer to subsection 3.4 in "MGI encode unit" and subsection 4 in "Large-type IC unit"

This is a defect of the heater control system.

1) Analog power circuit board: Defect of the circuit performing A/D conversion for the thermistor.

2) Heater protector circuit board: Only the 200 V system is confirmed. The 100 V system is passed through.

3) Heat roller unit: Defective thermistor etc.

This is a defect of the heater control system.

1) Analog circuit board: Defect of the circuit performing A/D conversion for the thermistor.

2) Heater protector circuit board.

3) Bend remedial roller unit: Defective thermistor etc.

Thermistor: Measure with a tester - about 220 kΩ at

normal temperature and about 1 kΩ at 200°C.

4) Measure the thermostat with a tester and confirm a value of about 2 or 3 Ω. The resistance is infinite in case of abnormalities.

5) Defective power supply unit.

1) Thermistor: Measure with a tester - about 220 kΩ at normal temperature and about 1 kΩ at 200°C.

2) When the thermistor is normal: Defective analog power circuit board, CPU circuit board.

1) Exchange the thermistor circuit board.

2) Analog power circuit board, CPU circuit board.

3) When the circumference temperature is 5°C or less.

1) Does the cooling fan operate? Check that the filters on both sides are not clogged. In case of clogging, clean or exchange the filters.

2) Does the thermal head cooling fan operate normally? Perform cleaning.

3) In case of reoccurrence, the thermal head is defective. Exchange the head.

1) When the head EEPROM is defective.

2) When the EEPROM on the CPU circuit board is defective.

Treatment contents

Exchange parts

* Heater protector

circuit board * Heat roller unit * Main circuit board * Heater protector

circuit board

* Heat roller unit

* Power supply unit * Heat roller unit

* Main circuit board, Thermistor

circuit board

Raise circumference temperature. * Cooling fan,

Filter

* Thermal head

cooling fan

* Thermal head

* Main circuit

board

* Thermal head.

2. Printing Defects and Countermeasures

Printing defect Cause Countermeasure

The printing result has horizontal lines (pulling wrinkles).

1) When large areas have been printed with high density.

2) When the back tension is strong.

1) When large areas are to be printed, set "Default LUT" of maintenance in the service mode to "Standrd" or "Low".

2) Check for smooth turning of the spring of the ink cassette. Disassembly and clean if the spring does not turn smoothly.

3) Check for smooth turning of the bobbin on the supply side. Exchange the cassette if the bobbin is not turning smoothly.

Spring

KXL46255-001

Bobbin holder for supply

No transfer to the left or the right side of the card.

Large card bend (

in case of single-sided printing

(

in case of double-sided printing

)

1) Retransfer position is wrong.

2) Card stop position is wrong.

Heat deformation occurs easily especially with PVC cards.

4) Check for a heavy load of mechanism, motor, etc. on the ink supply side.

1) Confirm if the operation of the card edge sensor and the film sensor is normal, and if these sensors are firmly secured.

2) When sensors are replaced, setting “Offset Trf X” for the film sensor and/or setting “Offset Card X” for the card edge sensor shall be adjusted.

1) The environmental temperature to use is adjusted to the temperature range of specification. If this is still not sufficient, additionally lower the temperature setting for the retransfer roller to reduce deformation by heat.

2) Adjust the temperature setting and the cooling time setting for the bend remedial roller.

3) When double-sided printing is done with the temperature setting for the bend remedial roller set to a high value, the cards will become deformed.

When the card is deformed with a convex face and a

concave reverse-side, make the reverse retransfer speed higher or change the setting of the bend remedy mode.

Printing defect Cause Countermeasure

Characters or photos appear as double images.

Defective registration

Some part is not transferred correctly (remains on the film side).

The ink ribbon feed system is not constant.

1) The card is dirty.

2) The use environment temperature is low.

3) The card material is not suitable.

1) Use the off-line test of service mode to print registration patterns. Confirm that the horizontal and vertical lines are within two dots.

