FLEXIBLE PLATFORM
FOR VOLUME
CARD ISSUANCE
OPERATOR MANUAL
Revision 1.3
Copyright
Important: the technical information contained in this
manual is property of MATICA System S.r.l. and is secured
by copyright. The terms of the license define and specify
permitted uses and other limitations.
Reproduction of any part of this manual, in any form, is
forbidden without the explicit written permission of MATICA
System S.r.l.
Technical information contained in the present manual is
subject to change without notice. If not otherwise specified,
any reference to companies, names, dates and addresses is
purely incidental and is only intended to illustrate the use of
the MATICA System S.r.l. product.
Every care has been taken in the collection and verification
of the documentation inserted in this manual; nevertheless
MATICA System S.r.l. cannot assume any responsibility
deriving from its use.
Copyright © 2012 MATICA System S.r.l.
All rights reserved
Published by MATICA System S.r.l.
Printed in Italy
Issue: February 2012
Revision 1.3
MATICA System S.r.l.
via Guido Rossa, 4/6
20037 – Paderno Dugnano
MILAN - ITALY
Phone +39.02.92272501
Fax +39.02.91084372
E-mail: techsupport@maticasystem.com
Web: http://www.maticasystem.com
System 7000 Operator Manual
Rev. 1.3
Page 2/48
Contents
Table of contents
Chapter 1 – Introduction .......................................................... 4
1.1 Specifications ............................................................................. 4
1.2 Warnings ................................................................................... 6
1.3 Choice of site.............................................................................. 6
Chapter 2 – Start up .................................................................. 7
2.1 Installation................................................................................. 7
2.2 Working cycle ............................................................................. 8
Chapter 3 – Consumables ......................................................... 19
3.1
3.2
3.3
3.4
3.5
Changing
Changing
Changing
Changing
Changing
Flip Over cleaning tape .................................................. 19
Thermal module printing ribbon....................................... 22
Top Indent ribbon ......................................................... 27
Rear Indent ribbon ........................................................ 30
Tipper ribbon ................................................................ 33
Chapter 4 – Error List ................................................................ 37
Chapter 5 – Cleaning and maintenance ................................. 45
5.1 Thermal Printer cleaning .............................................................. 45
5.2 Preventive maintenance schedule .................................................. 47
System 7000 Operator Manual
Rev. 1.3
Page 3/48
Chapter 1 - Introduction
Chapter 1 – Introduction
1.1 Specifications
Cabinet Size
Single Feed/Unload Width: 15.6 cm (6.1”)
Double Feed/Unload Width: 28.3 cm (11.1”)
Standard Cabinet Width: 37.2 cm (14.6”)
Standard Cabinet Depth: 55 cm (21.7”)
Double Feed Depth: 61 cm (24”)
Height (Cabinet Support included): 150 cm (59.1”)
User PC Support Width: 56 cm (22”)
User PS Support Depth: 52 cm (20.5”)
System 7000 Operator Manual
Rev. 1.3
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Chapter 1 - Introduction
Productivity Speed
Printing Mode
Card Format
Hopper Capacity
Comm. Interface
depending on the system configuration
Thermal Transfer and Sublimation
300 DPI Edge-to-edge printing
ISO CR80 – ISO 7810
Input: 600 cards
Output: 500 embossed cards (approx.)
LAN
The machine weight depends on the system configuration.
Requirements
Electrical
110V ÷ 120V, 60 Hz or 220V ÷ 240V, 50 Hz.
Room electrical circuit with safety and emergency
interlocks switch.
AC voltage must be stable and constant.
Environment
Room temperature: 13 ÷ 35°C (55/95°F).
Humidity: 20% to 80% non-condensing.
Room no subject to dust, smog and filing.
Place
The machine must be disposed in closed place.
At least 60 cm as free space around the machine
must be guarantied.
Pavement surface must be flat.
If pavement is raised by floor like platform, be
sure that it able to support the machine weight.
Avoid that the machine is disposed near to:
- heating sources
- cooling sources
- electromagnetic sources
- water sources
Power consuming
Elements Power
Modules
Feeder & Stacker
Encoder
Multichip 5 Stations
Thermo
Embosser
Tipper (1 Module)
Laser
System 7000 Operator Manual
Machine state
Standby
Pick
Working
Current Current Current
A
A
A
0.1
0.1
0.1
0.1
0.1
0.4
4
0.1
0.2
0.2
0.4
1.0
0.9
4
Rev. 1.3
0.1
0.2
0.2
0.4
1.0
0.4
4
Voltage
V
Power
W
Power
BTUh
220
220
220
220
220
220
220
22
44
44
88
220
198
900
75
150
150
300
750
675
3,070
Page 5/48
Chapter 1 - Introduction
1.2 Warnings
Respect these warnings and follow the indications labeled on the system.
Power the system through the electrical power supply indicated on the
related label.
Connect the system to plugs-in provided with a grounding device. Avoid
using plugs-in placed on the same circuit in connection with machines
starting up and stopping periodically. Take care of the power supply cable,
in order to avoid damaging or wearing out.
The system has never to be installed near heat or cooling sources.
When the cover is open the system automatically stops all the motors;
this kind of safety is useful when cleanings and changing of consumables
have to be performed.
