MX 2000 Owners

Datacard MX2000
Card Issuance System

Owners Manual
September 2011
Part No. 539675-001, Rev J
Liability Statement
Please do not attempt to operate or repair this equipment without adequate
training. Any use, operation, or repair in contravention of this document is at
your own risk.
Proprietary Notice
All drawings and information herein are the property of DataCard Corporation.
All unauthorized use and reproduction is prohibited.
Trademark Acknowledgments
Datacard is a registered trademark and service mark of DataCard Corporation in
the United States and other countries.
MX2000 and CardGard are trademarks of DataCard Corporation.
Windows is a registered trademark of Microsoft Corporation.
All other product names are the property of their respective owners.
Datacard Group
11111 Bren Road West
Minnetonka, MN 55343-9015
Phone: 952-933-1223
Fax: 952-933-7971
www.datacard.com
2006-2010, 2011 DataCard Corporation. All rights reserved.

Printed in the United States of America.
ii
Contents
Chapter 1: Introduction __________________________________________
1-1
System Overview _____________________________________________________ 1-2

Related Documents ___________________________________________________ 1-4
Starting and Stopping the System ______________________________________ 1-5
Pausing and Resuming the System _____________________________________ 1-6
Module Interlocks_____________________________________________________ 1-7
Removing AC Power __________________________________________________ 1-8
Interpreting Module Status Lights _______________________________________ 1-9
Computer BIOS Battery _______________________________________________ 1-10
Ordering Supplies ____________________________________________________ 1-10
CardGard Module Safety Information _________________________________ 1-11
CardGard Supply Film Precautions ________________________________ 1-11
Ultraviolet (UV) Light Warning _____________________________________ 1-12
Module Warning Labels ______________________________________________ 1-13
Chapter 2: Installation ___________________________________________
2-1
Specifications and Requirements ______________________________________ 2-2

Electrical Requirements____________________________________________ 2-2
Power Consumption ___________________________________________ 2-2
Permissible Current Load _______________________________________ 2-2
Electrostatic Discharge Susceptibility____________________________ 2-2
Physical Requirements _____________________________________________ 2-3
Dimensions ____________________________________________________ 2-3
Floor Space ___________________________________________________ 2-5
Environmental Requirements _______________________________________ 2-5
Storage Environment___________________________________________ 2-5
Operating Environment ________________________________________ 2-5
Audible Noise _________________________________________________ 2-5
Unpacking and Installation of New System _____________________________ 2-7
Adding a Module to an Existing System ________________________________ 2-7
Preparing the System ______________________________________________ 2-7
Inserting the New Module_________________________________________ 2-11
CardGard Module Adjustments _______________________________________ 2-14
UV Lamp Housing Gasket and Latch Adjustment ___________________ 2-14
UV Housing Interlock Activator Adjustment_________________________ 2-17
Removing Panels and Hoods _________________________________________ 2-19
Controller Rear Security Panel_____________________________________ 2-19
Controller Front Panels ____________________________________________ 2-21
Controller Side Panel _____________________________________________ 2-22
Hood Endcap Cover _____________________________________________ 2-23
Module Front Panel ______________________________________________ 2-24
Module Rear Panel and Hood Assembly ___________________________ 2-24
Disconnecting Cover Latches_________________________________________ 2-26
Expansion Kits _______________________________________________________ 2-27
iii
Additional Cooling Fans __________________________________________

Additional Ethernet Switches ______________________________________
Auxiliary AC Power Inlet___________________________________________
Optional Kits _________________________________________________________
Installation Troubleshooting___________________________________________
Chapter 3: Preventive Maintenance ______________________________
2-27
2-27
2-27
2-27
2-29
3-1
Overview_____________________________________________________________ 3-2
Cleaners, Tools, and Supplies __________________________________________ 3-2
System Preventive Maintenance Tasks _________________________________ 3-3
Module-Specific Preventive Maintenance Tasks ________________________ 3-4
Card Cleaning Module ____________________________________________ 3-4
Card Output Module ______________________________________________ 3-4
CardGard Topcoat Module________________________________________ 3-4
Single-Step Color Printing Module __________________________________ 3-5
Controller Module _________________________________________________ 3-7
Graphics Printing Modules _________________________________________ 3-7
Magnetic Stripe Encoding Module ________________________________ 3-11
Topper Module___________________________________________________ 3-13
Smart Card Module ______________________________________________ 3-14
Basic Topcoat Module____________________________________________ 3-15
Chapter 4: Loading Supplies _____________________________________
4-1
Introduction __________________________________________________________ 4-2

Card Cleaning Module ________________________________________________ 4-2
Card Input Module____________________________________________________ 4-4
CardGard Topcoat Module____________________________________________ 4-6
Replacing CardGard Supply Film___________________________________ 4-6
Repairing Broken CardGard Film ___________________________________ 4-8
Embossing and Indent Module_________________________________________ 4-9
Label Affixing Module ________________________________________________ 4-11
Graphics Printing Modules____________________________________________ 4-13
Topping Module _____________________________________________________ 4-14
Basic Topcoat Module _______________________________________________ 4-16
Single-Step Color Module ____________________________________________ 4-17
iv
Revision Log
MX2000 Card Issuance System Owners Manual
Revision
Date
April 2007
August 2007
September 2007
August 2008
May 2009
February 2010
June 2010
October 2010
September 2011
Description of Changes
First release of this document
Release of Multi-Card Buffer module
Release of Bar Code Scanner module
Release of Basic Topcoat module
Add card loading information to chapter 4.
Fix information for new PC.
Update for agency compliance and changes to PM.
Update to move installation information with
unpacking instructions.
Update for release of Single-Step Color module.
Regulatory Compliance
Notice for USA (FCC Notice)
This equipment generates, uses, and can radiate radio frequency energy. If it is
not installed and used in accordance with this instruction manual, it may interfere
with radio communications. This equipment has been tested and found to be
within the limits for Class A computing devices, pursuant to Title 47 CFR Part 15
Subpart B of FCC rules, designed to provide reasonable protection against radio
interference in a commercial environment. Operation of this equipment in a
residential environment may possibly cause interference. In the event of
interference, the users, at their own expense, will be required to take whatever
measures are necessary to correct the problem.
Notice for Canada

This digital apparatus does not exceed the Class A limits for radio noise for
digital apparatus set out in the Radio Interference Regulations of the Canadian
Department of Communications. The term IC: before the equipment
certification number only signifies that the Industry Canada technical
specifications were met.
Le prsent appareil numrique n'met pas de bruits radiolectriques dpassant
les limites applicables aux appareils numriques de la classe A prescrites dans le
Rglement sur le brouillage radiolectrique dict par le ministre des
Communications du Canada.
Notice for Europe

We hereby certify that this Datacard system complies with EMC Directive 89/
336/EEC and R&TTE Directive 1999/5/EC. This system conforms to Class A of
EN 55022 and to EN 301 489-5. Operation of this equipment in a residential
environment may possibly cause interference. In the event of interference, the
users, at their own expense, will be required to take whatever measures are
necessary to correct the problem.
Notice for Taiwan/China
Notice for Japan

This equipment is in the Class A category of information technology equipment
based on the rules of the Voluntary Control Council for Interference by
Information Technology Equipment (VCCI). When used in a residential area,
radio interference may be caused. In this case, the user may be required to take
appropriate corrective actions.
Safety
All Datacard products are built to strict safety and reliability specifications in
accordance with UL60950-1 and CUL requirements; therefore, safety issues
pertaining to operation and repair of Datacard equipment are primarily
environmental and human interface.
The following basic safety tips are given to make sure of safe installation,
operation, and maintenance of Datacard equipment and are not to be considered
as comprehensive on matters of safety.
vi
Safe Environment
Connect equipment to a grounded facility power source. Do not defeat

or bypass the ground lead.
Place the equipment on a stable surface, and make sure that the floors
in the work area are dry and non-slip. Insulated rubber floor mats are
preferred.
Know the location of equipment branch circuit interrupters or circuit

breakers and how to turn them on and off in case of emergency.
Know the location of fire extinguishers and how to use them. Use only
ABC type extinguishers on electrical fires.
Know local procedures for first aid and emergency assistance at the
customer facility.
Use adequate lighting at the equipment.
Maintain the recommended range of temperature and humidity in

equipment area.
Do not use this product in an environment containing volatile or

flammable compounds.
Safe Human Interface
Use proper lifting techniques when moving or installing the

equipment.
Use standard electrostatic discharge (ESD) precautions when working

on or near electrical circuits.
Do not defeat or disconnect safety interlocks on covers.
vii
viii
Chapter 1: Introduction
This chapter provides general information related to the MX Series
systems.
System Overview_____________________________________________________ 1-2