2) Check the take-up condition of ink ribbon and retransfer film. If the take-up is not uniform, check the condition of the shaft of the ink cassette.

3) Check that ink ribbon and retransfer film are set correctly when they are installed in the cassette. For the retransfer film, check that the film is in the guide.

4) Check that the platen solenoid is pulled completely.

5) Check the belt tension and the screw tighteness of the drive pully on the retransfer film supply motor.

1) Check that the card surface has not been touched with bare hands.

2) Use the unit at a higher use environment temperature.

3) Raise the temperature setting for the retransfer roller.

4) Lower the retransfer speed.

5) Wipe the card surface with alcohol.

6) In case of small retransfer defects, check for dirt and dust. * Cleaning roller * Fan and filter

(Retransfer defect)

There are white lines in the printing result or the printing is thin.

Defective thermal head. 1) Clean the thermal head.

2) When perfectly white lines occur, there are some broken heater element and the head must be exchanged.

3) When the same pattern is printed continuously, only those lines become thin.

Printing defect Cause Countermeasure

The picture position is shifted vertically or horizontally.

123456789

Resin characters are blurred Resin characters are thin. Resin characters are missing parts.

ABCDE ABCDE ABCDE

1) Setting of the retransfer film

2) Ink ribbon, retransfer film

3) Card

123456789 123456789

1) Character font

2) Head or platen roller

wear

1) Refer to page 31 of the instruction manual and check the film type setting.

2) Check the winding condition of the ink ribbon and the retransfer film. If the winding is not uniform, check the condition of the shaft of the ink cassette.

3) In case of preprinted cards, use "Offset Prt Y" or "Offset Trf X" of maintenance in service mode to adjust the position to that design.

1) When small characters are printed with a fine font, the characters may become blurred or may be missing some parts. In such a case, increase the character size or use bold characters. In case of using small characters due to print image design , refer to page 30 of the instruction manual.

2) When the head or the platen roller is worn out due to long time use, characters may be printed with some parts missing. In that case replace with a new head or platen roller.

* Resin character : When a character is printed in black ink.

The printing result shows white spots.

1) Dust on the card

2) Dirty cleaning roller

3) Dirty internal rollers

4) Dirty filter

This case occurs with printing to film. (This is different from defective retransfer.)

1) Remove any dirt from the cards.

2) Clean the cleaning roller. Exchange the cleaning roller if needed.

3) Clean the internal rollers with cleaning card.

4) Clean the fan filters. Exchange the filters if needed.

5) When this occurs every time at the same position in horizontal direction, a dent in the platen roller or retransfer roller can be considered.

Printing defect Cause Countermeasure

Lines appear. (In case of lines at uniform intervals)

(In case of random occurrence)

1) Uneven feed. 1) When this is notable with thin background colors, the ink ribbon is not being wound uniformly.

• Check the ink take-up motor and the mechanism.

• Check for smooth rotation of the bobbin holder of the ink cassette.

1) When this is notable with normal printing, the ink cassette has not been inserted completely. Confirm that it has been inserted until a cassette button locks.

3. Power Supply Check

12V

24V

Vth

H.T.Protector

—

MAIN

DRIVE

—

FRONT

—

Source Device

Power Supply Unit

Target PWB Usage

5V Logic IC

Analog IC (Amp, Comp etc)

Actuator

Thermal Head

3.3V

1.9V

2.5V

5VREF

3.3VREF

CPU

—

CPU

USB IF

—

MAIN

—

MAIN

—

DRIVE

—

Regulator IC (5V to 3.3V)

Regulator IC (5V to 1.9V)

Regulator IC (5V to 2.5V)

Shunt Regulator (12V to 5V)

3.3V LV IC (CPU, Memory etc)

CPU(only)

FPGA(only)

Reference Voltage (ADC etc)

Reference Voltage

(ADC in CPU (only))

1. The power supply unit outputs the following four kinds of voltages.

2. The voltages output from the power supply unit can be checked with the LEDs on the PWB of the unit.

1) Vth: The LED lights only during printing.

2) 24 V: The LED lights when the ink cassette and film cassette are present and the door is closed.

