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Chapter 5: Troubleshooting
The 150i Card Personalization System operates as a standalone card embosser. This chapter of the manual provides information and procedures to isolate a fault to the part, and/or component level. It includes symptoms, fault isolation procedures, use of diagnostic tools, and error codes. Troubleshooting Tips 5-3 Prerequisite Skills 5-4 Diagnostic Routines 5-4
Diagnostic Routines Menu 5-5 Sensors 5-6 MS Start Sentinel (NTT) 5-7 MS Start Sentinel (Standard) 5-7 Transport 5-7 Pick & Stack 5-7 Pick & Reject 5-7 Calibration Menu 5-8 Test Cards Menu 5-9 Standard Test Card 5-10 Mag Stripe Test Card 5-10 Indent Test Card 5-10 MagStripe/Emboss Test Card 5-10 MagStripe/Emboss/Top Test Card 5-10 Smart Card Test Card 5-11 Wheel Test Card 5-11 Topper Test Card 5-12 Run Without Cards 5-12 Preembossed Test Card 5-12 Character Height Test Card 5-12 Position Offsets Menu 5-13 Wheel Parameters Menu 5-15 Topper Parameters Menu 5-16 Configuration Menu 5-16 Status Request Menu 5-17
5
150i Card Personalization System Maintenance Manual
5-1
Restore MCB Defaults 5-17 Restore Mfg Settings 5-17 Save Changes 5-17
150i Interconnect Diagrams 5-18
Main Control Board Connections 5-19 Main Control Board Cable Connections 5-20 AC Wiring Diagram 5-21
Pin-Out Tables 5-22
Motor Pin-Outs 5-22 Sensor Pin-Outs 5-24 Serial Communications Pin-Outs 5-26
Identifying Errors Using Error Codes 5-27
Group xx 5-27 Group yy 5-28 Group zz 5-28 Error Codes 5-32 Main Control Board LEDs 5-38
5-2
Troubleshooting
Troubleshooting Tips
When correcting errors, it is a good idea to perform the following:
· · · · · · ·
Always power OFF the 150i. Load the Input Hopper if the card stock is low. Clear any rejected cards from the Reject Tray. Replace the foil in the Topper Module if it is getting low. Replace the Indent Ribbon if it is getting low. Make sure the Top Cover is closed and locked. Output Hopper door is fully closed.
Use these tips to correct the following general problems. If A Card Is Loose In The 150i
· ·
Check the inside of the 150i for cards that may have fallen from the Card Transport module. Remove the cards and attempt to resume printing.
If A Card Is Jammed In The Input Hopper
· ·
Remove any jammed cards from the Input Hopper module by pulling cards from the back of the Input Hopper through the card throat. Attempt to resume printing.
If A Card Is Jammed In The Embosser Module
· ·
Remove any jammed cards from the Embosser module. Attempt to resume printing.
If A Card Is Jammed In The Topper Module
· ·
Remove any jammed cards from the Topper module. Attempt to resume printing.
If A Card Is Jammed In The Front Or Rear Indent Module
· ·
Remove any jammed cards from the front or rear Indent module. Attempt to resume printing.
If A Card Is Jammed In The Smart Card Module
· ·
Remove any jammed cards from the Smart Card module. Attempt to resume printing. When removing jammed cards from the 150i, care must be taken not to damage components.
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5-3
Prerequisite Skills
Anyone troubleshooting the 150i system should possess the following skills:
·
Proficiency in CE communications setup as covered in the Datacard Network Connectivity Handbook.
Diagnostic Routines
The 150i software offers a number of diagnostic routines that test and exercise various components in the 150i. These diagnostics can be used to verify proper operation or to detect a point of failure.
Start Diagnostic Routines
To select the diagnostic programs on the 150i front panel, do the following: 1. Press *#3253 on the front keypad. 2. Press 2 (Diagnose) to select the diagnostic control application. 3. The system will reboot and go into the diagnostics mode. After a short pause, the 150i front panel will display the following message: 150i Diags Rev X.XX Service 4. To select the front panel options, press the # (pound) key. After a short pause, the 150i front panel displays the following message: Loading Onboard Diags Please wait... The main menu appears. When running diagnostics from the front panel, the 150i system is in the off-line mode. The keypad is used to navigate through the menus as they are displayed on the front panel of the 150i system.
5-4
Troubleshooting
Table 5-1: Keypad Navigation
Key # 0 2 3 4 5 6 8 Description Selects option (Enter key). Aborts menu option or backs-up 1 menu option. Scrolls the menu up or will increment a setting. Offset adjustments range toggle from ±1 times the increment to ±10. Scrolls the menu to the left. Changes offset from (-) negative to (+) positive. Scrolls the menu to the right. Scrolls the menu down or will decrement a setting.
Diagnostic Routines Menu
The Diagnostic Routine menu is used for the selection of various options listed below: 1. From the Main menu, select Diagnostic Routines. 2. Press the # key to select a one of the menu options below:
· · · · · ·
Sensors MS Start Sent. (NTT) MS Start Sent. (Standard) Transport Pick & Stack Pick & Reject
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5-5
Sensors
This diagnostic test is used to test all the photocells and switches on the 150i system. The test returns a status word on the front panel display. This test will indicate if a photocell or a switch is opened or closed. The test reads a hardware status port. Some of the signals for open or closed may be inverted. Check whether a photocell or switch has changed states. The example below shows the sensor value and their bit location.