Related Documents __________________________________________________ 1-4
Starting and Stopping the System _____________________________________ 1-5
Pausing and Resuming the System ____________________________________ 1-6
Module Interlocks ____________________________________________________ 1-7
Removing AC Power _________________________________________________ 1-8
Interpreting Module Status Lights ______________________________________ 1-9
Computer BIOS Battery ______________________________________________ 1-10
Ordering Supplies ___________________________________________________ 1-10
CardGard Module Safety Information ________________________________ 1-11
CardGard Supply Film Precautions ________________________________ 1-11
Ultraviolet (UV) Light Warning _____________________________________ 1-12
Module Warning Labels______________________________________________ 1-13
1-1
System Overview
The MX Series systems are modular card issuance systems with a series of
modules that work together to complete the personalization of elements on a
card. Each possible module in the MX2000 system is described in the following
table.
Module
Description
Bar Code Scanner/

Buffer
This optional module reads the bar code on a card, sends the
information to the Controller (for Read/Lookup function), and
passes the card to the next module.
Card Cleaning
This module cleans the card in the system prior to printing graphics
or color or before applying coatings. The module provides a dual
cleaning system that removes dirt and dust contaminants from the
card.
Card Flipper
This module rotates cards around a vertical axis for back side
personalization in the downstream modules. An MX Series system is
typically configured with a pair of Flipper modules. The first flipper
rotates the card 180 degrees. After processing, the second flipper
rotates the card back to its initial orientation.
Card Input
This module feeds cards into the system. Multiple Card Input
modules can be installed in a system to allow multiple card stocks
to be selected within a single card run or to increase the machines
card supply capacity for large jobs.
Card Output
This module has a tray to receive good cards and one for rejected
cards.Multiple Card Output modules may be installed within a
system in order to expand output capacity or to allow cards
groupings to be separated for quality control, downstream
processing/handling, or varying delivery methods.
CardGard UV-Curable
Topcoat
This module covers the entire front surface of a card with a

transparent, UV-cured, topcoat film. The topcoat film is first
laminated onto the card's surface and then cured by UV light
pulses. The CardGard module should be placed in the system
downstream of any printing modules and just upstream of the
Embossing module(s). Systems that have a CardGard module
should also have an upstream Card Cleaning module (even when
there is no Graphics module), so that the CardGard topcoat is
placed onto a clean card.
Single-Step Color
Printing
This module prints full-color, high-resolution photos and images

directly on the card. This module allows near-edge printing using
dye diffusion, thermal transfer technology.
1-2
Introduction
Module
Description
Embossing/Indent
This module performs embossing on the front of a card. It can

emboss multiple fonts and a wide range of special characters with
the 112-character emboss wheel. A module with the indent option
installed can also perform indent printing on the front, back, or both
sides of the card.
Up to two Embossing modules can be used in a single system.
Position all Embossing modules upstream of any Topping modules
and downstream of a CardGard module.
Graphics Printing
The Front or Back Graphics modules print monochrome custom

graphics on PVC cards using thermal transfer technology.
Label Affixing
This module applies a removable preprinted or blank adhesive label

to the front of a card. A set of Card Rotation (Flipper) modules is
required to apply a label to the back side of a card. The first Card
Rotation module will rotate the card so the label is affixed to the
back when it goes through the Label Affixing module. The other
Card Rotation module will rotate the card back to its original
position.
Blank labels can be printed on a per-card basis. Position the Label
Affixing module(s) directly upstream of the Graphics Printing
module when using Datacard UltraPrint labels.
If applying only preprinted labels, Datacard recommends
positioning the Label Affixing module directly upstream from the
Output module.
Magnetic Stripe
Encoding
This module provides high speed and reliable magnetic stripe

encoding. The write/read head writes the magnetic data at
specific track locations on the front or back of the card; it then
reverses and reads the information to verify it.
Smart Card
Personalization
This module provides flexible, high quality smart card

personalization of contact or contactless cards. The modular
architecture allows for the growth of smart card capacity, as
needed, to accommodate longer encoding times for contact
cards without limiting system throughput. The contactless stations
personalize cards with speed, accuracy and security. The module
can be configured with either up to six contactless programming
stations or up to 11 contact stations to load any combination of
applications onto cards within the same job.
System Controller
The System Controller provides the controls for the MX Series system
and is the primary interface point for the operator. It includes the
hardware and software needed to control the activities performed
by each module and to manage the system as a whole.
Each system has a dongle plugged into the Controller computer.
The dongle needs to be in place for the system to work.
1-3
Module
Description
Basic Topcoat
This module applies a protective coating of clear or holographic

coating to monochrome or color-printed surfaces on a card. The
topcoat material is applied horizontally from edge to edge on a
card. Special rollers enable laminate patterns that protect certain
card features such as a smart card chip.
Topping
This module applies a color foil to the tops of embossed characters

on the card surface. The module has the capability of topping
characters from the lower edge of the card up to the bottom of the
magnetic stripe.
Related Documents
The following documents provide information for the user of an MX2000 system.
Description
Part No.
Available on CD
CIS Data Formatting Manual
539684-001
this library and 539341-001
CIS Software Administrators Guide
539523-00x
539787-001
Unpacking and Installation Manual
539925-001
In paper with system and on this

library
Illustrated Parts Manuals for Modules
many
this library
CardGard Material Safety Data Sheet
---
this library
System Safety Rules
539576-001
this library
Preventive Maintenance Tools and

Supplies List
---
this library
Datacard Certified Supplies
---
this library and newer ones

on www.datacard.com
User Animations
---
this library
1-4
Introduction
Starting and Stopping the System

Once the system is plugged into AC power, turn on the Controller computer by
pressing the power button on the front of the computer.
Turn off the Controller computer by using the standard shutdown command
through the computer software as described in the CIS Administrators Guide.
Turn the system hardware on or off by using the E-stop switch on the front of the
Controller module. This switch controls all AC power to the modules, the cooling
fans, and to all additional power cords that have been installed on the system.
Turn on the system by rotating the switch clockwise. The current state (ON or
OFF) is visible in the dial cutout.
Turn off the hardware by turning the switch counterclockwise.
1-5
Pausing and Resuming the System

Pause a system to change supplies, perform preventive maintenance, or perform
other activities. The system can be paused using the mouse, monitor, and
software, or by pressing the Pause/Resume button located on the Card Output
module. The Pause/Resume button is useful when the operator needs to stop the
machine but is not near the Controller computer.
The Pause/Resume button on the Output module shows the following machine
states.
Green flashing lightMachine is in the
paused state.
Green light on, but not flashingMachine
is in the normal running or idle state.
No lightMachine is temporarily
between the pause and running states.
1-6
Introduction
Module Interlocks
Module interlocks are a safety feature that protects operators from injury. Lifting
a hood causes the motors to be disabled and the interlock indicator light for the
module(s) to go off. Interlock lights for the adjoining modules go off, but the
adjoining modules finish processing cards, park them, and then sit idle with
motors enabled.
Most systems have connected hoods so that all or many modules lose power to
the motors when hoods are opened. Wider modules have one interlock on the
upstream side.
The Output module has a special Pause/Resume switch and a special interlock
that does not affect other modules if the Output module cover is opened.
Interlock
Light
Top of Module
Right Side
1-7
Removing AC Power
Any time service is being performed on the systemespecially at the rear
enclosure where high voltage power is presentAC power should be removed
from the system.
Turning off the E-Stop switch on the Controller module removes power from all
modules and the system fans. It also removes power from modules that are
supplied by additional power cord inlets.
The Controller computer and the Ethernet switch box are disconnected from the
AC main by first shutting down the Controller computer and then removing the
power cord, or by switching off the customer-provided circuit breaker. Once the
computer has been turned off, the power cord(s) can be unplugged.
Procedure
1. Turn off the Controller computer using the standard shutdown instructions
for the computer software.
2. Rotate the E-stop switch counterclockwise to OFF.
3. Unplug the power cord(s) from the AC power source.
1-8
Introduction
Interpreting Module Status Lights

Each module (except for the Card Input and Output modules) has a status light
located on the front panel to alert the operator when the module needs attention.
When the light is either flashing or solid on, refer to the error message on the
Controller screen for more information.
FlashingModule error or failure in

normal operation; failure in module
firmware download during boot.
Not FlashingSupplies are low or
the module is in a paused state.
No LightModule is running
normally or power is off.
When a module error occurs, the other modules will process their current
tasks until completed. At that point, the system enters a paused state (all
module status lights are on, but not flashing).
1-9
Computer BIOS Battery