Only perform the adjustments reported in this manual: a wrong
adjustment may cause serious damages.
1.3 Choice of site
Follow the instructions reported below to choose the site where you want
to place the 7000 System and to remove the package.
Before starting the installation, choose a wide and functional area with the
following requirements:
- A level and rigid surface. Yielding surfaces, like pre-manufactured
platforms or floors covered with a fitted carpet, don’t guarantee the
right alignment of the modules making up the 7000 System.
- A good accessibility. Leave free spaces all around the machinery, in
order to allow access to inspection and maintenance areas, and a
right ventilation of the system. Also leave at least one meter in front
of the machine, so that the operator using the front panel has got a
proper working area.
- Favorable environment conditions. Install the 7000 System in a cool
and dry place; avoid too cold or too warm temperatures; keep the
machinery far from humidity, dust and smoke. Don’t directly expose
to heat or sunlight. No electromagnetic interferences.
- Proper electrical power supply. Connect the system and its devices
with cables fit to your electrical power supply net. When using
extensions or multiple plugs-in, be sure that the total absorption
doesn’t exceed the maximum allowed value.
System 7000 Operator Manual
Rev. 1.3
Page 6/48
Chapter 2 – Start up
Chapter 2 – Start up
2.1 Installation
The system specifications are written on the machine label; verify that the
voltage marked on the label corresponds with your country voltage
supply. Connect the power cord on the machine support to the wall
socket, then connect the LAN interface cable on the back panel of the
system.
The service key on the machine back panel enable or disable the cover
open safety. If the key can be removed, the cover open safety is enable
so the machine stops if a cover is opened. Otherwise if the key can’t be
removed, the cover open safety is disabled and the machine doesn’t stop
even if a cover is opened.
The emergency button on the machine front side bypass the service key;
when this button is pushed the machine stops even if the service key is in
the position that disables the cover open safety.
Power on the machine turning the main switch clockwise.
Now the system is ready to work.
LAN
System fuses
Sevice
key
Power cord
Main switch
System 7000 Operator Manual
Rev. 1.3
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Chapter 2 – Start up
2.2 Working Cycle
To perform a working cycle you must introduce the plastic cards to be
personalized into the automatic Input Hopper, with the magnetic stripe on
the bottom right side of the card. Then you had to run the desired job
with the Maticard Pro software.
If the machine is equipped with a Double Input Hopper, insert the card in
the desired one and it will be pushed into the Rotator module. This module
simply pass the card to the next module if it comes from the Hopper on Xaxis or rotate the card 90° if it comes from the Hopper on the Y-axis.
System 7000 Operator Manual
Rev. 1.3
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Chapter 2 – Start up
If the card it’s moved towards a Smart Station, this module can be
equipped with a Chip contact, a Chip contactless, a Barcode reader and a
OCR reader to personalize the card.
System 7000 Operator Manual
Rev. 1.3
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Chapter 2 – Start up
If the card it’s moved towards a Transport, this module just passes the
card to the next module.
If the card it’s moved towards an Encoder, this module encodes (write &
read) the magnetic stripe present on the card, with a capacity of reading
and writing 3 tracks at high or low coercivity.
System 7000 Operator Manual
Rev. 1.3
Page 10/48
Chapter 2 – Start up
If the card it’s moved towards a Multiple Smart Card personalization
module, this one can manage the personalization of the chip present up to
five cards in the same time. The mechanism works as an “elevator” by
which the 5-station Smart Card module raises itself one station at the
time until all 5 stations have been loaded, upon which the module
descends to its initial position. At this point the first card, now fully
personalized, is transferred to the next module and replaced by a new
card, and the process described above is repeated.
If there isn’t any chip personalization, the Multiple Smart Card module just
passes the card to the next module.
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Chapter 2 – Start up
If the card it’s moved towards a Small Transport, this module just passes
the card to the next module.
System 7000 Operator Manual
Rev. 1.3
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Chapter 2 – Start up
If the card it’s moved towards a Flip Over, this module can pass the card
to the Thermal Printer module, if the card has to be printed on the same
side, or rotate it 180° if the card has to be printed on the other side.
The Flip Over can be equipped with an AdvanceClean® system to ensure
that cards will be free from dust and debris.
System 7000 Operator Manual
Rev. 1.3
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Chapter 2 – Start up
The Thermal Printer module performs an edge to edge graphic printing of
the card in the desired position; the printing could be black, black with
overlay protection, scratch off or full color with overlay protection,
depending on the ribbon type. Refer to Chapter 5 for the Printer cleaning.
System 7000 Operator Manual
Rev. 1.3
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Chapter 2 – Start up
If the card it’s moved towards a Laser, this module engraves the card in
the desired position. The Laser Module needs a vacuum system to avoid
the dispersion of harmful dust (please refer to the related documentation).
System 7000 Operator Manual
Rev. 1.3
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Chapter 2 – Start up
If the card it’s moved towards an Embosser, this module emboss the
characters present into its drum in the desired position on the card. This
module can be equipped with two indent module, front and rear, to
perform the indenting personalization of both sides of the card in a single
pass.
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Rev. 1.3
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Chapter 2 – Start up
If the card it’s moved towards a Tipper, this module colors the embossed
characters; the color depends on the kind of ribbon mounted.