Sensor Value: 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 1 0 0 1 1 1 1 0 0 Bit Location: 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Table 5-2: Sensor Bit Locations
Bit Location 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 20 22 23 24 Description (0=open,1=closed) X Home Sensor Y Home Sensor Wheel Home Sensor Lower Emboss Motor Home Sensor Upper Emboss Motor Home Sensor Unused Input Hopper Empty/Low Sensor Unused Registration Sensor Unused Pick Home Sensor Output Hopper Full Sensor Topper Solenoid Sensor Indent Ribbon Motion Sensor Topper Foil Motion Sensor Card Pick Sensor MCB Type 1=4.0, 0=3.5 Reject Full Sensor Unused Unused Unused Unused Top Cover Interlock Throat Gap Home Sensor
1. From the Main menu, select Diagnostic Routines. 2. Press the # key to select Sensors option.
5-6
Troubleshooting
MS Start Sentinel (NTT)
Use this diagnostic to adjust the Magnetic Stripe Start Sentinel position. It will return an offset back to the display which is used for the stripe head offset. The test will return an X offset which can be saved as a reference. 1. From the Main menu, select Diagnostic Routines. 2. Press the # key to select MagStripe (NTT) option.
MS Start Sentinel (Standard)
Use this diagnostic to adjust the Magnetic Stripe Start Sentinel position. It will return an offset back to the display which is used for the stripe head offset. The test will return an X offset which can be saved as a reference. 1. From the Main menu, select Diagnostic Routines. 2. Press the # key to select MagStripe (Standard) option.
Transport
This diagnostic test exercises the transport. Use this test to exercise the transport without cards. 1. From the Main menu, select Diagnostic Routines. 2. Press the # key to select the Transport option.
Pick & Stack
This diagnostic test picks a card from the Input Hopper and stacks the card in the Output Hopper. 1. From the Main menu, select Diagnostic Routines. 2. Press the # key to select the Pick & Stack option.
Pick & Reject
This diagnostic test picks a card from the Input Hopper and stacks the card in the Reject Tray. 1. From the Main menu, select Diagnostic Routines. 2. Press the # key to select the Pick & Reject option.
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Calibration Menu
The Calibration Test moves the card to a fixed stop position. The [X and Y] offsets are displayed on the front panel for the card stop location. Adjust the offset as follows:
· · · · · · · ·
All Positions (Pick, Topper, Exit) Pick Position Topper Position Exit Position Reject Position Throat Gap Wheel Offset Smart Card XY
Adjust the offsets as follows:
· · · · · ·
Select Calibration from the main menu by pressing the # key. Press the 4 key to move the card X position to the left, toward the Topper. Press the 6 key to move the card X position to the right toward the Input Hopper X home photocell. Press the 8 key to move the card Y position back to the Y home photocell. Press the 2 key to move the card Y position away from the Y home photocell. Press the # key to select the new offsets. If the 0 key is pressed, the new offset is ignored.
5-8
Troubleshooting
Test Cards Menu
The Test Cards menu is used for the selection of various test card options.
· ·
When Test Cards appears on the main menu, press # to select. Press the # key to select a menu option.
Table 5-3: Test Card Menu
150i Test Cards Standard Mag Stripe Indent Mag Stripe/Emboss Mag Stripe/Emboss/Top Smart Card Wheel Topper Run Without Cards Preembossed Character Height
To make any Test Card, do the following:
· · ·
Use the 2 key or 8 key to scroll through the Test Cards menu. Select the Test Card to be made by pressing the # key. If you are making a Mag Stripe test card or a Preembossed test card, do the following: (For other test cards, skip this step.) · Press # to select encode format. · Use the 2 or 8 keys to scroll through options. · Press # to select an option. · For "Stop at One Card?", press # for Yes, 1 for No and 0 to Escape.
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5-9
Standard Test Card
This option is used to setup emboss line locations and margins. The test will emboss 3 characters on the card with 7 char/inch font using the character 8. The two line locations (800, 250) are used with a fixed margin of .250 of an inch.
.250
3.000
.800
.250
Standard Test Card
54740-78
Figure 5-1 : Standard Test Card
Mag Stripe Test Card
This option is used to encode 2 tracks of STD bank code data for tracks 1 and 2.
Indent Test Card
This option is used to make an Indent test card if the 150i is so equipped.
MagStripe/Emboss Test Card
This option is used to make a 3-line financial emboss test card with 2 tracks of encoded data.
MagStripe/Emboss/Top Test Card
This option is used to make a 3-line topped financial emboss test card with 2 tracks of encoded data.
5-10
Troubleshooting
Smart Card Test Card
If the 150i is so equipped, this option is used to verify the Smart Card option for the program head location. Use this test to verify the programming of the Smart Card head in the 150i System and to adjust the Smart Card chip card head offset.
· · ·
The test will require a Smart Card placed in the Input Hopper. A card will then stop at the Smart Card head location and the program head solenoid will fire. The test will then communicate to the Smart Card board application and reset the diagnostic. One of the following status messages is returned.
Table 5-4 : Smart Card Test Messages
Smart Card Messages Smart Card Comm Error Description Comm failure to Smart Card board. Check cables and see if application is running in the Smart Card system. No errors. Chip card is communicating to the program head. Card time-out error. The Smart Card chip card is not communicating. Failure could be the card, not enough pressure on the head or the card is not aligned correctly to the program head.
Card OK (Answer to Reset) Card Not Responding Not an ISO 7816 reset
This test will not test the Key Card readers. (Run an online application to test.) A Smart Card application for the 150i System needs to be loaded.
Wheel Test Card
This option is used to make a card with every character on the wheel, including indent and special characters.
9/-FWJYBDMSONARELIT HCUGKPVZQX.,'&
Wheel Test Card
54740d75
Figure 5-2: Wheel Test Card 150i Card Personalization System Maintenance Manual 5-11
Topper Test Card
This option is used to verify the topper platen squareness.
.301
3.074
.843
.172
Topper Test Card
54740-77
Figure 5-3: Topper Test Card
Run Without Cards
This option is used to exercise the 150i without using cards in the system.
Preembossed Test Card
This option is used to verify the throat gap adjustment for preembossed cards.