The motherboard in the Controller computer contains a battery backup for the
system BIOS. If the battery is improperly connected, damage to the motherboard
can result. Replace the battery with only the same or equivalent type
recommended by the manufacturer. Dispose of used batteries according to the
manufacturers instructions.
Ordering Supplies
Supplies for the modules are listed in the following locations. Refer to these
resources for supplies ordering information.
1-10
Supplies ordering information file (pdf) on the Owners Library CD that ships
with the system.
Datacard Web Site (www.datacard.com)

Datacard Home | Products & Solutions | Supplies
Introduction
CardGard Module Safety Information

If your system includes a CardGard module, be aware of the following safety
precautions when working with the CardGard supply film and around the
ultraviolet (UV) light used in the module.
CardGard Supply Film Precautions

The CardGard topcoat material is a clear, plastic, UV-curable film. The film is
sensitive to heat and UV light. Excessive heat can cause a roll of film to telescope.
To prevent this, place the supply weight on top of the supply roll. UV exposure
can cause discoloration or opacity on the edges of the film. UV light can also dry
the coating so that it does not stick as easily to cards, hampering machine
performance.
To protect the film from UV light, always store partial rolls of CardGard film in
the original container. If the CardGard module will not be used for three or more
days, remove the CardGard film from the module and store it in the original
container. For instructions on removing and replacing the CardGard film, refer to
page 4-6.
Caution: Repeated contact of the skin to uncured CardGard coating material
can cause minor skin irritation or sensitization (possibly leading to allergic
reactions) in some individuals. Sensitive individuals should wear gloves
when handling the uncured rolls of film. As a safeguard, wash your hands
with soap and water after touching the uncured material.
Caution: Do not touch eyes with gloves or hands that have been in contact
with the uncured CardGard material. Accidental transfer of uncured
CardGard particles (acrylate monomers) to the eyes can cause redness and
tears. If you experience these symptoms, flush eyes with large quantities of
water. Contact a physician if irritation persists.
For more material safety information, refer to the CardGard Material Safety Data
Sheet on the Owners Library CD.
1-11
Ultraviolet (UV) Light Warning

Caution: Ultraviolet (UV) light is used in the CardGard
module to cure the laminated film on the cards surface. UV
light can cause sunburns and damage to the retina of the
eye; however, the CardGard module is designed to prevent
leakage of UV light. Special gaskets, shutters, and materials
shield the user from exposure to UV light. Interlocks are
designed to break the electrical connection when the UV
lamp housing assembly is opened.
Caution: When working around the CardGard module,
observe standard precautions. Do not attempt to defeat any
of the safety mechanisms in the module. Although UV light
leakage is unlikely, it is recommended that you wear UV
eye protection that blocks UV radiation under 400nm as a
precaution.
1-12
Introduction
Module Warning Labels

When working around the system, observe the following warning and caution
labels affixed to various areas on the equipment.
Warning Label
Description
Heat Source
Parts that contain this warning label can become very hot
during operation.
Wait until the part cools or wear protective gloves to
prevent burns when making contact.
High Voltage Power Supply
This warning label is found on parts that contain a high
voltage current.
To avoid a possible electric shock, always remove power
from the module (as well as turning off power to the
Controller) before servicing.
Pinch-Point
This warning label is found on moving parts that can
potentially crush and cut.
Do not operate with the guard removed.
1-13
1-14
Introduction
Chapter 2: Installation
This chapter provides information such as requirements, site
preparation, and installation.
Specifications and Requirements _____________________________________ 2-2

Electrical Requirements ____________________________________________ 2-2
Power Consumption ___________________________________________ 2-2
Permissible Current Load _______________________________________ 2-2
Electrostatic Discharge Susceptibility ____________________________ 2-2
Physical Requirements _____________________________________________ 2-3
Dimensions ____________________________________________________ 2-3
Floor Space ___________________________________________________ 2-5
Environmental Requirements _______________________________________ 2-5
Storage Environment ___________________________________________ 2-5
Operating Environment ________________________________________ 2-5
Audible Noise__________________________________________________ 2-5
Unpacking and Installation of New System ____________________________ 2-7
Adding a Module to an Existing System________________________________ 2-7
Preparing the System ______________________________________________ 2-7
Inserting the New Module _________________________________________ 2-11
CardGard Module Adjustments ______________________________________ 2-14
UV Lamp Housing Gasket and Latch Adjustment ___________________ 2-14
UV Housing Interlock Activator Adjustment _________________________ 2-17
Removing Panels and Hoods ________________________________________ 2-19
Controller Rear Security Panel _____________________________________ 2-19
Controller Front Panels ____________________________________________ 2-21
Controller Side Panel _____________________________________________ 2-22
Hood Endcap Cover _____________________________________________ 2-23
Module Front Panel _______________________________________________ 2-24
Module Rear Panel and Hood Assembly ___________________________ 2-24
Disconnecting Cover Latches ________________________________________ 2-26
Expansion Kits_______________________________________________________ 2-27
Additional Cooling Fans __________________________________________ 2-27
Additional Ethernet Switches ______________________________________ 2-27
Auxiliary AC Power Inlet ___________________________________________ 2-27
Optional Kits ________________________________________________________ 2-27
Installation Troubleshooting __________________________________________ 2-29
2-1
Specifications and Requirements

Prior to installing an MX Series system, make sure the site meets the
requirements listed in the following sections.
Electrical Requirements
The system requires single-phase, grounded, 180 to 264-volt, AC power source at
47 to 63 Hz. The Controller standard system power cord requires a dedicated
power drop with a 15-amp circuit (U.S.) or 16-amp circuit (most other countries).
Power Consumption
The power consumption of the system is the sum of the power consumption of
the Controller and all of the modules in the system. To see the maximum current
draw for each module, refer to the products data sheet on the Datacard Web Site
(www.datacard.com) or in the Sales section on PartnerPage.
Permissible Current Load

Because the system is modular, it is possible to exceed the permissible load on the
main Controller power cord. If the calculated load on the Controller power cord
or an auxiliary power cord exceeds 12.8 amps, additional power inlets and
cord(s) must be added to the system.
Electrostatic Discharge Susceptibility

A system can withstand an electrostatic discharge of 15 kV, 330 pF storage, and
1.5 k series resistance in tests simulating a human discharge to the outer surface
of the machine. This does not include direct discharge on printed circuit boards.
2-2
Installation
Physical Requirements
The following section contains the physical site requirements needed for an
MX Series system.
Dimensions
The dimensions and footprint values for the overall system are the sum of those
for the Controller and individual modules. Dimensions of the Controller module
are as follows:
Controller-Input
Width
31.3 inches (79.5 cm)
Controller Work
Surface Width
21.3 inches (54.1 cm)
Controller Height
37.1 inches (94.2 cm)
Controller Depth
31.8 inches (80.7 cm) deep
To top of cabinet
The dimensions of the standard MX Series module are as follows:

Module Width
10 inches (25.4 cm)
Module Height
50.1 inches (127.3 cm)
Module Depth
27 inches (68.6 cm)
The CardGard module is 30 inches (76.2 cm) wide. The Input and Output modules are 33.8
inches (85.9 cm) deep. The Topcoat module is double wide (20 inches).
The weight of the system should be taken into account before installing it in a
particular location. To determine the system weight, calculate the sum of the
weights for each module, the Controller, and any additional casters. The weight
values are listed in the following table.
Module/Item
Weight in Pounds/Kilograms
(Including Panels and Casters)
Bar Code Scanner
93/42.2
Card Cleaning
132/59.9
Card Flipper
93/42.2
Card Input (additional)
100/45.4
2-3
Module/Item
Card Output
100/45.4
CardGard Topcoat
320/145.2
Embossing (Indent)
123/55.8
Plus 7 lbs/3.2 kg per Indent mechanism
Graphics Printing
116/52.6
Label Affixing
100/45.4
Magnetic Stripe Encoding
85/38.6
Smart Card Personalization