3) 5 V: The LED lights when the power switch is ON.

TOP

24V Vth

3. The voltages generated in the MAIN PWB are output to their target PWBs. For details, see the overall block diagram.

MAINTENANCE INSPECTIONS

1. Cleaning

The following parts should be cleaned as instructed of the list when you repair the unit.

No. Part name Cleanning metod

1 Thermal head Clean with alcohol .(dehydrated ethanol.) 2 Cleaning roller Wash it after repair. 3Feed roller Clean with alcohol .(dehydrated ethanol.) 4 Card feed rollers Use alcohol (anhydrous alcohol), or use a cleaning card and then implement

CLEANING in USER MODE. 5 Platen roller Clean with alcohol. (dehydrated ethanol.) 6

Fan filters (three places) 7 MG head Use a cleaning card. 8 Bobbin inner Clean with the vacuum cleaner etc. 9 Shaft of Ink Cassette / Film Cassette Alcohol (Use anhydrous alcohol) 10 Bearings of each rotating part and around them Clean with a vacuum cleaner, or wipe with a dry cloth 11 Card housing of hopper and around it Clean with a vacuum cleaner, or wipe with a dry cloth 12 Interior of hopper Clean with a vacuum cleaner, or wipe with a dry cloth 13 Inner side of front door, cassette slot Clean with a vacuum cleaner, or wipe with a dry cloth 14 Dust inside set and on inner side of top cover Remove the top cover, then clean the dust on the inner side and inside the

2. Lubrication

Apply the grease as illustrated to the ink ribbon cassette after every 5,000 pcs of cards are printed. There is no need for periodic application of oil or grease except this parts , but application should be made to the new parts at the time of parts exchange. When the oil or grease on the opposite part appears dirty, wipe it off and apply new oil or grease.

Caution

Refer to the "Parts table" in the disassembly drawing for the locations for application of oil or grease and the oil or grease to be used.

Clean with the vacuum cleaner etc.

set with a vacuum cleaner.

Film cassette(green)

Apply the grease by four grains of sesame between the white sheet and the spring of the bobbin.And rotate the bobbins to make the grease uniformly spread over the white sheet.Wipe out the excessive grease.

Supply bobin (green)

3. Maintenance Inspections for Main Parts and Execution Standard

This standard table applies for standard conditions, and there may be large differences according to the use environment and the use conditions. When the maintenance inspections are not performed suitably, the following times will not only be shortened considerably, but there may also be other bad influences. However, deformation or ageing may occur for rubber parts also when they are stored or not used for a long time.

Part No. Part name Replacement Remarks

CX320-HD1 Head assembly 30,000 screens At the time of YMCK printing TFS0116-002 C.L. roller assembly About one year Half a year with a high use frequency TSS0181-002 Heater assembly 2,000 hours With power save OFF TSS0182-002 Reform heater assembly 2,000 hours With power save OFF CX220-FFK1 Fan filter assembly About one year KEF1041-002 Suction 40,000 hours CX220-FAN2 Card cooling fan 20,000 hours Operates only for retransfer. KEF1037 Head cooling fan 40,000 hours

KEF1042-002 Ventilation 40,000 hours

CX220-PIM1 Card pick up motor 200,000 cards or more DC motor CX220-INW1 Ink take-up motor 180,000 screens DC motor CX220-INS1 Ink supply motor 180,000 screens DC motor CX220-MWM1 Film take-up motor 120,000 screens DC motor TSS0179-002 Platen solenoid 100,000 screens KJY32771-045 Timing belt 100,000 screens KJY32771-030 Timing belt 100,000 screens Belt for card feed motor KJY32771-044 Timing belt 100,000 screens Belt for card feed motor KJY32771-032 Timing belt 100,000 screens Belt for card feed motor KJY32771-035 Timing belt 100,000 screens Belt for card feed motor

Belt for film supply motor and card feed motor

4. Periodic Inspection Items

In case of performing periodic inspections by means of a maintenance contract, please use a copy of the following sheet.