Character Height Test Card
This option is used to verify character height on a standard wheel.
5-12
Troubleshooting
Position Offsets Menu
This option menu is used to control the X and Y position offsets used in the 150i System.
· · · · · · ·
Select the # key to change an offset value or to view offset values. When there are more than one editable offset, press the 4 or the 6 key to move between offsets. Press the 2 key to increment the offset or the 8 key to decrement the offset. Press the 3 key to toggle the increment constant between one and ten. The [x1] is used to display the times 1 or times 10 increment range. Once an offset has been changed, the display will show a . This is a reminder that the new offset has been detected and should be saved. Press the 0 key to Exit. Increasing the offset moves the carriage away from the home position. Decreasing the offset moves the carriage towards the home position.
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Table 5-5: Position Offsets Menu
Position Offsets Pick Smart Card MagStripe NTT MagStripe Standard MagStripe Variables # Key Pressed Example Pick [x1] X or Y Offset Smart Card [x1] X, Y Offsets [ [ 0] 0] 0] 0]
Magstripe Front [x1] X, Y, Coercivity Offsets [ Magstripe Rear [x1] X, Y, Coercivity Offsets [ Magstripe variables [x1] LTJ, BBJ Subinterval, Start Sent Var [ Emboss [x1] X or Y Offsets Topper [x1] X or Y Offset Topper Noise Offset Exit [x1] X or Y Offset Reject [x1] X Offset Emboss Offsets [x1] Lower or Upper Indent Offsets [x1] Lower or Upper Throat Gap [x1] Offset Wheel Home [x1] Offset Card Bow [x1] Offset [ [ [ [ [ [ [ [ [ [
0] 0] 0] 0] 0] 0] 0] 0] 0] 0] 0]
Emboss Location Topper Topper Noise Exit Reject Emboss Height Indent Depth Throat Gap Wheel Home Card Bow
5-14
Troubleshooting
Wheel Parameters Menu
This option menu is used to change the individual wheel finger parameters on the 150i System. This option also is used to move (remap) a character on the wheel, increase or decrease emboss pressure and dwell, adjust spacing of a character, and define the character type.
· · ·
Select the 2 key or 8 key to select the finger number menu. Valid wheel finger positions are from 1 to 75. Press the # key to select the correct finger to change. Keys 4 and 6 are used to scroll through the wheel mapping parameters. The example below is for the 1st finger position.
Table 5-6: Wheel Parameters Menu
Wheel Parameters Remap Dwell Lower Pos (Motor steps) Upper Pos (Motor steps) Spacing Char Type # Key Next Screen Example Finger 1 [x1] Remap [ Finger 1 [x1] Dwell [ Finger 1 [x1] Lower Pos Finger 1 [x1] Upper Pos Finger 1 [x1] Spacing Finger 1 [x1] Char Type 0] 0] [ [ [ [ 460] 460] 38] 2]
For Spacing and Char Type, the following choices are available: Table 5-7: Spacing and Character Type
Char Type Std Gothic Indent Indent OCR 7B Char Type Value 0 1 1 2 Spacing Value 27 27 19 38 Characters/Inch 10 10 14 7
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Topper Parameters Menu
This option menu is used to change each Topper table parameter on the 150i System.
· · · ·
When Topper Parameters appears on the main menu, press the # key. Select the 2 key or the 8 key to select the Topper table number menu. Valid tables are from 1 to 8. Press the # key to select the specific table. Keys 4 and 6 are used to scroll through the topper parameters. The example below is for table one position.
Table 5-8: Topper Parameters Menu
Topper Parameters Temperature Dwell # Key Next Screen Example Table 1 [x1] Temperature [ Table 1 [x1] Dwell [ 850] 235]
Configuration Menu
This option is used to configure the 150i System hardware options. The configuration menu is used for selecting the options below:
· · ·
When Configuration appears on the main menu, press the # key to select it. Press the 2 key or 8 key to scroll through Configuration menu selections. Press the # key to select the Configuration menu option.
Table 5-9: Configuration Menu
150i Configuration Configure Indent Configure Stripe Configure Smart Card Configure Topper Description Press the 2 or 8 key to scroll through Indent options. Press # to select an option. Press the 2 or 8 key to scroll through Mag Stripe options. Press # to select an option. Press the 2 or 8 key to scroll through Smart card options. Press # to select an option. Press the 2 or 8 key to scroll through Topper options. Press # to select an option.
5-16
Troubleshooting
Status Request Menu
This option menu is used to display status information.
· · ·
When Status Request appears on the main menu, press the # key to select it. Press the 2 key or 8 key to scroll through Status menu options. Press the # key to select a menu option.
Table 5-10: Status Request Menu
150i Status Request Last Reported Status Card Counts Description Press # to display last reported status message. Press # to display the card counts in the 150i System for total, good, and rejects. Press # to display 150i hardware options configured. Press the 2 or 8 keys to scroll.
Hardware Configuration
Restore MCB Defaults
This will restore all MCB offsets to pre-factory defaults. Press # when Restore MCB Defaults appears on the main menu. Press # again to confirm MCB settings.
Restore Mfg Settings
This will restore all offsets to manufacturing defaults. Press # when Restore Mfg Settings appears on the main menu. Press # again to confirm manufacturing settings.
Save Changes
When changes in offsets are detected, the display shows on the top line. This is a reminder to save the new offset values. Press # when Save Changes appears on the main menu.
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150i Interconnect Diagrams
The following diagrams show the 150i system cable connections.
