Eltron S820I Users Manual

3M MAXSecure

Printer Module

Maintenance Manual

Manual No. 980286-001 Rev. A

FOREWORD

This manual contains service and repair information for 3M MAXSecure Printer Modules manufactured by the
3M Corporation,St. Paul, Minnesota. The contents include maintenance, diagnosis and repair information.

TECHNICAL SUPPORT

For technical support, users should first contact the distributor that originally sold the product—phone +1 (800)
344 4003 to locate the nearest 3M Distributor.

COPYRIGHT NOTICE

This document contains information proprietary to 3M Corporation. This document and the information
contained within is copyright by 3M Corporation and may not be duplicated in full or in part by any person
without prior written approval of 3M..

While every effort has been made to keep the information contained within current and accurate as of the date of
publication, no guarantee is given or implied that the document is error-free or that it is accurate with regard to
any specification.

This information is not intended as a license to practice or infringe on the patents of this company or others. 3M
Corporation reserves the right to modify, update or revise this information at any time without notice.

TRADEMARKS

3M MAXSecure is a service mark, and 3M is a registered trademark of 3M Corporation. All other marks are
trademarks or registered trademarks of their respective holders.

FCC NOTICE:

This equipment has been tested and found to comply with the limits of a Class A digital device, pursuant to Part
15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference
when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate
radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful
interference to radio communications. However, there is no guarantee that interference will not occur in a
particular installation. Operation of this equipment in a residential area is likely to cause harmful interference in
which case the user will be required to correct the interference at their own expense.

CSA NOTICE:

This equipment does not exceed Class A limits per radio noise emissions for digital apparatus set out in the Radio
Interference Regulation of the Canadian Department of Communications. Operation in a residential area may
cause unacceptable interference to radio and TV reception requiring the owner or operator to take whatever
steps are necessary to correct the interference.

Ce matériel ne dépasse pas les limites de Classe A d’émission de bruits radioélectriques pour les appareils
numériques telles qu’établies par le ministère des Communications du Canada. L’exploitation faite en milieu
résidentiel peut entraîner le brouillage des réceptions radio et télé, ce qui obligerait le propriétaire ou l’opérateur
à prendre les dispositions nécessaires pour en éliminer les causes.