(Contact or Contactless)
111/50.3
Plus 1.5 lbs/0.68 kg per programming station
System Controller-Input
300/136.1
Basic Topcoat
197/89.4
Topping
101/45.8
Additional Casters
2-4
Weight in Pounds/Kilograms
(Including Panels and Casters)
11/5 (per set)
Installation
Floor Space
The floor space required to install the system is dependent on the number and
type of modules included. To determine how much floor space is required,
calculate the following:
1. Controller-Input width 31.3 inches (79.5 cm) + [number of CardGard modules x
30 inches (76.2 cm)] + [number of all other modules x 10 inches (25.4 cm)] = Total
width of system
2. Total width x 33.8-inch (85.9-cm) depth = Floor space used by system
3. Floor space used + 36-inch (45.72-cm) clearance on all sides for service access
and airflow = Total floor space
The floor must be level and flat within 0.1 inch per foot (1 mm per 10 cm) in any
direction.
Environmental Requirements
The following tables contain environmental specifications for the system.
Storage Environment
Temperature
-50 F to 130 F (-46 to 54 C)
Relative Humidity
0% to 100% (Non-Condensing)
Operating Environment
Temperature
65 F to 80 F (18 C to 27 C)
Relative Humidity
20% to 85% (Non-Condensing)
Audible Noise
The audible noise level of a system is dependent on the installed modules and
card personalization data. The following configuration has been measured:
Controller, Card Input, Magnetic Stripe, Smart Card, Cleaning, Graphics Printing,
Card Output (at maximum speed).
Front Bystander Position
70.5 dBA to 73 dBA
Front Operator Position
72.5 dBA to 74.5 dBA
2-5
Measurements are sound pressure measurements with a handheld sound

meter at the front bystander (1.0 meter from machine, 1.5 meters high) or
operator (0.25 meter from machine, 1.5 meters high) positions per ANSI
S12.10-1985, section 11. All measurements are averages over 60 seconds (60 L
equiv.).
2-6
Installation
Unpacking and Installation of New System

Refer to the unpacking and installation instructions provided in the pocket on the
crate. An electronic copy of the instructions is provided on this Owners Library
CD.
Adding a Module to an Existing System

Perform the following procedure to add a module to an MX Series system. The
following diagram shows one possible scenario.
When the system is split into two halves, it will be necessary to support both
sides of the split. Larger systems have multiple caster sets in the middle of the
system that can be relocated to the split. However, for smaller systems, it will
be necessary to acquire an additional pair of casters (Part No. 562879-002).
Preparing the System

Caution: The system must be powered off and unplugged before beginning
this procedure.
You will need four jacks or an extra pair (two sets) of casters for module
support during this procedure.
1. Shut down the Controller and unplug the system. Make sure that all power
cords on multiple corded systems are unplugged.
2. Locate the point where the new module will be inserted.
2-7
3. Prevent the system from moving by setting the brakes for all casters on the
system, based on the type of caster.
Older casters: Turn the dial inside the caster
counterclockwise to engage the brakes by lowering
the foot.
Newer casters: Press down the ON side

to lock the brakes.
4. Disconnect the hoods between the modules to be split by loosening the

screws and sliding the bracket away from the other module. Refer to
Disconnecting Cover Latcheson page 2-26 for detailed instructions.
5. Remove the front panels and rear panel/hood assemblies from the two
modules being separated. Refer to the instructions beginning on page 2-19.
6. Install a caster set (or jack) under both the upstream and downstream
modules of the split. Except for the Controller and Output module casters,
casters may be relocated from other parts of the system for this operation.
A. Slide the caster channel (caster assembly) under the module.
B. Secure the front and rear of the caster channel to the module frame with
two screws on each end.
2-8
Installation
7. Disconnect the AC power cables from the modules being separated.

8. Disconnect all of the downstream module Ethernet cables and lay them to the
side for easy reconnection later. Do not remove the cables; just disconnect the
downstream end.
9. Remove the two screws that secure the upstream modules platform to the
downstream pier bracket. Save the screws for reuse later in this procedure.
10. Remove the six bolts that secure the two modules together. Save the bolts for
reuse later in this procedure.
2-9
11. On both the new module and the last upstream module in the system, loosen
the two module platform mounting screws from the upstream side of the
module platform (for CardGard, see the note below). This allows the
downstream side of the module platform to rise up on the spring-loaded
shipping posts.
To secure a CardGard module, make sure that the UV housing assembly
is unlatched to release any pressure from around the gasket on the cure
assembly. Then loosen the screws (3 and 4 shown in a previous figure) on
the mid-module mounting bracket (on the entry side of the cure
assembly) instead of on the upstream end as for other modules.
12. Release the caster brakes on the downstream section, and move the
downstream section of the system away from the fixed upstream section.
Older casters: Turn the dial inside the caster
clockwise to unlock the brakes by raising the foot.
2-10
Newer casters: Press down the OFF side

to unlock the brakes.
Installation
Inserting the New Module

1. Secure the new module to the upstream half of the system:
A. Insert the two alignment guides (1) of the new module into the alignment
openings (2) in the upstream module.
B. Use the two shipping screws (3 in the figure below) to attach the upstream
modules platform to the pier bracket of the downstream module.
2-11
C. Install the six frame bolts (4) that secure the two frames together.
2. Repeat step 1 to secure the downstream half of the system to the new module.
3. Tighten the two module platform mounting screws on the upstream side of
the platform (for CardGard, see the note below).
Do not place any screws in the original shipping screw locations (over the
mounting posts). This could warp the module platform plate.
For a CardGard module, tighten the screws on the module in the
following sequence to secure it in place. It is important to use this
sequence for correct card track alignment.
a. Front platform mounting screw (left side)
b. Front mid-module mounting screw (right side of cure assembly)
c. Rear platform mounting screw (left side)
d. Rear mid-module mounting screw (right side of cure)
4. Remove any jacks. If casters were used, leave them in place.
5. Reconnect the AC power cables on all of the module control boards. (Refer to
the figure in the Unpacking/Installation Instructions manual included on the
Owners Library CD for details.)
A. Connect the AC power cable from the upstream system module to the
new module.
B. Connect the AC power cable from (Down) on the new module to (Up) on
the downstream system module.
6. Compare the length of the new module Ethernet cable with the existing cables
and route a new cable of the correct length from the Controller to the
module.Reconnect all of the Ethernet cables to the modules, beginning with
the shortest cable connected to the new module.
7. Verify that all module platform and module frame bolts are fully tightened.
2-12
Installation
8. Replace the panel and hood assemblies and the front panels. Refer to page
2-19 for instructions. Reconnect the panel hoods and reattach with the bracket
screws.
9. Reconnect power to the Controller and power on the system. The Controller
should automatically identify the new module.
10. For safety reasons, make sure the interlock switch is working correctly by
using Diagnostics. Select Applications | Utilities | Diagnostics and click the
Sensors tab.
If the addition of the module requires that an auxiliary power kit be installed
on the system, the kit must be installed after the module. Refer to the power
kit specification or Auxiliary AC Power Inleton page 2-27 for more
information.
If your system includes a CardGard module, it is recommended that you
adjust the module after installation is complete. Refer to CardGard Module
Adjustmentson page 2-14 for instructions.
2-13
CardGard Module Adjustments

If you installed a CardGard module as part of your system, perform the following
adjustments after installation is complete.
UV Lamp Housing Gasket and Latch Adjustment

The UV lamp housing assembly gasket prevents UV light from leaking out of the
cure chamber. The latch holds the UV lamp housing assembly tightly to the cure
chamber to prevent light leakage.
This adjustment sets the compression of the gasket between the cure chamber
and the UV lamp housing assembly and adjusts the tightness of the latch.
Adjustment Procedure
1. With the system up and running and the module in Service mode, lift the
hood of the module.
Caution: Directly viewing UV light for extended periods can result in
permanent damage to the retinas. Do not proceed with the next step until the
high voltage indicator light on the UV lamp housing assembly is off.
2. After the high voltage indicator light (1 in the following figure) on the UV
housing assembly is off, release the latch (2) that secures the UV housing (3) to
the cure assembly. Pull the assembly back to open it.
If the left front panel of the module is in the way of completely opening the
UV housing assembly, you may need to remove it. For more information,
refer to the Module Front Panelon page 2-24.
3. Loosen (but do not remove) the screws (4) that secure the rear duct (5) to the
module base.
4. Set the UV lamp housing assembly gasket compression:
A. Loosen (but do not remove) the three screws (6) on the bottom of the UV
housing duct. There is one screw on each side and one in the center front.
B. Position each of the three screws in the center of each brackets slotted
opening, and then partially tighten the screws to hold them in place.
2-14
Installation
C. Push the UV housing assembly against the cure chamber and check to see
that there is even compression of the housing gasket (7 in the figure
below) against the face of the cure chamber (8) and of the UV assembly
against the rear duct (9) when compressing (25% to 75% of full
compression).
D. Loosen and re-tighten the UV housing screws (6) as needed to adjust the
gasket compression and angle.
2-15
5. Adjust the tightness of the UV housing latch:

A. Release the latch (2 in the previous figure) that secures the UV housing
assembly (3) to the cure assembly, and pull the assembly back to open it.
B. Loosen (but do not remove) the two screws that secure the latch (2) to the
side of the cure assembly (3).
Caution: Make sure you do NOT remove the screws. They are attached to
a small plate inside the assembly. It would require considerable time to
repair the assembly if the screws were removed.
C. Move the latch forward or backward in the slotted openings to adjust.
Partially tighten the screws to hold the latch in place.
D. Close the UV assembly and secure the latch.
E. Verify that the gasket (7) is compressed (25% to 75% of full compression)
on all sides of the face of the cure assembly (8).
F. Adjust the latch screws as needed to correct the tightness of the seal, and
tighten the screws.
6. Adjust the tightness of the rear duct gasket compression:
A. Close the UV assembly (3) and secure the latch (2).
B. Align the rear duct (5) with the UV housing assembly, push the rear duct
against the UV housing, and partially tighten the screws (4) to hold it in
place.
C. Check the gasket compression; you want a 1 to 2-card thickness of
compression against the housing (0.030 to 0.100 inch or 0.076 to 0.253 cm).
D. Once the compression is correct, tighten the screws (4) on the base of the
rear duct.
E. Unlatch the UV housing and re-latch it to ensure the gasket (9)
compression is even and at the thickness described above.
7. Replace the panels and close the hood.
8. Run some test cards. Watch the first cards being processed by the module to
be sure no (or minimal) light escapes at the gasket area.
9. If there is still excessive leakage, repeat this procedure until leakage is
minimized.
2-16
Installation
UV Housing Interlock Activator Adjustment

In the UV lamp housing assembly, the UV housing closed interlock switch detects
that the UV housing is in an operational position to prevent exposure to
ultraviolet (UV) light. This interlock switch needs to be closed to enable high
voltage power to be distributed to the housing for curing.
This adjustment controls the pivot throw of the interlock activator to ensure the
switch is closed when the UV lamp housing is latched closed.
Adjustment Procedure
1. With the system up and running and the module in Service mode, lift the
hood of the module.
2. Access the Diagnostics program by selecting Applications | Utilities |
Diagnostics.
3. Select the CardGard Module and then display the Sensors tab. The UV
housing closed interlock switch is listed on the screen (High Voltage
Interlock).
4. Make sure that the UV housing is closed and latched (1 in the following
figure).
5. Loosen the two locking nuts (2) on either side of the interlock switch (3) on the
cure bracket (4).
6. On the cure assembly base, manually adjust the bracket (4) position (forward
and back) until there is a transition on the computer screen of the interlock
switch changing states from Open to Closed.
7. Tighten the locking nuts (2). There can be a 0.020 to 0.030-inch (0.051 to 0.076cm) overtravel when adjusting the locking nuts.
2-17
2-18
Installation
Removing Panels and Hoods

Panels are the outside covers for all of the modules in the MX Series system.
Hoods are the see-through covers that protect the operator from the modules
moving parts. All modules have hoods except for Card Input, Card Output, and
the Controller.
Each module has an independent interlock switch and only one hood interlock.
For safety reasons, a module that is more than one module frame wide must have
each of its hoods connected together or the interlock on that module will not be
functional on all the hoods.
Use the procedures in this section to remove the module panels and hoods.
Controller Rear Security Panel

A security panel covers the back of the Controller computer to prevent tampering
or unauthorized connections to the Controller computer.
Removal Procedure
Be careful when removing and installing the security panel because the
computers cables pass through the opening in the panel and can be pulled
out of the computer or damaged.
1. Remove the screws from the Controllers two rear security panels (1 and 2 in
the following figure). Remove the screws from the Controllers rear security
panel, and lean the panel against the back of the Controller.
2. As necessary, add or remove any cable connections to the Controller
computer.
Make sure that the security dongle is plugged back into the same USB
port on the back of the computer. The system will not operate without the
security dongle. The dongle is attached to the Controller frame with a
steel cable to prevent accidental loss.
2-19
2-20
Installation
Controller Front Panels

The front panels of the Controller module are different from the front panels of
other modules. Use the following procedure for removing either of the
Controllers two front panels.
Removal Procedure
1. Loosen, but do not remove, the three screws (1) across the top of the panel (2
or 3).
2. Pull outward on the bottom corners of the panel to release the two latches on
the inside of the panel.
3. Pull the unlatched panel down and away from the module.
2-21
Controller Side Panel

The Controller module has a side panel with a cutout for a fan filter. Use this
procedure to remove the Controller side panel.
Removal Procedure
1. Loosen the three screws (1) on the front and the three screws (2) on the back of
the side panel.
2. Remove the panel (3) from the side of the Controller module.
Replacement Note
Inspect and clean the filter (4) before replacing the panel.
2-22
Installation
Hood Endcap Cover

A hood endcap cover is installed on two modules:
The module immediately downstream of the last Input module in the system.
The module immediately upstream of the first Output module in the system.
Removal Procedure
1. Remove the three screws (1) that attach the endcap cover (2) to the hood
assembly (3).
2. Carefully remove the endcap cover by pulling it down and away from the
hood, making sure to detach the clip (4) from the hood assembly.
2-23
Module Front Panel

Use this procedure to remove the front panel of any module, other than the
Controller. This procedure can also be used to remove the rear panel of the Card
Input or Card Output module, and the side panel of the Card Output module.
Warning: Removing the front panel from a module exposes high voltage
electrical components. Do not remove any panels when the system is plugged
into facility power.
Removal Procedure
This procedure refers to the figure on the following page.
1. Raise the modules hood (1).
2. Loosen, but do not remove, the single retaining screw (6) at the bottom center
of the front panel. It is in a slotted opening.
3. Lift the front panel (7) up and forward until the two screws on the frame clear
the keyhole openings (8) in the panel.
Module Rear Panel and Hood Assembly

Each modules rear panel is attached to a hood assembly. The hoods are usually
interlocked so they can be opened as a unit. Use this procedure to remove the rear
panel and hood assembly of any module.
Removal Procedure
This procedure refers to the figure on the following page.
1. Raise the modules hood (1).
2. Disconnect the latching bar (3) from adjacent hoods by removing the two
screws from the bar. Refer to Disconnecting Cover Latcheson page 2-26 for
further instructions.
3. Loosen, but do not remove, the two retaining screws (4) at the bottom of the
rear panel. These screws are in a slotted opening.
4. While standing behind the system, grasp the open hood on both sides just
above the hinges, and then lift up slightly and pull back to remove the hood
(1) and rear panel (5) assembly from the module.
5. Lay the hood assembly on its side on a piece of cardboard to prevent
scratching the clear plastic.
2-24
Installation
2-25
Disconnecting Cover Latches

When you are adding modules to, moving them within, or removing them from a
system, disconnect and reconnect the latches between covers as needed.
1. Remove the two screws from the side of the latch (2) where the module is to
be disconnected.
2. Reattach the two screws when adjoining modules are again in position.
3. If the covers will not be reattached, fix them so the latch does not protrude
when covers are lifted.
A. Remove the other two screws.
B. Rotate the latch.
C. Reaffix with the two screws.
Wider modules with more than one frame must have the cover latches
connected or the module interlock will not function.
2-26
Installation
Expansion Kits
The following kits may be needed on large systems. These kits are automatically
included in the order if your configuration requires additional cooling fans or
power inlets.
Additional Cooling Fans

Larger MX Series systems may require that an additional cooling fan be inserted
into a Card Output module. The cooling fan is available as an installation kit.
Refer to the Card Output Module Illustrated Parts Manual for the part number of
this kit. The kit is installed before shipping on new systems, supplied with
expansion systems as needed, or it can be ordered for a system. Refer to the kit for
installation instructions.
Additional Ethernet Switches

Systems with more than 24 modules or with more than two cameras need another
Ethernet switch installed into the Controller. The switch is installed on any new
systems that require one. If additional modules/cameras make one necessary in a
field system, the field kit is shipped with the modules.
Auxiliary AC Power Inlet

There will be times when a large system needs an auxiliary AC power inlet. Refer
to the System and Controller Module Illustrated Parts Manual for the part number of
this kit. Refer to the kit for installation instructions and guidelines on determining
when a system needs an additional inlet. Kits are sent with expansion systems
that exceed the power limit.
Each power inlet and power cord requires a dedicated power drop with a 15amp breaker (U.S.) or 16-amp breaker (non-U.S.).
Optional Kits
For some modules, an optional kit can be ordered and installed to add more
functionality to the module. Part numbers for these kits are provided in the
modules Illustrated Parts Manual. Refer to the kit for installation instructions.
Magnetic Stripe Encoding ModuleMagnetic Head Lift Kit

When you are running a job that does not require magnetic encoding, the
write/read head of the Magnetic Stripe Encoding module can be retracted by
the head lift kit so it is not subjected to unnecessary wear.
2-27
Embossing ModuleIndent Printing Mechanism