System 7000 Operator Manual
Rev. 1.3
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Chapter 2 – Start up
At the end of the cycle, the card is stored in the Output module; if the
card is well personalized will be in the upper Output Hopper, while if the
card is rejected or defective will be in the lower Reject Box.
System 7000 Operator Manual
Rev. 1.3
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Chapter 3 – Consumables
Chapter 3 – Consumables
3.1 Changing Flip Over cleaning tape
When the Thermal Printer cleaning tape is finished it must be replaced, in
order to avoiding plastic cards from dust before printing.
First of all remove the used tape from its rolls.
System 7000 Operator Manual
Rev. 1.3
Page 19/48
Chapter 3 – Consumables
Now insert partially the spools of the new tape in the two rolls with the full
spool in the right roll and the empty spool in the left one; the tape must
unwind counterclockwise.
Be sure to put the tape outside the lower shaft and inside the upper shaft.
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Rev. 1.3
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Chapter 3 – Consumables
Push completely the tape spools in the two rolls and finally turn clockwise
the left roll to tension the tape.
System 7000 Operator Manual
Rev. 1.3
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Chapter 3 – Consumables
3.2 Changing Thermal module printing ribbon
When the Thermal printing ribbon is finished, it must be replaced.
First of all unhook the print head by pulling leftward the related handle, in
this way the head lifts up horizontally.
System 7000 Operator Manual
Rev. 1.3
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Chapter 3 – Consumables
Then remove the used ribbon from its rolls.
System 7000 Operator Manual
Rev. 1.3
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Chapter 3 – Consumables
Now insert the full spool of the new ribbon in the right roll; the tape must
unwind counterclockwise.
Then pass the ribbon under the related shaft and under the print head.
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Rev. 1.3
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Chapter 3 – Consumables
Now insert the empty spool of the new ribbon in the left roll.
Then push down the print head until it will be hooked to the related pin on the
printer module.
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Chapter 3 – Consumables
Finally turn counterclockwise the left roll to tension the ribbon.
System 7000 Operator Manual
Rev. 1.3
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Chapter 3 – Consumables
3.3 Changing Top Indent ribbon
To change the Top Indent ribbon, first of all you must unscrew the two
cover disk knobs and remove the two disks (fig. 1).
Cover disk
Knob
Knob
Cover
disk
fig. 1
Now you can remove the used ribbon (fig. 2).
fig. 2
System 7000 Operator Manual
Rev. 1.3
Page 27/48
Chapter 3 – Consumables
Then you can insert the empty spool on the left disk matching one of the
spool hole with the related disk pin and full spool on the right disk
matching one of the spool hole with the related disk pin; be sure that the
ribbon unwinds on the left side of the full spool (fig. 3).
Full spool
Pin
Pin
Empty spool
fig. 3
Be sure that the ribbon will pass trough this path: over the first roll, under
the second and third rolls, between the rubber red roll and its pin, over
the empty spool (fig. 4).
Empty spool
Rubber
Roll
Pin
1st Roll
2nd Roll
3rd Roll
fig. 4
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Rev. 1.3
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Chapter 3 – Consumables
Fasten the ribbon on the empty spool with a stick tape (fig. 5).
Stick tape
fig. 5
Match the hole on each of the two cover disks with the related ones on the
ribbon disks and tighten the disks knobs into the aforesaid holes (fig. 6).
Cover disk
Knob
Knob
fig. 6
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Rev. 1.3
Page 29/48
Chapter 3 – Consumables
3.4 Changing Rear Indent ribbon
To change the Rear Indent ribbon, first of all you must unhook the desired
Indent cartridge by pulling the related lever on the right side (fig. 1).
Lever
fig. 1
Now you can pull out the lower cartridge (fig. 2).
fig. 2
Then you have to put the lower cartridge on a plain surface (fig. 3) and
pull the spring that releases the ribbon cover (fig. 4).
Spring
fig. 3
System 7000 Operator Manual
fig. 4
Rev. 1.3
Page 30/48
Chapter 3 – Consumables
At this point you need to lift up the ribbon cover (fig. 5) and remove the
used ribbon from the cartridge (fig. 6).
fig. 5
fig. 6
Now you can insert the new ribbon in the related pins with the full spool
on the left pin and the empty spool on the two right pins (fig. 7), from the
ribbon rolls point of view.
fig. 7
You must be absolutely sure that the ribbon runs with the ink side
opposite to the pin spools, trough this path: outside the two rolls near
the full spool (fig. 8), outside the first roll and inside the second roll near
the empty spool and finally outside the big red roll (fig. 9).
fig. 8
System 7000 Operator Manual
fig. 9
Rev. 1.3
Page 31/48
Chapter 3 – Consumables
Now you have to put the side projections of the lower cartridge in the
related left (fig. 10) and right (fig. 11) inserts on the module
Insert
fig. 10
Insert
fig. 11
Finally you must push the cartridge in order to hook it, paying attention to
pass the ribbon over the lower punches (fig. 12).
fig. 12
System 7000 Operator Manual
Rev. 1.3
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Chapter 3 – Consumables
3.5 Changing Tipper ribbon
When the Tipper ribbon is finished (fig. 1) you have to unhook the ribbon
cartridge, by pulling the black knob on the left of the module, in order to
extract the cartridge itself (fig. 2).
