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

25

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.

I

(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

Z

V

ab

A

c

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

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.

II

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

1

HOW TO CONNECT SEPARATELY SOLD PARTS

1. Connecting the Small-type IC Unit

1.

Remove the cover on the side of the printer.

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

2.

Connect the connector.

Please note that the connector has directionality.

3.

Install the unit with three screws.

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

4.

Install the cover with two screws.

Screw with washer
(provided)

Pass the cable through the notch.

Screw
(provided)

2

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.

6

Pass the wires of
power switch.

CN3

13

KWS0744-001

KWR18416-001

x6

9

8

12

Clamp

1

(TFA0023)

J10

J9

Explanation drawing 1

J14

(TSA0141)

G.NO.004

Make the cable routed
away from the rail

2

MG PWB SA

Explanation
drawing 1

J10

8

CLAMP

Explanation
drawing 2

14

6

KWS0767-002

15

J14

J10

KWS0768-001

Clamp

6

J1

J8

J7

Explanation
drawing 2

J4

J5

J3

J10

J14

8

8

3pin

CLAMP

Explanation drawing 1

CN12

11

KWR17110-001

Clamp

CLAMP

6

6

3

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.

4

THERMAL HEAD

HEAD

CONN

PWB

U1

EEPROM

32Kbit

HEAD BLOCK

MAIN PWB

FRONT PWB

POWER

SUPPLY

UNIT

U1

CPU

X1

XTAL

66.67MHz

U7

EEPROM

32Kbit

U2

SDRAM

64Mbit

U3

FLASH ROM

16Mbit

TR THERMISTOR

RR

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

U5

SDRAM

64Mbit

U5

FLASH ROM

16Mbit

SENSORS

THERMISTOR &

CONNECTOR (PWB)

EXTERNAL UNIT

HEATER PROTECTOR PWB

USB

I/F

Q13

REGULATOR

(A+5V)

U8

REGULATOR

(3.3V)

Q11

REGULATOR

(1.5V)

U10

REGULATOR

(1.8V)

DC-DC circuit

U11

FPGA

U12

SDRAM

64Mbit

U1

DAConverter

LCD module

(16columX2line)

SWX6

COLOR

LED

LEDX2

BUZZER

U17

USB

chip

X1

XTAL

48MHz

U7

STEP MOTOR DRIVER

Q2

Q3

TRANSISTOR

Q5

TRANSISTOR

Q6

TRANSISTOR

Q7

TRANSISTOR

U8

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

INK MOTOR

TURN

MOTOR

CARD MOTOR (TURN)

CARD MOTOR (PICK UP )

U9

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

U2

Serial to Parallel

U19

INVERTER

CPU BUS

U13

ADConverter

U2

RESET IC

(5V)

CLEANING ROLLER INTERLOCK SW

DOOR INTERLOCK SW

CASSETTE INTERLOCK SW

CARD TRAY INTERLOCK SW

FAN (PRINTER)

U7

CLK

DRIVER

X2

XTAL

32MHz

BLOCK DIAGRAM

1. OVERALL BLOCK DIAGRAM

5

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

5V

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

AC

VOLTAGE

DETECT

PHOTO

COUPLER

ABNORMAL

CURRENT

DETECT

PHOTO

COUPLER

Primary

Secondary

SSR1L

SSR2L

ON/OFF

CN5

SSR

CN7

CN6

SSR

6

3. INTERLOCK SW BLOCK DIAGRAM

24V

U9

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

J7

J6

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

Pick up Motor STOP

Specification of Interlock Switch

CN3

Vth

CN1

5V

12V

CN2

24V

CN4

24V_RC

Vth_RC

MAIN PWB

7

4.

BLOCK DIAGRAM OF THE FPGA CIRCUMFERENCE ON A MAIN BOARD

Motor
Solenoid
Control
Signals

Sensor input

Retransfer
Heater
Temperature

7

Bend Remedial
Heater
Temperature

8

TPH
Temperature

9

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

78

HEATER
CONTROL
BLOCK

(The Heaters
are controlled
by each
temperature.)

D/A
Interface

16bit
Data

6

1

2

PRINT BLOCK
(Temperature
correction,
Outline emphasis,
LUT)

Data Processor

Microcode
Memory(*1)
512Word x 16bit

9

TPH I/F BLOCK

Line Buffer Memory

Flash
Memory

INTERNAL
CLOCK
GENERATOR

SDRAM I/F BLOCK

x 2

32bit CPU BUS

4

56

SDRAM
4MWordx16bit

1

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

2

Heater control
Table(*2)

3

16bit
Data

3

TPH Control
Table(*2)
(Strobe)

4

Tables for
Print Data
Correction(*2)

5

Work Memory
for PRINT BLOCK

6

Plane Memory
2MByte

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

Print Data
Strobe
Lutch

Thermal Print Head

from Flash Memory.