With the Indent mechanism, the Embossing module has the option to print
indent characters on the front, back, or both surfaces of cards.
Basic Topcoat ModuleHolographic Topcoat Registration Kit

This addition to the Basic Topcoat module enables a site to place a holograph
in a precise position on a card.
Topping ModuleFoil Slitter Assembly

The foil slitter assembly is an optional feature with the Topping module. It
mounts on the module base and splits the foil ribbon approximately down the
center along its length. This provides a higher level of security when
disposing of used topping foil because the split halves of foil can be discarded
in separate locations.
Input and Output ModulesLocking Kit

Both Input and Output modules can be installed with locking covers so that
only authorized personnel can insert or remove cards.
Input Module Thin Card Kit

To personalize cards thinner than the standard 30-mil cards on the MX2000
Card Issuance system, an upgrade kit must be installed on the Input module
so that only one card is picked at a time. The kit enables the Input module to
process 24-mil or 18-mil cards. Thin card stocks must also be defined in Stock
Management and selected in the Card Setup. If the system might resume
using 30-mil cards in the future, keep the standard upper pick guide to
replace the one in the kit.
2-28
Installation
Installation Troubleshooting
Before the system left the factory, it was fully tested for proper operation. If the
system fails to start properly after installation, use the following guidelines to
isolate the most likely cause. Some of these troubleshooting scenarios may require
a trained technician to isolate and correct the problem.
Controller Problems
If the Controller computer cannot be turned on:
Verify that the main power cord is connected to the system and the facility
outlet.
Verify that the facility power is available and is of the correct voltage for the
system. The system requires single-phase, grounded, 180-264-volt, AC power
at 47 to 63 Hz.
Make sure the power cord on the back of the Controller computer is properly
connected.
If the Controller computer starts but does not properly boot up, follow the
diagnostic procedures for Microsoft Windows.
Module Boot Problems
If none of the modules boot up:
Verify that the red module power switch on the front of the Controller is on.
Verify that the power cable between the Controller and the first module
(Input module) is connected.
Verify that the Ethernet connection between the Controller computer and the
Ethernet switch is correct. Also verify that the Ethernet switch has power.
If all modules boot up except for one, the most likely cause is a bad Ethernet
connection.
If all modules downstream from a module fail to boot up, the most likely cause is
a disconnected power jumper between modules, or there may be an auxiliary
power cord on that module that is not plugged in to facility power.
2-29
2-30
Installation
Chapter 3: Preventive
Maintenance
This chapter provides routine preventive maintenance schedules
and procedures for periodic cleaning and inspection of the system.
Overview ____________________________________________________________ 3-2

Cleaners, Tools, and Supplies _________________________________________ 3-2
System Preventive Maintenance Tasks ________________________________ 3-3
Module-Specific Preventive Maintenance Tasks _______________________ 3-4
Card Cleaning Module ____________________________________________ 3-4
Card Output Module ______________________________________________ 3-4
CardGard Topcoat Module ________________________________________ 3-4
Single-Step Color Printing Module __________________________________ 3-5
Controller Module _________________________________________________ 3-7
Graphics Printing Modules _________________________________________ 3-7
Magnetic Stripe Encoding Module ________________________________ 3-11
Topper Module ___________________________________________________ 3-13
Smart Card Module_______________________________________________ 3-14
Basic Topcoat Module ____________________________________________ 3-15
3-1
Overview
MX Series systems require routine preventive maintenance to optimize
performance and minimize downtime. Preventive maintenance procedures
should be performed either at specified time intervals or machine-cycle intervals,
depending on the module in question. In addition, preventive maintenance
should be performed after any of the following activities:
Replacing any module, assembly, sub-assembly or adjustable part
Performing any unscheduled maintenance
Some activities require that system power be off. Refer to the information on the
following pages for performing preventive maintenance activities.
Cleaners, Tools, and Supplies

The cleaners, tools, and supplies required to maintain the MX Series system are
listed in the special Preventive Maintenance Tools and Supplies document on this
CD.
3-2
Preventive Maintenance
System Preventive Maintenance Tasks

Site personnel need to perform the following preventive maintenance procedures
on all modules in the system.
Procedure
Frequency
Clean all card

tracks
Once per
week or
50,000 cards
Comments
Check for debris in both upper and lower card

guides.
Vacuum the area to remove dust and debris as
necessary.
Wipe the card track with a clean cloth dampened
with isopropyl alcohol.
Clean reflective
optical sensors
Once per
week or
50,000 cards
Wipe the sensors with a soft, dry cloth.

This includes all card entry and exit sensors.
This excludes all tabbed belt sensors and fiber optic
sensors.
Clean card track

sensors
Once per
week or
50,000 cards
Vacuum clean card sensors (in card track only), or wipe

with soft brush or cotton swab.
Clean transport
rollers
Once per
week or
50,000 cards
Wipe the roller surfaces with a soft cloth dampened with

isopropyl alcohol.
Vacuum the
upper half of the
system
Once per
week or
50,000 cards
Vacuum dust and debris from the module platform area

(above the frame only).
Do not vacuum near circuit boards or other
electronic devices.
Clean Controller
air filter
Once every
two weeks
Remove the filter (it is not necessary to remove the side

panel) and vacuum it at least once every two weeks.
3-3
Module-Specific Preventive Maintenance Tasks

Some modules have no specific operator maintenance tasks; others have
preventive maintenance tasks that should be performed by the operator. This
section describes those tasks.
Card Cleaning Module

Procedure
Clean all soft
rollers
Frequency
Comments
Once per day
Clean the tape

drive rollers
As needed
Remove the cleaning rollers and wipe with a

soapy water solution.
Note: Air dry the rollers after cleaning. Blowdrying can damage the rollers.
The roller surface must remain intact; if it
becomes damaged, the customer engineer
must replace the roller.
Inspect the drive rollers for accumulation of
adhesive.
If needed, clean the shafts with isopropyl
alcohol.
Card Output Module

If the system has an extra cooling kit installed on the Card Output module,
vacuum its air filter at least once every two weeks.
CardGard Topcoat Module

Procedure
Frequency
Comments
Inspect and clean

the card track
and moving
mechanism
surfaces
Daily
Inspect the card track and all moving mechanism

surfaces. Clean off any card residue to avoid issues with
downstream modules.
Clean the film

guide pins
Weekly, or as
needed
When the film guides have material sticking to them,

clean them with isopropyl alcohol.
Note: Never use sandpaper or other abrasive materials
that could scratch the surface of the guides.
Clean the grit

rollers
Daily
Inspect the grit-coated rollers in the interstage and cure

assemblies. Clean off any card residue from the rollers
with the wire bristle tool (or stiff bristle toothbrush).
Vacuum away any debris or dust.
3-4
Single-Step Color Printing Module

The preventive maintenance procedures done by the operator are described in the
following sections. Remove the ribbon supply from the Supply and Take-Up
assemblies before cleaning the module.
Start of Shift
1. Remove the print ribbon from the module.
2. Vacuum the card track sensors or wipe them with a soft brush or cotton swab.
See the locations of the track sensors in the following figure. Vacuum or wipe
the sensors even if the module is operating in pass-through mode.
3. Clean debris from all rollers using a damp cloth.

4. Clean any debris from all upper and lower card tracks.
5. Use isopropyl alcohol to clean the guide pins that route the ribbon.
6. Rethread the print ribbon.
3-5
Weekly
1. Clean the transport rollers weekly or after producing 50,000 cards. Wipe the
roller surfaces with a soft cloth dampened with isopropyl alcohol.
2. Clean the print and capstan rollers with a cloth dampened with alcohol.
3. Vacuum the area to remove dust and debris as necessary.
4. Wipe the upper and lower card tracks, especially near the exit and entrance,
with a clean cloth dampened with isopropyl alcohol.
Only As Needed
The print line or the printhead dot row on the printhead is indicated on the
following figure. It needs to be cleaned with lapping paper (Part No. 803359-003)
as print quality declines. The dot row also needs to be cleaned with swabs dipped
in alcohol to remove residue as part of routine maintenance.
Do not use lapping paper more frequently than once every 5,000 cards. The
residue is easily removed with a few strokes, applying very light pressure.
If print quality declines, perform the following procedure:
1. Power off the system.
2. Open the cover of the module to access the printhead.
3. Put on the special gloves that are shipped with the printhead kit. (The gloves
can be ordered as 810750-001 for a pair or 810750-002 for 50 pair).
Caution: Never touch the ceramic printhead surfaces or pins with your
fingers. Follow proper procedures to avoid electrostatic discharge.
4. Hold the supplied, colored lapping paper with the shiny side toward your
hand. Slide the lapping paper up and down the printhead dot row (see the
following figure) five to ten times, applying light pressure.
5. Moisten a swab in 90% (or greater) alcohol and remove any residue from the
use of the lapping papers.
6. Power on the machine and print a test card. Print quality should have
improved significantly. If poor printing continues, replace the printhead.
3-6
Controller Module
Procedure
Clean the exterior
components
Frequency
As needed
Comments
1. Shut down the Controller and turn off the power.