iiiiii

TABLE OF CONTENTS

CHAPTER 1 GENERAL DESCRIPTION

1.1 PRINTER MODULE DESCRIPTION ..................1-1

1.1.1 Clear CardMaterial Feed, Shear,and Flip-Over ··············1-3

1.1.2 Print Station ·······························1-3

1.1.3 White CardFeeder Station ························1-4

1.1.4 Card AssemblerStation··························1-5

1.2 OPTIONS AND ACCESSORIES ....................1-5

1.3ABOUTTHISMANUAL........................1-5

1.4 CAUTIONARY NOTES.........................1-6

1.5 PACKAGING CONSIDERATIONS ...................1-9

1.6 PREPARING A STATIC-SAFE WORK AREA...............1-9

1.7 ENVIRONMENTAL AND SHOCK PROTECTION . . . ........1-9

CHAPTER 2 INSTALLATION AND OPERATION

2.1 INSTALLATION ............................2-2

2.1.1 Unpacking ································2-2

2.1.2 Location Concerns ····························2-3

2.1.3 Adding theLaminator and DieCutter ···················2-3

2.1.4 Attaching Cables ·····························2-4

2.1.5 Cable Diagrams ·····························2-5

2.2 OPERATION..............................2-6

2.2.1 Controls andIndicators ··························2-6

2.2.2 LCD MessagesRelated to PrinterModule ·················2-7

2.2.3 LCD MessagesRelated to LaminatorModule ···············2-7

2.2.4 LCD MessagesRelated to EncoderModule ················2-8

2.2.5 LCD MessagesRelated to Adjustments,Testing, and MicrocodeDownloads 2-8

2.2.6 LCD MessagesRelated to Cleaning ····················2-8

2.2.7 Print HeadLatch and ReleaseLevers ···················2-9

2.2.8 Ribbon Installation ···························2-10

2.2.9 Card Media ·······························2-11

2.2.10 Clear CardMaterial Loads ·······················2-11

2.2.11 White CardFeeder Loading ······················2-12

2.2.12 Two- versesThree-Layer Selection ···················2-13

CHAPTER 3 THEORY OF OPERATION

3.1 COLOR FUNDAMENTALS ......................3-1

3.2 PRINTER INTRODUCTION ......................3-5

3.3 CIRCUITRY ..............................3-8

CHAPTER 4 TROUBLESHOOTING

4.1 DIAGNOSING BASIC PRINTER PROBLEMS ..............4-2

4.2 DIAGNOSING COMPUTER INTERFACE PROBLEMS .........4-5

CHAPTER 5 REPLACEMENT PROCEDURES

5.1 REQUIRED TOOLS ..........................5-2

5.2 PART REPLACEMENTS ........................5-3

5.2.1 Case Removal ······························5-3

5.2.2 White CardFeeder Station Removal ···················5-4

5.2.3 White CardFeeder Station Replacements ·················5-5

5.2.4 Upper ClearCard Station Removal ····················5-6

5.2.5 Upper ClearCard Station ComponentReplacements ···········5-7

5.2.6 Lower ClearCard Station Removal ····················5-8

5.2.7 Lower ClearCard Station Components ··················5-9

5.2.8 Card AssemblyStation Removal·····················5-10

5.2.9 Card AssemblyStation Component Replacements············5-11

5.2.10 Print HeadReplacement ························5-12

5.2.11 Fan Replacement ···························5-17

5.2.12 Ribbon SensorReplacement ······················5-18

5.2.13 Cleaning RollerSpring Clip Replacement················5-19

5.2.14 Front BeltRemovals ··························5-20

5.2.15 Printer StationRemoval ························5-21

5.2.16 Printer StationMotors and RearBelts and Sensors ···········5-22

5.2.17 Ribbon SupplySpindle and ClutchReplacements ···········5-24

5.2.18 Ribbon TakeUp Spindle Replacements ················5-26

5.2.19 Print StationCard Sensor ·······················5-28

5.2.20 CPU Boardand Socketed ICRemovals·················5-29

5.2.21 Extension PCBACircuit Board andSocketed IC Replacements ·····5-30

5.2.22 Clear CardStation Controller BoardReplacements ···········5-31

5.2.23 Power SupplyReplacements ······················5-32

5.2.24 Operator PanelReplacement ·····················5-33

CHAPTER 6 MAINTENANCE AND ADJUSTMENTS

6.1 CLEANING MATERIALS ........................6-2

6.2 CLEANING ..............................6-2

6.2.1 Print HeadCleaning ···························6-3

6.2.2 Replacing CleaningRoller Sheath ·····················6-4

6.2.3 Cleaning Card-Feedand Card-Transport Rollers ·············6-5

6.3 ADJUSTMENTS ............................6-6

6.3.1 Print HeadResistance ··························6-6

6.3.2 Peel BarAdjustment ···························6-6

6.3.3 Image Centering ·····························6-8

6.3.4 Pressure RollerPosition ·························6-10

6.3.5 Stepper BeltTension Adjustment ····················6-11

6.3.6 Front BeltTension Adjustments ·····················6-14

iv

APPENDIX A TEST SOFTWARE

A.1 INSTALLATION ............................A-1

A.2 OPERATION .............................A-1

A.2.1 Launching theCard Printer TestSoftware ················A-2
A.2.2 Changing theCOM Port ·························A-3
A.2.3 Operating inTerminal Mode ·······················A-4
A.2.4 Typical SubList ·····························A-5
A.2.5 Typical PotAdjustment Selection ·····················A-6
A.2.6 Downloading Firmware ·························A-7