Knob
fig. 1
Knob
fig. 2
While you are holding the cartridge, you must remove the used ribbon
from its spool (fig. 3) and pull the disk spring that holds the old carton
core (fig. 4).
fig. 3
System 7000 Operator Manual
fig. 4
Rev. 1.3
Page 33/48
Chapter 3 – Consumables
Then you can extract the old carton core (fig. 5) and insert in the same
position the new ribbon by pulling the related disk spring (fig. 6). Be
careful that the ribbon unwinds over the core.
fig. 5
fig. 6
Now you must be absolutely sure that the ribbon follows this path: under
the nearest shaft, over the first little roller, under the black shaft (fig. 7),
between the third shaft and the second little roller and finally under the
farer little roller (fig. 8).
fig. 7
System 7000 Operator Manual
fig. 8
Rev. 1.3
Page 34/48
Chapter 3 – Consumables
At this point you have to pull up the ribbon, pass it over the upper shaft,
and put the cartridge in its beginning position on the module (fig. 9);
then you can hook the cartridge by pushing it until the black knob clicks
(fig. 10).
fig. 9
fig. 10
Now you must insert the new carton core in the top spool (fig. 11) and
fasten the ribbon on it with a stick tape (fig. 12).
fig. 11
System 7000 Operator Manual
fig. 12
Rev. 1.3
Page 35/48
Chapter 3 – Consumables
Finally you have to push the black button on the module (fig. 13) in order
to tighten the ribbon and wind it on the top spool (fig. 14).
fig. 13
System 7000 Operator Manual
fig. 14
Rev. 1.3
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Chapter 4 – Error List
Chapter 4 – Error List
When an error occurred the PC will show the messages listed below; apply
the proper procedure to remove the error condition and read carefully the
error comments. If there are more modules of the same kind, in order to
distinguish which module generated the error, the related module name is
followed by a number that represents the order, in the working cycle, of
one module compared to the other ones of that kind.
ERROR CODE
0001 FEEDER x
NOT CONNECTED
0002 FEEDER x
NACK ANSWERED
0003 FEEDER x
RESET (NACK-3!!)
3012 FEEDER x
START LOAD ERROR
3013 FEEDER x
END LOAD ERROR
3014 FEEDER x
EMPTY
3015 FEEDER x
JAM ERROR
0001 FLIP OVER x
NOT CONNECTED
0002 FLIP OVER x
NACK ANSWERED
0003 FLIP OVER x
RESET (NACK-3!!)
3004 FLIP OVER x
CARD ALREADY INSIDE
3005 FLIP OVER x
2 SENSORS ARE BUSY
3006 FLIP OVER x
ROTATE ERROR
3007 FLIP OVER x
CARD-IN ERROR
3008 FLIP OVER x
CARD-OUT ERROR
3009 FLIP OVER x
UNABLE TO ROTATE
3010 FLIP OVER x
UNABLE TO MOVE
3125 FLIP OVER
CLEANING RIBBON ERROR
System 7000 Operator Manual
POSSIBLE CAUSES
Communication error with the Feeder board.
System error; please contact the technical support.
System error; please contact the technical support
The card can’t be loaded; check if:
a) Card jam;
b) Card in sensor damaged;
c) Loading motor damaged.
The card can’t be loaded; check if:
a) Card jam;
b) Card out sensor damaged;
c) Loading motor damaged.
If the hopper is empty add cards; while if the hopper isn't
empty, check if:
a) Cards are stuck together or bowed;
b) Mechanical impediments;
c) Alignment between modules;
d) The Loading motor moves correctly.
Card Jam. Remove the card
Communication error with the Flip Over board.
System error; please contact the technical support.
System error; please contact the technical support
Card already present inside the module while expected free.
Card jam. Remove the card.
Movement error when searching the 180° sensor.
Error on module card input. Check if:
a) Card jam;
b) Card-in sensor damaged;
c) Motor damaged.
Error on module card output. Check if:
a) Card jam;
b) Card-out sensor damaged;
c) Motor damaged.
The Flip Over can’t rotate because of a card not positioned
in the middle of the module (but under the card in or the
card out sensor).
The Flip Over is in a incorrect position. Check the motor.
Ribbon finished or not present or cleaning cycle error
Rev. 1.3
Page 37/48
Chapter 4 – Error List
ERROR CODE
POSSIBLE CAUSES
0001 ENCODER x
NOT CONNECTED
0002 ENCODER x
NACK ANSWERED
0003 ENCODER x
RESET (NACK-3!!)
3004 ENCODER x
CARD ALREADY INSIDE
3005 ENCODER x
2 SENSORS ARE BUSY
3016 ENCODER x
CARD JAM
3007 ENCODER x
CARD-IN ERROR
3008 ENCODER x
CARD-OUT ERROR
3018 ENCODER
DATA ERROR
5019 ENCODER
TRACK 1 EMPTY
5020 ENCODER
TRACK 2 EMPTY
5021 ENCODER
TRACK 3 EMPTY
x
x
x
x
5022 ENCODER x
TRACK 1 ERROR
5023 ENCODER x
TRACK 2 ERROR
5024 ENCODER x
TRACK 3 ERROR
5025 ENCODER x
TRACK 1 STX ERROR
5026 ENCODER x
TRACK 2 STX ERROR
5027 ENCODER x
TRACK 3 STX ERROR
5028 ENCODER x
CHIP ERROR
5059 ENCODER x
VERIFY ERROR TRACK 1
5060 ENCODER x
VERIFY ERROR TRACK 2
5061 ENCODER x
VERIFY ERROR TRACK 3
System 7000 Operator Manual
Communication error with the Encoder board.