2. Clean the monitor with a soft cloth dampened with
3.
4.
5.
6.
water. Immediately wipe the monitor dry with a

clean cloth.
Vacuum the keyboard. If necessary, wipe the keys
with a cloth dampened with water.
Remove the track ball from the mouse and wipe it
with a lint-free tissue.
Wipe the cabinet down with a clean cloth
dampened in a mild detergent.
Remove the filter from the side of the Controller (it is
not necessary to remove the side panel) and
vacuum it at least once every two weeks.
Graphics Printing Modules

Start of Shift
1. Remove the print ribbon from the module.
2. Vacuum clean the card track sensors or wipe them with a soft brush or cotton
swab. See the locations of the track sensors in the following figure. Vacuum or
wipe the sensors even if the module is operating in pass-through mode.
3-7

3-8
5. Use isopropyl alcohol to clean the guide pins that route the ribbon.
6. Rethread the ribbon using the path in the following figure (Back Graphics
module depicted).
Weekly
2. Clean the print and capstan rollers with a cloth dampened with alcohol.
Only As Needed
If print quality deteriorates, clean the printhead dot row as described below.
Caution: Never touch the ceramic surfaces, printhead face, or pins with your
fingers.
ESD! The thermal printhead assembly is a static sensitive device. Electrostatic
discharge precautions must be followed when handling, installing, or

servicing the printhead to prevent damage. If you do not have an ESD kit,
always touch the frame of the system before touching a printhead. Always
wear special ESD-sensitive gloves when handling the printhead.
1. Power off the system and open the cover.

2. Release the printhead.
3-9
3. Hold the very fine lapping paper (supplied with the printhead) with the shiny
side toward your hand and lightly slide the paper up and down the dot row
five to ten times. You can also use a cotton swab dipped in alcohol to clean the
dot row. The dot row is visible at the left side of the print head. It is the shiny
line above the green area.
4. Power on the system and print a test pattern. If print quality is still poor,
replace the printhead using instructions supplied with the replacement part.
3-10
Magnetic Stripe Encoding Module

Start of Shift
1. Vacuum clean the card track sensors or wipe them with a soft brush or cotton
swab. See the locations of the track sensors in the following figure. Vacuum
the sensors even if the module is operating in pass-through mode.

4. Check the first card produced using an analyzer to detect proper placement of
data.
Weekly
Clean Heads Only As Needed
When the module requires excessive retries, use a magnetic stripe cleaning card
to clean the read/write heads.
1. Place a drop of cleaning solution in the center of the cloth patch on the
cleaning card (Part No. 589248-001).
3-11
2. Place the cleaning card into the card guide in the exit area of the upstream
module, and feed it into the entrance of the Magnetic Stripe module.
3. Turn the Transport motor drive plate to move the card back and forth under
the heads until they are clean. The number of times to move the card back and
forth depends on the degree of accumulation.
4. Remove the card from the module.
3-12
Topper Module
Start of Shift
See the locations of the track sensors in the following figure. Vacuum the
sensors even if the module is operating in pass-through mode.
2. Use a damp cloth to clean debris from all rollers.

Weekly
3-13
Smart Card Module

Start of Shift
See the locations of the track sensors (exit and entry sensors in red) in the
following figure. Vacuum these sensors even if the module is operating in
pass-through mode.
2. Use a damp cloth to clean debris from all rollers.

Weekly
3-14
Basic Topcoat Module

Procedure
Frequency
Comments
Clean the transport

rollers
Weekly, or as needed
Dampen a cloth with alcohol and

rotate the rollers as you wipe.
Clean the guide pins
Weekly, or as needed
Dampen a cloth with alcohol and

rotate the rollers as you wipe.
3-15
3-16
Chapter 4: Loading Supplies

This chapter provides procedures for loading supplies in various
modules.
Introduction _________________________________________________________ 4-2

Card Cleaning Module _______________________________________________ 4-2
Card Input Module ___________________________________________________ 4-4
CardGard Topcoat Module ___________________________________________ 4-6
Replacing CardGard Supply Film ___________________________________ 4-6
Repairing Broken CardGard Film ___________________________________ 4-8
Embossing and Indent Module ________________________________________ 4-9
Label Affixing Module _______________________________________________ 4-11
Graphics Printing Modules ___________________________________________ 4-13
Topping Module ____________________________________________________ 4-14
Basic Topcoat Module_______________________________________________ 4-16
Single-Step Color Module____________________________________________ 4-17
4-1
Introduction
Some of the modules have supplies that must be periodically loaded or changed.
This section describes the procedures for loading or replacing the supplies.
Card Cleaning Module

Datacard cleaning tape is supplied on a disposable core. When the module
cleaning tape supply core is empty, replace the tape using the following
procedure. An animated version of this procedure is available from the User
Animations option on the CD.
Cleaning Tape Replacement Procedure
1. Remove the full take-up roll and discard.
2. Move the empty supply core to the take-up spindle.
3. Place the new cleaning tape roll onto the supply spindle so it rotates
counterclockwise as the tape unrolls.
4. Thread the new tape. (If re-threading broken tape, start from wherever the
tape broke.)
A. Peel off the edge of the cleaning tape (1 in the following figure) and wrap
it around the idler roller (2) with the adhesive side away from the roller.
B. Wrap the tape around the gold drive roller (3) and then around the
backup roller (4).
C. Wrap the tape around the black drive roller (5) and then onto the empty
take-up core (6). Use the small piece of tape on the end of the roll to fasten
the cleaning tape to the core.
4-2
Loading Supplies
4-3
Card Input Module

Use the following procedure to load cards into the card tray. An animated
version of this procedure is available from the User Animations option on the
CD.
Wear lint free gloves to load cards. Finger oils interfere with graphics
printing.
All cards in the tray should be the same thickness.
1. Open the transport cover.
2. Press and hold the release lever on the stack pusher, and pull the stack pusher
all the way to the back of the tray.
3. Release the lever to lock the stack pusher in place.

Visually inspect the card grippers for cracked or damaged plastic. If
damaged, they should be replaced before loading cards in the tray.
4. Load cards into the card tray, working from front to back. Cards are usually
inserted with the magnetic stripe facing to the back and on top; some jobs
may require a different position. See the following figure for placement of
various types of cards.
4-4
Loading Supplies
5. When the tray is full, press the lever on the stack pusher again to release the
catch, and gently guide the pusher until it is resting against the last card in the
stack.
Caution: To avoid injury, never manually force the stack (card) pusher into
operating position and keep your free hand away as you release the lever.
6. Straighten the cards by aligning them evenly along the top and on one side of
the tray.
The following figure shows how to load various types of cards into the Card
Input module.
4-5
CardGard Topcoat Module

The CardGard topcoat material is a clear, plastic film that includes both a (tacky)
carrier layer and a cover layer. The beginning length of the film contains a leader,
which is a plastic strip for easy threading. The leader should be long enough to
thread around the supply guide pins to the carrier take-up spindle.
Replacing CardGard Supply Film

When the supply is empty, replace it with a new roll as described below.
Wear lint-free and powder-free gloves while removing and loading
CardGard film.
Procedure
1. Remove the cover and weight over the empty supply roll.
2. Turn the carrier and cover knobs clockwise and lift to remove them.
3. Remove any remaining film, carrier, and cover material.
4. Pull about 10 inches of tape leader from the new supply roll.
5. Place the new roll (1 in the following figure) on the supply spindle so it
unwinds counterclockwise.
6. Unwind the carrier leader from the roll and thread it around the film guide
pins (2 and 3) and capstan roller (4) separating the cover layer before the
second pin guide (2).
4-6
Loading Supplies
7. Wrap the film a full turn around the carrier take-up spindle (5). Replace the
carrier take-up knob so that the film is enclosed by the pin. Turn the knob to
seat it on the spindle.
8. Pull the tab on the cover layer to separate it from the carrier layer. Wind the
carrier around the guide pins (6 and 7) and onto the carrier spindle (8).
9. Wrap the carrier a full turn around the spindle (just enough to keep it in
place).
10. Simultaneously turn the carrier take up knob (5) and cover take up knob (8)
counterclockwise to continue winding the cover and carrier around their
spindles and remove any slack in the film. Turning only the cover or carrier
spindle will cause slack in the material.
Capstan
Supply
Carrier
Cover
4-7
Repairing Broken CardGard Film