TABLE OF FIGURES

Figure 2-1. Packaging Materials .......................2-2

Figure 2-2. Laminator Installation.......................2-3

Figure 2-3. Cables. .............................2-4

Figure 2-4. Cable Wiring. ..........................2-5

Figure 2-5. Printer Controls and Indicators. .................2-6

Figure 2-6. Print Head Latch and Release Levers. ..............2-9

Figure 2-7. Ribbon Installation. ......................2-10

Figure 2-8. Clear Card Material Loads....................2-11

Figure 2-9. White Card Hopper Loading. .................2-12

Figure 2-10. Card Layer Selection Lever...................2-13

Figure 3-1. 3M MAXSecure Card Path. ...................3-7

Figure 3-2. Block Diagram. .........................3-9

Figure 4-1. Problems Duplicated by a Test Print. ..............4-2

Figure 4-2. Interface Diagnostic Flow. ....................4-5

Figure 5-1. Case Fasteners. .........................5-3

Figure 5-2. White Card Feed Station Removal. ...............5-4

Figure 5-3. White Card Feeder Components. ................5-5

Figure 5-4. Upper Clear Card Station Removal. ...............5-6

Figure 5-5. Upper Clear Card Station Replaceable Components. ......5-7

Figure 5-6. Lower Clear Card Station. ....................5-8

Figure 5-7. Lower Clear Card Station Components. .............5-9

Figure 5-8. Card Assembly Station Removal. ................5-10

Figure 5-9. Card Assembly Station Components...............5-11

Figure 5-10. Print Head Upper Fastener Removal. .............5-12

Figure 5-11. Print Head Assembly Fasteners.................5-13

Figure 5-12. Print Head Assembly Parts. ..................5-14

Figure 5-13. Print Head Connectors.....................5-15

Figure 5-14. Properly positioned Print Head. ...............5-16

Figure 5-15. Fan Replacement. ......................5-17

Figure 5-16. Ribbon Sensor. ........................5-18

Figure 5-17. Cleaning Roller Spring Clip...................5-19

v

Figure 5-18. Front Belt Removals. .....................5-20

Figure 5-19. Printer Station Removal. ...................5-21

Figure 5-20. Printer Station Rear Parts....................5-23

Figure 5-21. Supply Spindle Assembly....................5-25

Figure 5-22. Ribbon Take Up Spindle. ...................5-27

Figure 5-23. Printer Station Card Sensor...................5-28

Figure 5-24. CPU Board...........................5-29

Figure 5-25. Extension PCBA. .......................5-30

Figure 5-26. Clear Card Station Controller Board. .............5-31

Figure 5-27. Power Supply Removal. ...................5-32

Figure 5-28. Operator Panel Board Removal. ...............5-33

Figure 6-1. Cleaning Materials........................6-2

Figure 6-2. Print Head Cleaning. ......................6-3

Figure 6-3. Changing the Upper Cleaning Roller ..............6-4

Figure 6-4. Card Transport Rollers. .....................6-5

Figure 6-5. Peel Bar Fasteners. .......................6-7

Figure 6-6. Lower Clear Card Feeder Pressure Roller Adjustment. .....6-10

Figure 6-7. Stepper Motor Fasteners. ...................6-11

Figure 6-8. Stepper Motor Belt Tensioning Fixture..............6-12

Figure 6-9. Stepper Belt Tensioning. ....................6-13

Figure 6-10. Front Belt Tension Adjustments. ...............6-14

vi

CHAPTER 1

GENERAL DESCRIPTION

1.1 PRINTER MODULE DESCRIPTION

3M MAXSecure Printer Modules can operate as stand-alone card imaging devices or, as shown
above, become part of a larger system that can also include a 3M Lamination and Die Cutter
Module. 3M MAXSecure can also include a Magnetic Stripe Encoder Module (not shown).

3M MAXSecure can produce either two- or three-layer cards composed of either a Clear Card
and a White Card or a white card sandwiched between two Clear Cards. Clear Card imaging
occurs first. A Clear Card can receive full color CMY (cyan, magenta, yellow) and/or black resin
imaging. Imaging on the White Card can occur next. The White Card can receive Kr (Black
Resin) monochrome images. A second Clear Card serves to prolong card life and protect any
image placed on the White Card. Notably, an image placed on the White Card ends up on the
side opposite the Clear Card image. Security imprints appear on the side of the White Cards that

980286-001 Rev. A 1-1

CHAPTER 1
GENERAL DESCRIPTION

receive no image by the Printer Module. On the finished cards, however, these images underlie
the Clear Card image.

After imaging, the Printer Module assembles and delivers a Clear and White Card to the
Laminator and Die Cutter Module. For three-layer cards, a second Clear Card follows. An
attached Laminator and Die Cutter Module fuses the Clear and White Card material and die
cuts the result to a standard credit/debit/etc card size.