36 Volt Power Supply
Interlock Switch
Interlock Circuitry
5 Volt Regulator
12 Volt Regulator
556008-000 150i Main Control
U15 L298 U14 L298 U13 L298 U17 L298
Stepper Driver Stepper Driver Stepper Driver Stepper Driver Stepper Driver Stepper Driver Stepper Driver Stepper Driver Solenoid Driver
X Axis Motor Wheel Motor Punch Motor Die Motor Y Axis Motor IH Motor OCR Motor
1.0 Amp 1.0 Amp 1.0 Amp 1.0 Amp 0.56 Amp 0.56 Amp 0.56 Amp
Sensors
X-Axis Home Y-Axis Home A Encoder B Encoder Wheel Home Punch Home Die Home Registration Hopper Empty Output Full Hopper Home OCR Motion Platten Home Foil Motion Reject Full Throat Gap Cord Picked
U27 XL5210 I/O Controller
U28 L6219 U31 L6219 U30 L6219 U29 LU6219 U12 L298
Throat Gap Motor 0.56 Amp OCR Sol. Lock Sol.
U59 L6219
Mag Stripe Driver
Mag Stripe Head
Q6 FET Q2 FET
Heater Topper Solenoid
Heater + Output Topper + Solenoid Foil + DC Motor SC Solenoid
Q5 Foil Transistor DC Motor Q4 FET SC Solenoid
Figure 4: Main Control Input/Output Block Diagram
5-18
Troubleshooting
Main Control Board Connections
Punch Motor Wheel Motor X axis Motor Die 36 Volt Motor Supply Door Indent Input Lock Motor Motor Sel Rear Throat Topper Indent Gap Sel Motor Sel
J10
J9
J11
Flash J tag
J3
Serial Comm Front Panel J14 Jumper Position 1-2 Normal Op 2-3 Program J tag J16 J7 J12 J13
Display Pot Adjustment
Sensors Magnetic Stripe Interlock
Sensors
Figure 5-5: Main Control Board Connections
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Main Control Board Cable Connections
555961-001 Cable Assy, DC Power
556008-001 150i PWA
555037-002 Cable Assy, Comm I/O
555039-001 Cable Assy, Display
555962-001 Cable Assy, Sensor
Figure 5-6: Main Control Board Cable Connections
5-20
Troubleshooting
AC Wiring Diagram
594032-001 Main ON/OFF Switch EMI Power Line Filter
Chassis Ground J9 804960-024 FUSE 596679-001 Cable Assy.
555033-001
JP2
++ _+
36V Switching Power Supply
556008-001 Main Control 150i
Figure 5-7: AC Wiring Diagram
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Pin-Out Tables
Motor Pin-Outs
Table 5-11: Motor Pin-Outs for Connector J10 Pin #
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Signal Name
OCR_SolLock_Sol+ PBPA+ YBYA+ WBWA+ XBXA+ N/C GND OCR_Sol+ Lock_SolPB+ PAYB+ YAWB+ WAXB+ XAN/C 36V_NINV
Signal Description
Rear Indent Solenoid - Output Lock Solenoid + Output Punch Motor B phase Punch Motor A phase + Y Axis Motor B phase Y Axis Motor A phase + Wheel Motor B phase Wheel Motor A phase + X Axis Motor B phase X Axis Motor A phase +
Ground Rear Indent Solenoid + Output Lock Solenoid - Output Punch Motor B phase + Punch Motor A phase Y Axis Motor B phase + Y Axis Motor A phase Wheel Motor B phase + Wheel Motor A phase X Axis Motor B phase + X Axis Motor A phase -
36 volt non-interlock
5-22
Troubleshooting
Table 5-12: Motor Pin-Outs for Connector J11 Pin #
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Signal Name
Top_SolSC_Sol+ SCM_BSCM_A+ OCR_BOCR_A+ IHBIHA+ DBDA+ Heater+ GND Top_Sol+ SC_SolSMC_B+ SMC_AOCR_B+ OCR_AIHB+ IHADB+ DAFOILMTR+ GND
Signal Description
Topper Solenoid - Output Smart Card Solenoid + Output Smart Card Motor B phase Smart Card Motor A phase + Rear Indent Motor B phase Rear Indent Motor A phase + Input Hopper B phase Input Hopper Motor A phase + Die Motor B phase Die Motor A phase + Heater + Output Ground Topper Solenoid + Output Smart Card Solenoid - Output Smart Card B phase + Smart Card A phase Rear Indent Motor B phase + Rear Indent Motor A phase Input Hopper Motor B phase + Input Hopper Motor A phase Die Motor B phase + Die Motor A phase Foil Motor + Output Ground
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Sensor Pin-Outs
Table 5-13: Sensor Pin-Outs for Connector J12 Pin #
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Signal Name
Pullup Sensor 15 Sensor 0 Vcc GND Sensor 14 GND GND Pullup HD1Sensor 1 HD1+ GND HD0GND HD0+ Pullup InterSensor 2 Inter+ GND N/C GND N/C Pullup
Sensor Name
Pin #
26
Signal Name
N/C Sensor 3 N/C GND N/C GND N/C Pullup Vcc Sensor 4 GND GND GND GND Sensor 6 Pullup Pullup Sensor 5 N/C GND N/C GND N/C N/C N/C
Sensor Name
Encoder B X Axis Home
27 28 29 30
Punch Home
Encoder A
31 32 33 34 35
Die Home
Y Axis Home
36 37 38 39 40 41 42 43
Registration
Hopper Empty
Wheel Home
44 45 46 47 48 49 50
5-24
Troubleshooting
Table 5-14: Sensor Pin-Outs for Connector J13 Pin #
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Signal Name
GND Pullup GND Sensor 8 Sensor 7 GND Pullup GND GND Pullup GND Sensor 10 Sensor 9 GND Pullup GND GND Pullup GND Sensor 12
Sensor Name
Pin #
21 22 23
Signal Name
Sensor 11 GND Pullup GND GND Pullup GND Sensor 13 Sensor 16 GND Pullup GND N/C N/C N/C N/C N/C N/C RTD2 RTD1
Sensor Name
Foil Motion
Output Full Hopper Home
24 25 26 27 28 29 30 31
Reject Full Throat Gap
OCR Motion Platen Home
32 33 34 35 6 37 38 39
Card Picked
40
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5-25
Serial Communications Pin-Outs
Table 5-15: Serial Communications Pin-Outs (J16) Pin #