System error; please contact the technical support.
System error; please contact the technical support
Card already present inside the module while expected free.
Card Jam. Remove the card.
If there is one card in the Encoder check if:
a) The card is slipping on rollers, if so clean them;
b) Check if pulleys are fixed correctly on their shaft;
c) Check if the Encoder motor is damaged;
If there isn’t any card in the Encoder check if:
a) Check if one of the three card movement sensors is
damaged or dirty.
Error on module card input. Check if:
a) Card jam;
b) Card-in sensor damaged;
c) Motor damaged.
Error on module card output. Check if:
a) Card jam;
b) Card-out sensor damaged;
c) Motor damaged.
Invalid data.
a) Check if the cards are up side down;
b) Check if the encoder head is connected correctly.
a) Check if the cards are up side down;
b) Check if the encoder head is connected correctly.
a) Check if the cards are up side down;
b) Check if the encoder head is connected correctly.
a) Check if the magstripe is scratched or dirty on track 1;
b) Check if the Encoder head is dirty;
c) Check for timing belt tension.
a) Check if the magstripe is scratched or dirty on track 2;
b) Check if the Encoder head is dirty;
c) Check for timing belt tension.
a) Check if the magstripe is scratched or dirty on track 3;
b) Check if the Encoder head is dirty;
c) Check for timing belt tension.
Error on the track 1 Start Sentinel.
Error on the track 2 Start Sentinel.
Error on the track 3 Start Sentinel.
Smart card reading / writing error
Error during the track 1 verification.
Error during the track 2 verification.
Error during the track 3 verification.
Rev. 1.3
Page 38/48
Chapter 4 – Error List
ERROR CODE
0001 TRANSPORT x
NOT CONNECTED
0002 TRANSPORT x
NACK ANSWERED
0003 TRANSPORT x
RESET (NACK-3!!)
3004 TRANSPORT x
CARD ALREADY INSIDE
3005 TRANSPORT x
2 SENSORS ARE BUSY
3007 TRANSPORT x
CARD-IN ERROR
3008 TRANSPORT x
CARD-OUT ERROR
0001 MCHIP x
NOT CONNECTED
0002 MCHIP x
NACK ANSWERED
0003 MCHIP x
RESET (NACK-3!!)
3004 MCHIP x
CARD ALREADY INSIDE
3005 MCHIP x
2 SENSORS ARE BUSY
3007 MCHIP x
CARD-IN ERROR
3008 MCHIP x
CARD-OUT ERROR
3030 MCHIP x
RESTORE ERROR
3031 MCHIP x
CASTLE-IN ERROR
3032 MCHIP x
CASTLE-OUT ERROR
3033 MCHIP x
CONTACTS MOVEMENT ERROR
5025 MCHIP x
CHIP ERROR !
System 7000 Operator Manual
POSSIBLE CAUSES
Communication error with the Transport board.
System error; please contact the technical support.
System error; please contact the technical support
Card already present inside the module while expected free.
Card jam. Remove the card.
Error on module card input. Check if:
a) Card jam;
b) Card-in sensor damaged;
c) Motor damaged.
Error on module card output. Check if:
a) Card jam;
b) Card-out sensor damaged;
c) Motor damaged.
Communication error with the Multichip board.
System error; please contact the technical support.
System error; please contact the technical support
Card already present inside the module while expected free.
Card Jam. Remove the card.
Error on module card input. Check if:
a) Card jam;
b) Card-in sensor damaged;
c) Motor damaged.
Error on module card output. Check if:
a) Card jam;
b) Card-out sensor damaged;
c) Motor damaged.
Lift module error; check if:
a) Card jam;
b) Home sensor damaged;
c) Castle motor damaged;
d) Castle belt broken.
Card transport input error.; check if:
a) Card jam;
b) Castle-in sensor damaged;
c) Castle motor damaged;
d) Castle belt broken.
Card transport output error.; check if:
a) Card jam;
b) Castle-out sensor damaged;
c) Castle motor damaged;
d) Castle belt broken.
The chip contacts remain opened/closed.
Check the contacts motor.
Smart card reading / writing error
Rev. 1.3
Page 39/48
Chapter 4 – Error List
ERROR CODE
0001 ROTATOR x
NOT CONNECTED
0002 ROTATOR x
NACK ANSWERED
0003 ROTATOR x
RESET (NACK-3!!)
3004 ROTATOR x
CARD ALREADY INSIDE
3005 ROTATOR x
2 SENSORS ARE BUSY
3006 ROTATOR x
ROTATE ERROR
3007 ROTATOR x
CARD-IN ERROR
3008 ROTATOR x
CARD-OUT ERROR
3009 ROTATOR x
UNABLE TO ROTATE
3010 ROTATOR x
UNABLE TO MOVE
0001 UNLOAD x
NOT CONNECTED
0002 UNLOAD x
NACK ANSWERED
0003 UNLOAD x
RESET (NACK-3!!)