Because the image on the Clear Card faces the White Card, scratches and ultraviolet radiation
have little affect on this image. Resin images offer substantial resistance to wear factors without
needing added protection, but for three-layer cards, an additional Clear Card maximizes wear
resistance. These features result in cards that can accept a fair amount of abuse and, with
reasonable treatment, can remain in service for 10 years.

Figure 1-1 shows the Printer Module assemblies visible with the cover raised.

Figure 1-1. Major Assemblies

1-2

980286-001 Rev. A

CHAPTER 1

GENERAL DESCRIPTION

1.1.1 Clear Card Material Feed, Shear, and Flip-Over

The upper part of this assembly contains a motor and a shear. The middle part has two
sensors—one for signaling the shear point and another to sense splices. The lower part
implements flip-overs of a second Clear Card.

All three parts of the assembly have rollers that move the material, due either to a manual
advance or by a motor powered drive roller. Clear Card material feeds off of a roll and into a slot
in the top of this assembly and then down vertical card guides.

The motor moves card-sized segments beyond the shear. A shear occurs when an associated
sensor detects material. As more media enters the upper part, the sheared segment enters either
the flip-over or the horizontal card guides. The assembly ultimately delivers Clear Cards to the
horizontal drive rollers.

Only one Clear Card surface has a bonding agent. So that the bonding material on the second
Clear Card can face the White Card, a solenoid-operated gate directs Clear Cards for a flip-over
before directing their entry into the horizontal guides.

Rolls of Clear Card material contain splices that require operator removals. A sensor in the
guides detects the splices, which results in related LCD messages to the operator.

1.1.2 Print Station

The printer first receives a Clear Card segment. Associated color imaging results from multiple
passes across the Print Head. Because the imaging occurs on the side opposite the viewed side,
Clear Cards receive mirrored images.

A motor-driven cam controls the position of the Print Head. Imaging occurs with a card and the
ribbon sandwiched between the lowered Print Head and the platen roller below. Card
transports not related to imaging occur with the Print Head raised sufficiently to allow freer
movement of cards, typically at faster rates.

Ribbon, having dye- and sometimes resin-coated panels, feeds from the supply to the take-up
spindles. During imaging, the coated side contacts the card, and the non-coated side contacts
the Print Head. Incremental ribbon advances accompany associated incremental advances of a
card across the Print Head. Card increments correspond to 300 dpi (dots-per-inch) image
resolution, which duplicates the density of elements across the Print Head.

Each dot imaged occurs from a ribbon dye transfer due to heat produced by an associated Print
Head element. For color, each element can produce 32 different heat levels, which correspond
to 32 different dye densities. When dots get superimposed on other dots to produce a
YMC-blended color, 32K combinations become possible. This imaging process is typically
called Dye Sublimation.

Resin imaging occurs at only one dot density. Resin, while excellent for bar codes and other solid
imaging, only responds well when transferred using a single temperature. An associated Print
Head element is either fully on or completely off. Solid imaging occurs for all internally
generated bar codes, text, and graphic elements. Users wishing to produce gradients of gray
while using resin imaging must resort to dithering and deliver an associated bit map. Because

980286-001 Rev. A 1-3

CHAPTER 1
GENERAL DESCRIPTION

dithering creates a pixel (picture element) using a small dot matrix, reduced picture resolution
results. This resin imaging process is called Thermal Transfer. In contrast, users can create 32
levels of gray using YMC blends without loosing any image resolution.

By the time a card is fully imaged, a whole set of ribbon panels is used. Users can obtain ribbon
media in several configurations, each offering a cost optimization for a particular set of card
design requirements. For example, YMC ribbons cover the need for only Clear Card color
imaging without resin. The need for YMCKr ribbons occurs when resin imaging, of say bar
codes, must alsoappear, YMCKrKr ribbons serve those instances when black resin imaging must
occur on both the Clear and White cards.

After completion of the Clear Card imagingand the card moves to the Card Assembler Station, a
White Card feed occurs. The feed injects the White Card directly into the horizontal card guides.
White Cards can only receive black resinimages. Also, as stated previously, imaging depends on
a remaining unused Kr ribbon panel. A second Clear Card, when used, receives no image.