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
IC Pin
RX2 A RX3 A RX1 A TX2 A TX1 A RX4 A TX3 A RX5 A GND N/C RX2 B RX3 B RX1 B TX2 B TX1 B RX4 B TX3 B RX5 B GND N/C
Signal
DCD DSR RXD RTS TXD CTS DTR RI GND N/C DCD DSR RXD RTS TXD CTS DTR RI GND N/C
Connector/Pin #
Host 1 Host 6 Host 2 Host - 7 Host - 3 Host - 8 Host - 4 Host - 9 Host - 5 Host - N/C Debug - 1 Debug - 6 Debug - 2 Debug - 7 Debug - 3 Debug - 8 Debug - 4 Debug - 9 Debug - 5 Debug - N/C
5-26
Troubleshooting
Identifying Errors Using Error Codes
When the Error indicator is illuminated, an Administrator Recoverable Error has occurred. An Error Code is displayed on the 150i display. Use the following Error Code list to identify and repair the error. Errors detected by the 150i firmware are reported as 16-bit values. These values consist of three basic parts: 1. Which module reported the error. 2. When was the error reported, and 3. Which device reported the error and why. For clarity, the error codes are grouped as xx-yy-zz. Once an error coded is displayed, it can be deciphered to give the operator and service personal a clear understanding on exactly what happened, when it happened, and the offending module. For example: the 150i displays the error PK 0826:
· · ·
PK (xx) tells the operator that an error occurred while the pick mechanism was being accessed. 08 (yy) tells the operator that the interlock was detected. 26 (zz) tells the operator that the interlock was opened unexpectedly
So, PK 0826 tells the operator that while the 150i was attempting to pick a card, the interlock was opened.
Group xx
This group identifies which module reported the error, but not necessarily which module was at fault.
Function Picking Transport Mag Stripe Embosser Stacker Interlock Value PK yy zz XP yy zz MS yy zz EM yy zz STyy zz IN yy zz Description 150i is accessing the Pick mechanism. 150i is accessing the Transport mechanism. 150i is accessing the Mag Stripe mechanism. 150i is accessing the Emboss mechanism. 150i is accessing the Stacker mechanism. 150i is accessing the Interlock.
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Group yy
This group identifies during which process did the error occur.
Function Homing Pick Embossing Stacking Moving Registration Verify Reg Interlock Encode SCInit Value xx 01zz xx 02 zz xx 03 zz xx 04 zz xx 05 zz xx 06 zz xx 07 zz xx 08 zz xx 09 zz xx 0A zz Description 150i is homing mechanisms. 150i is picking a card. 150i is embossing (and topping) a card. 150i is stacking a card. 150i is moving a card. 150i is defining the card origin. 150i is verifying that the card/mechanism has slipped. 150i detected interlock. 150i is encoding a card. 150i is initializing a Smart Card.
Group zz
This group identifies which device caused the error and why.
Function X Sensor Hit X Sensor Miss X Sensor Early X Sensor Late Y Sensor Hit Y Sensor Miss Y Sensor Early Y Sensor Late Pick Sensor Hit Pick Sensor Miss Wheel Sensor Miss Wheel Sensor Early Value xx yy 01 xx yy 02 xx yy 03 xx yy 04 xx yy 05 xx yy 06 xx yy 07 xx yy 08 xx yy 09 xx yy 0A xx yy 0B xx yy 0C Description X-Sensor was seen. X-Sensor was not seen. X-Sensor was seen early. X-Sensor was seen late. Y-Sensor was seen. Y-Sensor was not seen. Y-Sensor was seen early. Y-Sensor was seen late. Pick home Sensor was seen. Pick home Sensor was not seen. Wheel home Sensor not seen. Wheel home Sensor seen unexpectedly.
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Troubleshooting
Function Upper Emboss Sensor Hit Upr Emboss Sensor Miss Upr Emboss Sensor Early Upper Sensor Late Lower Emboss Sensor Hit Lwr Emboss Sensor Miss Lwr Emboss Sensor Early Lwr Emboss Sensor Late Coord. Err Cmd Seq Err No Cards Card Not Picked Card Not Taken Motor On User Stop Illegal Emb Char Illegal Cmd X Reg Hit X Reg Miss X Reg Early X Reg Late Y Reg Hit Y Reg Miss Y Reg Early Y Reg Late Interlock
Value xx yy 0D xx yy 0E xx yy 0F xx yy 10 xx yy 11 xx yy 12 xx yy 13 xx yy 14 xx yy 15 xx yy 16 xx yy 17 xx yy 18 xx yy 19 xx yy 1A xx yy 1B xx yy 1C xx yy 1D xx yy 1E xx yy 1F xx yy 20 xx yy 21 xx yy 22 xx yy 23 xx yy 24 xx yy 25 xx yy 26
Description Upper Emboss Home Sensor seen. Upper Emboss Home Sensor missed. Upper Emboss Home Sensor seen early. Upper Emboss Home Sensor seen late. Lower Emboss Home Sensor seen. Lower Emboss Home Sensor missed. Lower Emboss Home Sensor seen early. Lower Emboss Home Sensor seen late. Illegal position requested (card or transport). 150i Command out of sequence (e.g. emboss before pick). No cards in card stack. Card was not seen a card exit Sensor. Card was not gripped. Requested motor is on. User requested motor stop. Illegal wheel position requested. Illegal device command. X-Registration Sensor was seen. X-Registration Sensor was not seen. X-Registration Sensor was seen early. X-Registration Sensor was seen late. Y-Registration Sensor was seen. Y-Registration Sensor was not seen. Y-Registration Sensor was seen early. Y-Registration Sensor was seen late. Interlock was broken.