*FPGA=

FieldPrgrambleGateArray

8

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

DC

Motor

CN8 CN9

Step

Motor

DC Motor

DC Motor

DC Motor

Step

Motor

OPTION

(MG/IC Block)

Step

Motor

S3

S1

S2

T2

F1

T1

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

AC

AC

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

IC

CONTACT

XID580i BLOCK DIAGRAM

Head position2

Head position3

Remedial

Heatroller

Positionning sensor

Card Cooling Fan

J6

J7

J4

J8

J13

J12

J11

J24

J23

J10

J9 J15

J5

J21

J22

J2

J18

J16

J17

J14

RF-ID PWB

J9

J8

J11

J12 J16

J14

J7 J6

J3

J4

J2

J1

CN1

CN2 CN3

to J13

J13 J15

J10

J9

J12

to

J16

to J9

to J12

to J8

to J13

to J13

to

J8

to J16

to J10

J1

to J11

CN1

CN1

CN3

to J15

CN3

CN301

CN1

CN201

CN4 CN5

CN6

CN7

to J8

CN2

9

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)

10

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

11

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

12

MAIN PWB

Thermal head
cooling fan

Ventilation fan

Ventilation fan

Card cooling fan

13

7. RF-ID

14

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

15

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.

16

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)

18

QYSPSPD
4008N

Bearing

Thermistor bracket

Pass the wires
behind the lever

15

(-010)

screw B

1

(TSS0181)

Clamp

F1

(-010)

15

Retransfer roller

17

KJJ46271-003

17

A

B

Bend remedial roller

(TSS0182)

3

12

KJJ46271

-003x2

T1

H1

17

KJJ46271

-003x2

KJJ46271-003

T1

Clamp

(T2,H2)

P4

(FD M.MOTOR ASY)

Screw A

T2

T2

Clamp

H2

(F1)

Cam motor

5

(TSS0189)

Clamp

(P4)

17

KJJ46271

-003x2

Screw A

17

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

20

Apply grease to
this side also

12

Apply grease to this side also

13

20

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

9

7

Apply grease to
this side also

14

QYREE4000X

Engage with

20

10

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.

7

QYREE4000X

8

Bobbin holder

17

18

P4

Cam motor

Before installing the gear,
install it on the bracket.

6

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)

J7

F2

J6

P3

F1

J11

(KWS0751-002)

(Tray interlock)

D3

Clamp

D1

P5

P1

P2

J5

D1

Clampx3

(KWS0757-002)

D2

D4

P4

(Door interlockSA)

DRIVE PWB SA

D2

P1

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

J5

J11

P2

F3

J7

J6

F2

D3

P5

D4

P3

F1

P4

18

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)

5

18

D3

11

12

17

QYSPSPD4008Nx2

(-007)

P3

19

19

QYSPSPD4008Nx3

Retransfer film supply motor

Tighten provisionally.

KJJ46271

-003x2

Clanp

Clanp

Retransfer film take up motor

20

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.

7

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

13

11

15

80S2M224

A

B

F689ZZ

11

QYSBST3006Nx2

14

10

15

80S2M224

8

19

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

18

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.

8

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

8

%.

7

P1 P2

D1
D2

3

Turnover card feed motor

Turnover motor

KJJ46271

20

-001x3

Clamp

Clamp

Set the belt
to the pulley.

P5

Card feed motor

Tighten provisionally

DPSP4008Nx2

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

(-006)

15

19

11

12

(M180)

13

(M224)

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

10

11

15

Tighten provisionally

DPSP3006Nx2

16

Motor SA

the belt, and then tighten the screw A
securely.

A

B

20

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

4

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

5

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

Insert the gear shaft

Card pikup motor

18

KJJ46271

-001x2

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

M

G
IS

O

I

C

4

SDSP4008Nx6

21

2.10 REMOVAL OF THE PLATEN SOLENOID

100V/200VCommon

H1

H2

CN8

CN4

CN5

CN6

CN7

CN8

CN4

CN2

CN1

CN3

H1

H2

6

KWS0639-001

POWER SUPPLY SA

F3

H1

H2

10

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

0

.

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

22

Explanation drawing 1

Platen solenoid

(TSS0179)

11

QYSPSPD4008Nx2

19

12

QYSPSPD

17

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

F1

11

S3

7

KJJ46271-003

21

KJJ46271

20

-003x2

Ink Encoder

Cam sensor

18

KJJ46271

-003

19

KJJ46271-003

Card outlet
sensor

Yellow

23

2.12.5 Removal of the Turnover Initial Position

1

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

17

17

A

B

(-010)

TSS0239-U

HEATER SENSOR SA

F1

(-010)

15

15

1

(TSS0181)

(TSS0182)

12

T1

17

3

H1

T1

CLAMP
(T2,H2)

P4

(FD M.MOTOR ASY)

T2

T2

CLAMP
(F1)

H2

(TSS0189)

5

CLAMP
(P4)

17

Head cooling fan

Turnover initial
position sensor

24

KWS0757-002

15

17

KJJ46271

-003

No Card
sensor

Card near-empty

18

sensor

KJJ46271

-003

11

11

19

1

12

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

13

Pass the wire through the notch
in the bracket.

REAR PLATE SA

F1

Card supply sensor

C. LInterlock switch

6

25