A standard feature of all 3M Card printers lets users print bar-codes using any of the 10
printer-resident formats. An associated image results from entry of a single command line,
where a related set of parameters precedes the data. Data refers to the alphanumeric string that a
bar code reader decodes when scanning the card. Associated parameters format the bar code,
specify size and position, and determine whether or not an associated text string appears under
the bar code.

Sensors in the Printer assembly include one that detects incremental advances of the ribbon,
one that detects the presence of a card entering the horizontal card guides,and one that finds the
yellow ribbon panel following an operator initialization. All synchronized card and ribbon
movement within the Printer Station depends on these sensors. Two microswitches form
sensors that signalwhen the PrintHead has reachedan either fullyup or fullydown position.

Motors in the Printer assembly include a stepper for precise control of card positioning in the
card path and dc motors to advance ribbon and raise and lower the Print Head.

1.1.3 White Card Feeder Station

This assembly delivers White Cards placed in the Feeder to the horizontal card guides of the
Printer assembly. Included are a dc motor that powers two feed rollers and a Card Gate that lets
only one card feed at a time. White Card thickness for two-layer cards measures 0.022 inches,
while those used for three-layer cards measures 0.015 inches.

Cards easily pass through a gate opening one and one-half times the card thickness without
allowing multiple feeds or rubbing against the upper restraint. When cards fail to feed, a user
typically finds acard with excessivewarping. The frontpanel LCD indicatesOUT OF CARDSif a
card fails to appear at the Printer assembly before a related time out occurs.

1-4

980286-001 Rev. A

CHAPTER 1

GENERAL DESCRIPTION

1.1.4 Card Assembler Station

After imaging, a Clear and a White Card come together in the Card Assembler. The card path
deepens here, so that a White Card can rest on top of a Clear Card. The assembly includes a
motor, a solenoid, and two sensors. After these card components come to rest in this assembly,
as signaled by the lower of the two sensors, the solenoid-coupled roller raises to push the cards
against the motor-powered drive roller. The powered roller then delivers these two layers to the
exit opening of the Printer Module. An attached Laminator and Die Cutter Module would sense
this event and draw the cards into its card path. The upper sensor signals the presence of cards at
the output. Until these cards are taken away, no new cards should enter for card assembly. An
attached Laminator and Die Cutter Module waits for a second Clear Card, in instances where
the Layer Lever is set to 3 Layer.

The sensors can detect two error conditions. The CLEAR AT EXIT error signals that a second
Clear Card has entered the assembly instead of the expected White Card. The WHITE AT EXIT
error signals that a second White Card has entered the assembly prior to removal of a previously
assembled set.

1.2 OPTIONS AND ACCESSORIES

A Full Complement of Card and Ribbon Supplies—distributors of 3M Products stock these
items in order to assure that 3M MAXSecure users can obtain supplies that consistently produce
the best possible results.

1.3 ABOUT THIS MANUAL

3M Products has directed the Information contained in this manual at returning Printer module
functions to normal operation in the shortest time possible. With this in mind, service personal
should focus on items listed in the recommended spares list. Avoid lower level replacements
whenever possible. Service personnel should keep a log of the repairs made in support of the
concept of continuous product improvement. Chapters include: General Description,
Installation and Operation, Theory of Operation, Troubleshooting, Part Replacement
Procedures, and Maintenance and Adjustments. Appendix A describes software developed for
testing 3M MAXSecure printers.

Follow the instructions as closely as possible. When unsure of any procedure, please contact
either a 3M Products Service Representative (contact 3M Product Management for nearest
representative) or 3M Products Technical Support at 1-800-344-4003 or 805-578-1800.

3M Products stocks all commonly used replacement parts for 3M MAXSecure printers. A list of
the recommended spares appears in this Chapter. For depot repairs, contact 3M Product Sales
to place orders and to establish a program for bulk purchases and credited returns of warranted
parts.

980286-001 Rev. A 1-5

CHAPTER 1
GENERAL DESCRIPTION

1.4 CAUTIONARY NOTES

Exercise reasonable care when servicing the printer, as follows:

Other than prescribed operator maintenance, only qualified personnel
should remove the case or otherwise attempt to repair this equipment. 3M
Products offers training to those wishing to service this equipment.