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Function Interlock Missed Out Door Open Platen Stuck Home Platen Stuck Out Card Not Stacked Topper Foil Out Reject Tray Full Topper Temp High Topper Temp Low Topper Temp Indent Rib. Out Indent Stuck In Indent Stuck Out SC Not Present
Value xx yy 27 xx yy 28 xx yy 29 xx yy 2A xx yy 2B xx yy 2C xx yy 2D xx yy 2E xx yy 2F xx yy 30 xx yy 31 xx yy 32 xx yy 33 xx yy 34
Description Interlock should have been broken before continuing. Output stacker door is open. Output stacker is full. Topper platen did not drop. Topper platen did not return home. Card was not placed in output after verifying registration. Topping foil is empty. Reject tray is full. Topper temperature is too high. Topper temperature is too low. Topper temperature is not in control. Indent ribbon is empty. Indent (solenoid) is stuck in. Indent (solenoid) is stuck out. Smart Card application is not responding.
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Troubleshooting
Encode errors are handled separately as follows:
MS Error CARD_POSITION_ERROR TRACK_TABLE_NOT_FOUND INVALID_START_CODE INVALID_START_SENTINEL INVALID_END_SENTINEL INVALID_CHARACTER INVALID_DATA_LENGTH READ_OVERRUN_ERROR NO_TRANSITIONS_FOUND NO_START_FOUND START_POSITION_ERROR LTJ_ERROR BBJ_ERROR PARITY_ERROR LRC_ERROR COMPARE_ERROR Value MS0901 MS0902 MS0910 MS0911 MS0912 MS0913 MS0914 MS0915 MS0916 MS0917 MS0918 MS0919 MS091A MS091B MS091C MS091D Description Error positioning card. Requested track table not found. (Possible financial password violation.) Bad start code given. Invalid start sentinel. Bad end sentinel given. Bad character to encode. Data is too long. Overrun while reading stripe data from card. No transitions seen on stripe. No start sentinel found. Start code was in wrong position. Long term jitter. Short term jitter. Parity error. Checksum error. Data read did not match data written.
150i Card Personalization System Maintenance Manual
5-31
Error Codes
Error codes and messages are displayed on the display located to the left of the keypad on the front of the 150i. The error codes are structured to tell the operator not only what the failure is but where the failure occurred in the system. Use the following table to identify and correct these errors: Table 5-16: Error Code Troubleshooting Chart
Error Code
EM0301
Error Message
Transport Error
Possible Cause
The card carriage could not verify its position. The card carriage could not verify its position. The card carriage could not verify its position. The card carriage could not verify its position. The embossing wheel could not verify its position. The embossing wheel could not verify its position. The emboss mechanism jammed. Two cards may have been picked. The emboss mechanism jammed. Two cards may have been picked. The emboss mechanism jammed. Two cards may have been picked. The emboss mechanism jammed. Two cards may have been picked. The emboss mechanism jammed. Two cards may have been picked. The emboss mechanism jammed. Two cards may have been picked.
Corrective Action
Open the top cover and verify no obstructions to prevent moving Transport to the right or left. Open the top cover and verify no obstructions to prevent moving transport in or out. Open the top cover and verify no obstructions preventing Transport from moving backward. Open the top cover and verify no obstructions preventing Transport from moving backward. Check Embosser Wheel Home sensor.
EM0305
Transport Error
EM0306
Transport Error
EM0307
Transport Error
EM030B
Emboss Wheel Error
EM030C
Wheel Error
Check Embosser Wheel Home sensor.
EM030E
Embossing Error
Check Input Hopper mechanism..
EM030F
Embossing Error
Check Input Hopper mechanism..
EM0310
Emboss Char Err
Check Input Hopper mechanism..
EM0312
Embossing Error
Check Input Hopper mechanism..
EM0313
Embossing Error
Check Input Hopper mechanism..
EM0314
Embossing Error
Check Input Hopper mechanism..
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Troubleshooting
Error Code
EM0315
Error Message
Coordinate Out Of Range
Possible Cause
The 150i could not make the card due to physical limits of the card. Either too many emboss characters on the card or they are in the wrong position on the card. The top cover was opened during card processing. The topper platen did not come down correctly.
Corrective Action
Redo card layout..
EM0326
Interlock Seen
Close the Top Cover.
EM0329
Topping Platen Error
Open the top cover and verify no obstructions around or in Topper or platen photocell. Check Topping foil for correct routing. Open the top cover and verify no obstructions around or in Topper or platen photocell. Check Topping foil for correct routing. Verify no obstructions around or in Topping foil. Is there foil and is it loaded correctly? Topper temperature too hot. Shut down 150i and allow to cool at least 5 minutes then send card data again. Allow Topper to warm up. Check heater platen. Broken ribbon, out of ribbon or not installed correctly. Close the Top Cover.
EM032A
Topping Platen Error
The topper platen did not come down correctly.
EM032C
Foil Advance Error
The 150i did not detect topper foil motion. The 150i detected the topper temperature is out of its limits. The 150i detected the topper temperature is not hot enough. The 150i did not detect indent ribbon motion. The top cover was opened during card processing The 150i could not verify the information that it encoded on the magnetic stripe. The 150i could not verify the information that it encoded on the magnetic stripe. The 150i could not verify the information that it encoded on the magnetic stripe. The 150i could not verify the information that it encoded on the magnetic stripe. The 150i could not verify the information that it encoded on the magnetic stripe.