POSSIBLE CAUSES
Communication error with the Rotator board.
System error; please contact the technical support.
System error; please contact the technical support
Card already present inside the module while expected free.
Card jam. Remove the card.
Movement error; check the motor.
Error on module card input. Check if:
a) Card jam;
b) Card-in sensor damaged;
c) Motor damaged.
Error on module card output. Check if:
a) Card jam;
b) Card-out sensor damaged;
c) Motor damaged.
The Rotator can’t rotate because of a card not positioned in
the middle of the module (but under the card in or the card
out sensor).
The Rotator is in a incorrect position. Check the motor.
Communication error with the Unloader board.
System error; please contact the technical support.
System error; please contact the technical support
3007 UNLOAD x
CARD-IN ERROR
Error on module card input. Check if:
a) Card jam;
b) Card-in sensor damaged;
c) Motor damaged.
3010 UNLOAD x
UNABLE TO MOVE
The module can’t move. Check the motor.
3035 UNLOAD x
HOME POSITION ERROR
3036 UNLOAD x
UP POSITION ERROR
3037 UNLOAD x
STACKER FULL
3038 UNLOAD x
UNABLE TO LOAD
System 7000 Operator Manual
During a reset operation or if the card has been ejected:
a) Check if the motor is damaged;
b) Check if the home sensor is damaged or dirty;
If the card hasn’t been ejected:
a) Check for mechanical impediments.
Card Jam. Remove the card.
If the stacker is full unload it.
If the stacker isn’t full check if the full sensor is damaged.
The card can’t be loaded; check if:
a) Card jam;
b) Loading sensor damaged;
c) Loading motor damaged.
Rev. 1.3
Page 40/48
Chapter 4 – Error List
ERROR CODE
0001 TIPPER x
NOT CONNECTED
0002 TIPPER x
NACK ANSWERED
0003 TIPPER x
RESET (NACK-3!!)
3004 TIPPER x
CARD ALREADY INSIDE
3005 TIPPER x
2 SENSORS ARE BUSY
3007 TIPPER x
CARD-IN ERROR
3008 TIPPER x
CARD-OUT ERROR
3050 TIPPER x
RIBBON ERROR
3057 TIPPER x
TIPPER TEMPERATURE LOW
3058 TIPPER x
TIPPER TEMPERATURE HIGH
5051 TIPPER x
TIPPER ERROR
5055 TIPPER x
TIPPER PRESSURE ERROR
5056 TIPPER x
TIPPER TEMPERATURE ERROR
System 7000 Operator Manual
POSSIBLE CAUSES
Communication error with the Tipper board.
System error; please contact the technical support.
System error; please contact the technical support
Card already present inside the module while expected free.
Card jam. Remove the card.
Error on module card input. Check if:
a) Card jam;
b) Card-in sensor damaged;
c) Transport Motor damaged.
Error on module card output. Check if:
a) Card jam;
b) Card-out sensor damaged;
c) Transport Motor damaged.
Tipper ribbon finished or broken.
Tipper temperature too low
Tipper temperature too high
The Tipper can’t reach or leave its home position; check if:
a) Home sensor damaged;
b) Pad motor damaged.
The Tipper pad has not enough pressure.
Check the pad motor.
Tipper temperature out of range
Rev. 1.3
Page 41/48
Chapter 4 – Error List
ERROR CODE
0001 THERMO x
NOT CONNECTED
0002 THERMO x
NACK ANSWERED
0003 THERMO x
RESET (NACK-3!!)
5100 THERMO x
UNKNOWN ERROR
5101 THERMO x
COMMAND ERROR
5102 THERMO x
PARAMETER ERROR
5103 THERMO x
COORDINATES ERROR
5104 THERMO x
NUMBER OF PARAMETERS ERR
3105 THERMO x
FLASH MEMORY ERROR
5106 THERMO x
SECURITY ID ERROR
5107 THERMO x
SENSOR ERROR
5108 THERMO x
END OF RIBBON
5109 THERMO x
RIBBON DETECT ERROR
5110 THERMO x
CARD TRANSPORT ERROR
5111 THERMO x
INPUT ERROR IN PRINT MOD
3112 THERMO x
OUTPUT ERROR IN PRINT MOD
5113 THERMO x
EDGE INPUT CARD IN PRINT M
5114 THERMO x
MOVING BACK ERROR
5115 THERMO x
PRINT HEAD COVER OPEN
5116 THERMO x
HEAD TEMPERATURE ERROR
5117 THERMO x
HEAD TRANSPORTATION ERROR
5118 THERMO x
COMMUNICATION ERROR
System 7000 Operator Manual
POSSIBLE CAUSES
Communication error with the Thermo board.
System error; please contact the technical support.
System error; please contact the technical support
Unknown error.
Wrong command sent.
Wrong parameter value.
Wrong coordinates values.
Wrong parameters values.
Hardware error.
Mismatch between Thermal printer ID card in buffer and ID
card present under the printing head.
Error on one of the printer sensors.
Ribbon finished.
Wrong ribbon type or ribbon parameter.
Error during the card navigation; check the transport
motors, belts and rollers.
Card stopped in the module input; check the input motor,
belts and rollers
Card stopped in the module output; check the output
motors, belts and rollers.