Servicing personnel must avoid touching exposed circuitry. Inputs to the
Power Supply operate at power line voltages. Any removal of protective
insulation can expose dangerous voltages. Always remove the power cord
when effecting repairs.

During printing, the Print Head operates at an elevated temperature.
Exercise caution when touching the parts on or near these areas.

Servicing Personnel should avoid any rough handling of the printer or its
component parts. The Print Head in particular requires careful handling.
Never lower the Print Head onto any object other than the card and
ribbon media.

An electrostatic discharge (ESD) of energy can damage or destroy the print
head and other electronic Printer Module components. People can acquire
such charges while moving around. ESD problems increase as the
humidity drops.

Users should not twist the Ribbon Take Up spindle manually. Doing so
unnecessary stresses the associated belt. Any slack left after a ribbon
installation gets removed during the initialization produced by pressing the
panel button.

To avoid deposits, clean only with fiber free Cleaning Swabs and
99-percent or better pure alcohol.

1-6

980286-001 Rev. A

Part Replacement Spares

CHAPTER 1

GENERAL DESCRIPTION

Recommended Quantity

(Per 100 Printers)

A/R

5
5
5
5
5
5

10

1
3
1
1

9
A/R
A/R
A/R
A/R
A/R

2

2

1
A/R

2

2

2

1

2

15
10

2

5

1

2

1

2

10

2

2

2

2

2

5

2

2

2

5

10

2

Item Part No.

Lock Set for Enclosure
Kit, Print Engine
Kit, White Card Feeder
Kit, Clear Material Cutter
Kit, Clear White Material Entry Assembly
Kit, Printer Exit
Kit, Electronics, Printer
Kit, Roller, Card Feeder
Kit, Power Supply Fuse (Set of 10)
Kit, Main Circuit Board, Printer
Kit, Head Up/Down Sensor Switch
Kit, Cleaning Roller Clip
Kit Pressure Roller (Set of 5)
Kit, M4 x 8, Flat Head Phillips Screws (Set of 100)
Kit, M4 x 8, Pan Head Phillips Screws (Set of 100)
Kit, Printer Enclosure (Light Gray)
Kit, Printer Enclosure (Dark Gray)
Kit, Rubber Foot, Base
Kit, Printer Input/Output Extension Board
Kit, Printer AC Power and Filter
Kit, AC Power Switch (Set of 5)
Kit, Forcep, Curved
Kit, Solenoid
Kit, Ribbon Sensor
Kit, Ribbon Spindles
Kit, Clear Material Shear
Kit, Clutch Assembly
Kit, Exit Pressure Roller Assembly
Kit, Upper Cleaning Roller
Kit, Power Supply Assembly 120/240 Auto Ranging
Kit, DC Motor
Kit, Stepper Driver IC (L6219 at U12)
Kit, Flag Sensor
Kit, DC Motor Driver IC
Kit, Cleaning Roller Bearing
Kit, Ribbon Take Up O-Ring Belt
Kit, Rear Main Drive 0.08P, 40Deg, 63T
Kit, Belt, 0.080P, 40Deg, 88T x 3(1/8)
Kit, Belt, 0.080P, 40Deg, 63T x 3(1/8) (Set of 5)
Kit, Front Right Encoder Roller Drive, Belt 50T x 3 (1/8)
Kit, Front Left Encoder Roller Drive, Belt 95T x 3 (1/8)
Kit, Cam, Printhead Lift
Kit, PCBA, LCD Display
Kit, Timing Belt, 105T x 1/8 (Feeder)
Kit, Fan, Print Head
Kit, Stepper Motor
Kit, Replacement Print Head—Style 2
Kit, Knob, Max

105901-067
105901-203
105901-205
105901-207
105901-208
105901-063
105901-233
105901-226
105901-013
105901-218
105901-018
105901-019
105901-029
105901-032
105901-033
105901-211
105901-212
105901-037
105901-042
105901-050
105901-051
105901-052
105901-055
105901-057
105901-058
105901-231
105901-241
105909-005
105909-010
105909-020
105909-021
105909-024
105909-026
105909-028
105909-033
105909-038
105909-040
105909-043
105909-044
105909-045
105909-046
105909-058
105909-089
105909-098
105909-099
105901-230
105909-112
105901-087

980286-001 Rev. A 1-7