EM032E
Top Temperature Error
EM0330
Top Temperature Error
EM0331 IN0826
Indent Ribbon Error Interlock Seen
MS 0902
TRACK_TABLE_NOT_FOUND
Reload table magnetic stripe table and send card data again (unique table). (Possible financial password violation.) Examine data for correct start sentinel. Send card data again.
MS0910
INVALID_START_CODE
MS0911
INVALID_START_SENTINEL
Examine data for correct start sentinel. Send card data again.
MS0912
INVALID_END_SENTINEL
Examine data for correct end sentinel. Send card data again.
MS0913
INVALID_CHARACTER
Examine data for correct information. Send card data again.
150i Card Personalization System Maintenance Manual
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Error Code
MS0914
Error Message
INVALID_DATA_LENGTH
Possible Cause
The 150i could not verify the information that it encoded on the magnetic stripe. The 150i could not verify the information that it encoded on the magnetic stripe. The 150i could not verify the information that it encoded on the magnetic stripe. The 150i could not verify the information that it encoded on the magnetic stripe. The 150i could not verify the information that it encoded on the magnetic stripe. The 150i could not verify the information that it encoded on the magnetic stripe. The 150i could not verify the information that it encoded on the magnetic stripe. The 150i could not verify the information that it encoded on the magnetic stripe. The 150i could not verify the information that it encoded on the magnetic stripe. The 150i could not verify the information that it encoded on the magnetic stripe. The top cover was opened during card processing. The card carriage could not verify its position. The card carriage could not verify its position. The card carriage could not verify its position. The card carriage could not verify its position.
Corrective Action
Examine the data sent. Send card data again.
MS0915
READ_OVERRUN_ERROR
Check cards in the Input Hopper. Check coercivity (refer to CPX Manual). Send card data again. Check coercivity (refer to CPX Manual). Verify the card has a magnetic stripe and cards are stacked in the Input Hopper correctly. Clean Magnetic Strip head.
MS0916
NO_TRANSITIONS_FOUND
MS0917
NO_START_FOUND
MS0918
START_POSITIION_ERROR
Check for obstructions in the magnetic stripe encoding area. Send card data again. Check for bad card stock. Send card data again.
MS0919
LTJ_ERROR
MS091A
BBJ_ERROR
Check for bad card stock. Send card data again.
MS091B
PARITY_ERROR
Check for bad card stock. Send card data again.
MS091C
LRC ERROR
Check for bad card stock. Send card data again.
MS091D
COMPARE_ERROR
Check for bad card stock.
MS0926
Interlock Open
Close the Top Cover.
PK0102 PK0105 PK0106 PK010A
Transport Error Transport Error Transport Error Transport Error
Verify no obstructions are between Transport and the right side of the 150i. Verify no obstructions between Card Carriage and back of the Transport. Verify no obstructions between Card Carriage and back of the Transport. Verify no obstructions between Transport and Input Hopper. Remove all cards and reload Input Hopper.
5-34
Troubleshooting
Error Code
PK010B
Error Message
Emboss Wheel Error
Possible Cause
The emboss mechanism jammed. Two cards may have been picked. The emboss mechanism jammed. Two cards may have been picked. The emboss mechanism jammed. Two cards may have been picked. 150i failed to pick a card.
Corrective Action
Verify no obstructions preventing the Emboss wheel from turning. Verify no obstructions preventing the Die mechanism from returning to home. Verify no obstructions around punch.
PK010E
Embossing Error
PK0112
Embossing Error
PK0119
Card Feed Error
Open the top cover and remove all cards from the Input Hopper and reload. Close Top Cover and send card data again. Close Output Door or empty Output Stacker. Open Output Supply door and remove card from rollers. Open Top Cover and empty Reject Stacker. Reload cards and send card data again. Verify that there are no obstructions preventing Transport from moving to the left. Verify that there are no obstructions preventing Transport from moving to the right or left. Verify no obstructions preventing Transport Carriage from moving forward or backwards. Verify no obstructions preventing Transport Carriage from moving backward or forward. Verify no obstructions around Card Supply Stack preventing stack from moving. Two cards may have be picked, remove and reload cards. Verify no obstructions around Card Supply Stack preventing stack from moving. If two cards were picked, remove and reload cards. Place cards in card Input Hopper. Remove all cards, reload and retry. Verify cards are in Input Hopper.
PK0126
Interlock Seen
The top cover was opened during card processing. Output door is opened during card processing or output tray is full. Card did not make it to the output stacker. Reject Stacker full. Throat home sensor not found during homing. The card carriage could not verify its position. The card carriage could not verify its position. The card carriage could not verify its position. The card carriage could not verify its position. The card carriage could not verify its position.
PK0128
Check Output Tray
PK012B PK012D PK0135 PK0201
Card Not Stacked Reject Stack Full Card Feed Error Transport Error
PK0202
Transport Error
PK0205
Transport Error
PK0206
Transport Error
PK0209
Transport Error i+
PK020A
Transport Error i+
The card carriage could not verify its position.
PK0217 PK0218
Card Supply Empty Card Feed Error
No cards in the input hopper. 150i failed to pick a card.
150i Card Personalization System Maintenance Manual
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Error Code
PK0219
Error Message
Card Feed Error
Possible Cause
150i failed to pick a card.
Corrective Action
Remove all cards, reload and retry. Verify no obstructions around Input Hopper card throat and cards are in Input Hopper. Close Top Cover and send card data again. Empty Output Tray and/or close door.
PK0226
Interlock Seen
The top cover was opened during card processing Output door is opened during card processing or output tray is full. Reject Tray is full 150i failed to pick a card. The 150i failed to communicate with the Smart Card logic board. The card carriage could not verify its position. The card carriage could not verify its position. The card carriage could not verify its position. The card carriage could not verify its position. The top cover was opened during card processing. Cards not stacked properly in Input Hopper.