The card doesn’t enter into the printer; check the modules
alignment.
Error during the card backward navigation; check the
transport motors, belts and rollers.
The print head is up.
Low print head temperature.
Print head movement error; check the print head motor.
Communication error between the PC and the printer.
Rev. 1.3
Page 42/48
Chapter 4 – Error List
ERROR CODE AND DESCRIPTION
0001 EMBOSSER x
NOT CONNECTED
0002 EMBOSSER x
NACK ANSWERED
0003 EMBOSSER x
RESET (NACK-3!!)
3039 EMBOSSER x
X HOME ERROR
SYMPTOM AND CORRECTIVE ACTION
Communication error with the Embosser board.
System error; please contact the technical support.
System error; please contact the technical support
Check for X home sensor:
a) X home sensor is dirty: clean it with compressed air or
lint free cloth;
b) X home sensor isn’t connected correctly on the board.
Check that all pulleys are fixed on the shaft.
Check X motor connection.
Check the belt’s state.
Card is picked by embossing clamp and is taken to the
embosser’s exit.
3040 EMBOSSER x
X END ERROR
3041 EMBOSSER x
Y HOME ERROR
3042 EMBOSSER x
Z HOME ERROR
Check for X end sensor:
a) X end sensor is dirty: clean it with compressed air or lint
free cloth;
b) X end sensor isn’t connected correctly on the board;
c) Remove any impediments along the X embossing travel;
d) Check that all pulleys are fixed on the shaft;
e) Check X motor connection;
f) Check the belt’s state.
Card is embossed in a wrong way.
Remove any impediments along the embossing Y travel.
The card can even be picked or not by the embosser’s clamp
and the embossing sequence isn’t completed correctly.
If the clamp picks the card but doesn’t start punching and
the drum keeps on moving:
a) Check drum motor home sensor;
b) Drum motor home sensor is dirty: clean it with
compressed air or lint free cloth;
c) Drum motor home sensor isn’t connected correctly on the
board.
If the card is picked, but it is embossed in a wrong way
check:
a) Belt tension;
b) If pulleys are fixed on the shafts;
c) If the motor is moving correctly or it stalls.
If the card is picked by the clamp but the drum doesn’t
move check:
a) Drum motor connection on the board.
3046 EMBOSSER x
COVER OPEN
3008 EMBOSSER x
CARD-OUT ERROR
3053 EMBOSSER x
CARD LOST
System 7000 Operator Manual
Machine cover open
Check the output sensor or card jam.
Card correctly loaded and then lost by the Embosser card
guide.
Rev. 1.3
Page 43/48
Chapter 4 – Error List
ERROR CODE AND DESCRIPTION
3054 EMBOSSER x
CARD MISFEED
5043 EMBOSSER x
X EMBOSS ERROR
5044 EMBOSSER x
Y EMBOSS ERROR
5045 EMBOSSER x
Z EMBOSS ERROR
5047 EMBOSSER x
PUNCH ERROR
SYMPTOM AND CORRECTIVE ACTION
The clamp holds the card, but the embossing cycle doesn’t
start.
Check the entry sensor:
a) Entry sensor is dirty: clean it with compressed air or lint
free cloth;
b) Entry sensor isn’t connected correctly on the board.
The clamp moves straight to embossing area without a card
or after having made a bad noise:
a) Check for Y home sensor;
b) Y home sensor is dirty: clean it with compressed air or
lint free cloth;
c) Y home sensor isn’t connected correctly on the board;
d) Check Y motor electrical connections;
e) Check if the pulley is fixed on Y motor shaft;
f) Check belt state.
X-axis card movement error; reject the card.
See ERROR 3039
Y-axis card movement error; reject the card.
See ERROR 3041
Z-axis card movement error; reject the card.
See ERROR 3042
The embossing clamp picks the card but the embossing
sequence isn’t completed correctly.
Check for any mechanical impediments along the embossing
leverage.
If the card is picked by the embosser’s clamp but just one
character is embossed:
a) Check punch motor home sensor;
b) Punch motor home sensor is dirty: clean it with
compressed air or lint free cloth;
c) Punch motor home sensor isn’t connected correctly on the
board.
If the card data aren’t embossed correctly check:
a) Belt status;
b) All pulleys are fixed on the shaft correctly.
The card is picked correctly by the embosser’s clamp and it
is placed correctly under the drum, but the embosser
mechanism doesn’t start, check:
a) If the embossing motor is connected correctly on the
board;
b) replace the motor.
Card not punched in infill way.
5048 EMBOSSER x
INFILLER ERROR
If ribbon is finished replace it.
If ribbon isn’t finished:
a) Check if ribbon is installed correctly;
b) check if ribbon advance sensor is working correctly.
5049 EMBOSSER x
CASSETTA ERROR
Infiller cartridge movement error.
0001 SERVICE-BOARD
NOT CONNECTED
Communication error with the Service board.
0002 SERVICE-BOARD
NACK ANSWERED
System error; please contact the technical support.
0003 SERVICE-BOARD
RESET (NACK-3!!)