PK0228
Check Output tray
PK022D PK0235 SC0A34
Reject Stack Full Card Feed Error Smart Card Comm Error
Open the top cover and remove cards from the Reject Tray. Turn off 150i, remove all cards, reload cards and send card data again. Reload Smart Card application.
ST0401 ST0402 ST0406 ST040A ST0426
Transport Error Transport Error Transport Error Transport Error Interlock Open
Verify no obstructions around Transport and Output Stacker. Verify no obstructions around Transport and Output Stacker. Verify no obstructions around Transport and Output Stacker. Verify no obstructions around Output Stacker. Card jammed. Close the Top Cover.
ST042B
Card Not Stacked
Remove card from Output Stack rollers. Verify no obstructions around Output Stacker that would prevent card from exiting. Verify no obstructions in X transport direction. Verify no obstructions around Y- Sensor. Verify no obstructions around Registration photocell or Transport. Verify no obstructions around Registration photocell or Transport. Send card data again. Verify no obstructions around Registration photocell or Transport. Close the Top Cover.
XP0501 XP0505 XP061E XP061F XP0622 XP0623 XP0626
Transport Error Transport error Card Registration Error Card Registration Error Card Registration Error Card Registration Error Interlock Open
The card carriage could not verify its position. The card carriage could not verify its position. The 150i could not verify the correct card position. The 150i could not verify the correct card position. The 150i could not verify the correct card position. The 150i could not verify the correct card position. The top cover was opened during card processing.
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Troubleshooting
Error Code
XP071F
Error Message
Verify Regist. Error
Possible Cause
This error is due to possible card slippage during processing. This error is due to possible card slippage during processing. This error is due to possible card slippage during processing. This error is due to possible card slippage during processing. The top cover was opened during card processing.
Corrective Action
Verify that the embossing on the card is correct. Send card data again if necessary. Verify that the embossing on the card is correct. Send the card data again if necessary Verify that the embossing on the card is correct. Send the card data again if necessary Verify that the embossing on the card is correct. Send the card data again if necessary Close the Top Cover.
XP0720
Verify Regist. Error
XP0723
Verify Regist. Error
XP0724
Verify Regist. Error
XP0726
Interlock Open
150i Card Personalization System Maintenance Manual
5-37
Main Control Board LEDs
The following describes the LED functions for the Main Control Board of the 150i. These LEDs serve as a quick visual indication that the LED, sensor and the associated wiring harness to that LED is functional. See Figure 5-8 for LED locations. See Figure 5-9 for the physical location of the sensor. Table 5-17: Main Control Board LEDs LED ID
D17 D18 D19
Description
Throat Gap Sensor Xilinx Done Reject Full Sensor
LED is ON
Indicates the Throat Gap sensor is fully open. Indicates the Xilinx processor is busy. Indicates the Reject Hopper if filled with cards.
LED is OFF
Indicates the Throat Gap sensor is closed. Indicates the Xilinx processor is not busy. Indicates the Reject Hopper is not completely filled with cards
D20 D21 D22
Topper Foil Motion Sensor Card Picked Sensor Topper Platen Home Sensor
Indicates the Topper Foil is moving. Indicates that a card has been picked. Indicates the Topper Platen is at home position. Indicates that no card is blocking the sensor. Indicates the Topper Platen is not at home position.
D23 D24
OCR Motion Sensor Input Home Sensor
Indicates the OCR ribbon is moving. Indicates the Input Home Picker is at home position.. Indicates the Output Input Hopper is filled with cards. Indicates a card is blocking the Card Registration sensor. Indicates there are no cards in the Input Hopper. Indicates the Upper Emboss cam is in the home position. Indicates the Lower Emboss cam is in the home position. Indicates the Embosser Wheel is in the home position. Indicates the Input Home Picker is not at home position. Indicates the Output Input Hopper is not completely filled with cards. Indicates that nothing is blocking the Card Registration sensor. Indicates there is at least one card in the Input Hopper. Indicates the Upper Emboss cam is not in the home position. Indicates the Lower Emboss cam is not in the home position. Indicates the Embosser Wheel is not in the home position.
D25
Output Full Sensor
D26
Card Registration Sensor
D27
Input Hopper Empty Sensor
D28
Upper Emboss Home Sensor
D29
Lower Emboss Home Sensor
D30
Wheel Home Sensor
5-38
Troubleshooting
LED ID
D31
Description
Y-Home Sensor
LED is ON
Indicates the Y Carriage is in the home position.
LED is OFF
Indicates the Y Carriage is not in the home position.
D32 D33
ENC B X-Home Sensor
Indicates the B section of the Magnetic Stripe Encoder Wheel is moving. Indicates the X Carriage is in the home position. Indicates the X Carriage is not in the home position.
D34 D35 D36 D37
ENC A +12V2 +12V1 +5V
Indicates the A section of the Magnetic Stripe Encoder Wheel is moving. Indicates the +12 VDC V2 Power Supply is on. Indicates the +12 VDC V1 Power Supply is on. Indicates the +5 VDC Power Supply is on. Indicates the +12 VDC V2 Power Supply is off. Indicates the +12 VDC V1 Power Supply is off. Indicates the +5 VDC Power Supply is off.
D17 D18
D19 D20
D21 D22
D23 D24
D25 D26
D27 D28
D29 D30
D31 D32
D33 D34
D35 D36
D37
150i015s
Figure 5-8: Main Control Board LEDs
150i Card Personalization System Maintenance Manual
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Topper Platen Sensor
Reject Full Sensor Topper Foil Motion Sensor Throat Gap Sensor
X-Home Sensor Y-Home Sensor
Wheel Home Sensor Punch Cam Home Sensor Die Cam Home Sensor
Card Registration Sensor
Card Picked Sensor
REAR VIEW Output Full Sensor Input Hopper Empty Sensor Input Home Sensor
Figure 5-9: Sensor Locations
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Troubleshooting