System error; please contact the technical support
System 7000 Operator Manual
Rev. 1.3
Page 44/48
Chapter 5 – Cleaning and maintenance
Chapter 5 – Cleaning and maintenance
To ensure that the system operates correctly, it is necessary to carry out
periodic cleaning of some of the components that otherwise could cause
problems in cards production.
To clean all the transport rolls of the system and the Encoder module
head, you must absolutely use isopropyl alcohol; at this purpose you can
use an apposite cleaning card supplied by Matica System.
It is recommended to use the aforesaid products only for the indicated
components, in order to avoid damaging the system.
It is also useful to carry out a periodic general cleaning of the system, by
using a vacuum cleaner every week or 10,000 cards performed.
5.1 Thermal Printer cleaning
Classic cleaning of the printer
It is recommended to clean the print engine periodically every cycle of
5000 printed cards by means of a cleaning card.
Procedure:
•
•
•
•
Remove the ribbon out of the Printer.
Put the head-bracket down.
Place a cleaning card at the input of the print engine.
Use the command “Clean”.
The cleaning card will be taken, and will pass several times in the machine
to clean the transport rollers and the print head.
Note: If the cleaning sequence doesn’t run, check that the ribbon has
been removed from the printer.
System 7000 Operator Manual
Rev. 1.3
Page 45/48
Chapter 5 – Cleaning and maintenance
Print head cleaning
It is recommended to clean the print head periodically after each
replacement of the ribbon, using a swab.
Procedure:
First ensure that the system is powered off.
• Lift the print head bracket.
• Take a swab and press the tube to release the alcohol.
• Using the swab, rub the surface of the head softly.
The printer should not be used for 2 minutes after a cleaning as the print
head needs to be perfectly dry.
Advanced cleaning of the transport rollers
Sometimes it is necessary to make an advanced cleaning of the rollers
(about 50000 cards)
Procedure:
• Use the command “Roller 1” to rotate the module transport rollers.
• Use a swab to clean each of the rollers.
• Use the command “Roller 0” to stop the transport rollers.
System 7000 Operator Manual
Rev. 1.3
Page 46/48
Chapter 5 – Cleaning and maintenance
5.2 Preventive maintenance schedule
The S7000 Card Personalization Systems have been designed and
manufactured using high quality and high technologies materials
guaranteeing so, reliability, performance and long life.
Nevertheless to have always the best performances of the system it’s
advisable to make periodical inspections and preventive maintenances
taking under control the parts listed in the “Preventive Maintenance
Schedule”.
The “Preventive Maintenance Schedule” includes all the operations and
actions fundamental for the reliability of the system and must be
performed by qualified technical personnel.
The non correct or missing maintenance execution can carry out the decay
of the warranty in every form and type.
PREVENTIVE MAINTENANCE SCHEDULE
Time
Cleaning and Lubrication
Controls and inspections
Daily or
5.000 cards
- Cleanliness of all machine rubber rolls
- Cleanliness of encoding head
- Cleanliness of thermal print head
Weekly or
25.000 cards
- Cleanliness and removal of dust and dirty
from the machine
- General Visual Inspection
Monthly or
100.000 cards
- Cleanliness and removal of dust and dirty
from the machine
- General Visual Inspection
- Cleanliness and lubrication of all machine
moving axis.
- Embossing X Axis Belt (tension and
integrity)
Note: only PTFE oil must be used and few
drops must be put
- Lubrication/greasing of Embossing Pins
Striker
- Embossing Y Axis Belt (tension and
integrity)
- Multichip Elevator belt (tension and
integrity)
Replacement
- Embossed character height
- Drum Home Position
Six months or
500.000 cards
- Cleanliness of sensors
- Tipper Pad (pressure and integrity)
- Encoding head
- Machine bearings
- All machine belts
- No play on mechanical axis
Yearly or
1.000.000 cards
- Power Supply output voltages
- All machine
springs
- Embossing punch cycle
- All machine offset
- Drum wheel & Drum Motor Pulley for
joining
- All machine belts
- All machine rolls
- Embossing Arm
Bearing
- Tipper Pad
The above schedule is referred to a working cycle of 8 hours having 500
cards per hour as throughput.
NOTE:
Belts, Rubber Rolls, Springs, Gears & Pulley, Encoding Heads and Thermal
Printer Heads (except the electrical part) are considered worn out parts
and not covered by machine warranty.
System 7000 Operator Manual
Rev. 1.3
Page 47/48
DECLARATION OF CONFORMITY
Declares that the product
System 7000
Has been designed and constructed to comply fully with the following EU Directives:
-
Machinery Directive (2006/42/EEC)
Low Voltage Directive (2006/95/EEC)
Electromagnetic Compatibility Directive - EMC (2004/108/EEC)
WEEE Directive (Waste Electrical and Electronic Equipment) (2002/96/EC)
RoHS directive (waste electrical and electronic waste, substance
prohibitions) (2002/95/CE)
The declaration is based upon compliance of the product to the following standards:
EN 55022:2006+A1:2007
EN 55024:1998 + A1:2001 + A2:2003
EN 61000-3-2:2006 + A1 2009 + A2:2009
EN 61000-3-3:2008
EN 60950-1:2006+ A1:2009 + A11:2010
EN 6024-1:2006
Quality Manager
MATICA SYSTEM S.r.l.
Via Guido Rossa 4/6
20037 Paderno Dugnano (MI)
Italy