If the CardGard film breaks during operation, use this procedure to re-thread
film without leader tape.
Procedure
1. Identify where the film break occurred and remove the threaded film from
the point of the break to both the carrier and cover spindles.
2. Place a piece of tape on each side of the broken edge of the film.
3. Pull the two pieces of tape apart, separating the cover and carrier layers of the
film.
4. Fold back the carrier end over the sticky coating material to form a new tape
leader of about 10 inches (25.4 cm).
5. Using the previous threading diagram, thread the tacky carrier layer of the
film around the supply film guides (3) and capstan roller (4), and then wind it
around the carrier take-up spindle (5). Thread the cover layer around the
guide pins (6 and 7) and then wind it around the cover take-up spindle (8).
6. Turn the capstan, take-up, and cover knobs as needed to continue wrapping
the film around the spindles until there is no slack.
4-8
Loading Supplies
Embossing and Indent Module

Indent mechanisms use a colored supply ribbon to transfer pigment to the
indented characters on the cards surface for readability. When the indent ribbon
supply roll is empty, replace it with a new roll as described below.
Indent Ribbon Replacement Procedure
The following instructions are for a rear indent mechanism.
1. On the Controller screen, right-click the Embossing module and select access
ribbon to raise the card transport, or manually raise the assembly by lifting
the lever marked with a green up-arrow label.
2. Tip the indent mechanism back for access to the ribbon.

3. Turn the green t-handle counterclockwise to remove it.
4. Remove the full take-up core and discard.
5. Remove the empty core on the supply hub and place it on the take-up hub.
6. Replace the green t-handle.
4-9
7. Place the new supply roll on the supply hub (1 in the following figure) so it
unwinds clockwise and pull the end of the ribbon from the roll.
8. Unwind the ribbon from the roll and thread it under the ribbon guides (2 and
3).
9. Thread the ribbon past the ribbon guide (3). Twist the ribbon so the dull side
with pigment faces the cards, and thread the ribbon across the two ribbon
guide arms (4).
10. Thread the ribbon down to lay underneath the ribbon guide roller (5), and
twist the ribbon again so the shiny side is facing up.
11. Thread the ribbon into the take-up hub from the bottom and pull it through
the slot (6) in the hub. Turn the t-handle to wrap the ribbon several turns until
it is secure. Tape the end of the ribbon to the side of the take-up plate.
When properly loaded, the shiny (non-pigment) side of the ribbon contacts
the roller and guides (2, 3, 4, and 5).
12. Place the Indent mechanism back in position; let the system lower the card
transport assembly as it does a reset.
4-10
Loading Supplies
Label Affixing Module

The Label supply material consists of a paper or polyester liner with adhesive
labels to affix to card surfaces. When the Label supply roll is empty, replace it
with a new roll as described below.
Label Replacement Procedure
1. Pull out on the knob to remove the supply retainer (1 in the following figure).
2. Lift the shoe mechanism (2) to lock the assembly in the load position.
3. Push the knob (3) forward and then release it to lock the supply and take-up
assemblies in the load position.
4. Pull the retainer plate (4) out of the take-up spindle to open the two halves of
the spindle, and remove any remaining label supply material from the
module.
5. Pull the label material away from the supply and peel labels off
approximately 24 inches (60 cm) of the material to form a leader (5).
6. Place the roll on the supply spindle and thread the leader up and over the
supply roller, then down under the shoe, and finally up and over the take-up
roller as shown.
7. Insert the label material between the spindle halves and push the retainer
plate (5) back in to close the take-up spindle (the smooth side of the plate
should face the label material).
4-11
8. Wind the label material around the take-up spindle to secure it. Wind up
enough material so the leading label is between the supply roller and the peel
edge.
9. Simultaneously push the knob (3) forward and the latch lever (7) down to
engage the supply and take-up roller assemblies.
10. Push the release lever (6) forward to place the shoe mechanism back into
position for production.
4-12
Loading Supplies
Graphics Printing Modules

Datacard print ribbon is supplied on a disposable core. Load or replace the ribbon
using the following procedure. An animated version of this procedure is available
from the User Animations option on the CD.
Printing Ribbon Replacement Procedure
2. Move the empty supply core from the supply spindle to the take-up spindle.
3. Load the new tape by placing the new print ribbon roll onto the supply
spindle (1) so it will rotate clockwise as the ribbon unwinds.
4. Rotate the knob (2) to move the printhead away from the assembly.
5. Thread the print ribbon in the following manner.
A. Peel the edge of the print ribbon from the spool.
B. Route the ribbon through the ribbon sensor (3), around the first guide
post, and then around guides (4 and 5) and the printhead (6) as shown in
the following figure.
C. Wrap the ribbon onto the empty take-up core (7) and use a piece of tape to
secure it to the core.
D. Wind the knob on the roller (8) to remove slack.
4-13
Topping Module
The Topping supply material is a colored foil ribbon whose pigment is
transferred to the top of the cards embossed characters for readability. When the
supply roll is empty, replace it with a new roll as described below.
Topping Foil Replacement Procedure
1. Remove the take-up roll with core from the module and discard.
Light pressure is required to unseat the cores from the retainers on the
spindles.
2. Move the empty core from the supply spindle to the take-up spindle.
3. Pull off the end of the new supply roll and place the roll on the supply spindle
(1 in the following figures) so that it unwinds in a clockwise direction.
4. Unwind the foil from the spindle and unroll it down the ramp under the card
track (2).
5. Thread the foil under the lower foil guide roller (3) and over the lift arm.
6. Raise the lift arm (4) to pull the foil up through the opening in the upper card
guide assembly and around its upper guide shaft (5).
7. If you have a foil slitter assembly installed:
A. Thread the foil through the assembly and around its foil guide shaft (7)
before threading it around the take-up core.
B. Pull the operator knob on the slitter assembly downward to thread the foil
through.
8. Thread the material around the take-up core (6) from the bottom and tape the
leading edge to the core.
4-14
Loading Supplies
Topping Module Without Foil Slitter Assembly
Topping Module with Foil Slitter Assembly
4-15
Basic Topcoat Module

Use the following figure as a guide to threading the supply roll through the
module.
2. Move the empty supply core from the supply spindle to the take-up spindle.
3. Load the new roll onto the supply spindle to unwind in a clockwise direction.
4. Thread the supply in the following manner.
A. Peel the edge of the roll from the spool.
B. Wrap the supply around the spindles, guides, and heated area.
C. Wrap the supply onto the empty take-up core and use a piece of tape to
secure it to the core.
4-16
Loading Supplies
Single-Step Color Module
4-17
4-18
Loading Supplies

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Datacard MX2000

Card Issuance System

Part No. 539675-001, Rev J

2006-2010, 2011 DataCard Corporation. All rights reserved.

System Overview _____________________________________________________ 1-2

Chapter 2: Installation ___________________________________________

Specifications and Requirements ______________________________________ 2-2

Additional Cooling Fans __________________________________________

Chapter 3: Preventive Maintenance ______________________________

Chapter 4: Loading Supplies _____________________________________

Introduction __________________________________________________________ 4-2

Notice for Canada

Notice for Europe

Notice for Taiwan/China

Notice for Japan

Connect equipment to a grounded facility power source. Do not defeat

Know the location of equipment branch circuit interrupters or circuit

Use adequate lighting at the equipment.

Maintain the recommended range of temperature and humidity in

Do not use this product in an environment containing volatile or

Safe Human Interface

Use proper lifting techniques when moving or installing the

Use standard electrostatic discharge (ESD) precautions when working

Do not defeat or disconnect safety interlocks on covers.

System Overview_____________________________________________________ 1-2

MX2000 Card Issuance System Owners Manual

Bar Code Scanner/

This module covers the entire front surface of a card with a

This module prints full-color, high-resolution photos and images

This module performs embossing on the front of a card. It can

The Front or Back Graphics modules print monochrome custom

This module applies a removable preprinted or blank adhesive label

This module provides high speed and reliable magnetic stripe

This module provides flexible, high quality smart card

MX2000 Card Issuance System Owners Manual

This module applies a protective coating of clear or holographic

This module applies a color foil to the tops of embossed characters

CIS Data Formatting Manual

this library and 539341-001

CIS Software Administrators Guide

Unpacking and Installation Manual

In paper with system and on this

Illustrated Parts Manuals for Modules

CardGard Material Safety Data Sheet

System Safety Rules

Preventive Maintenance Tools and

Datacard Certified Supplies

this library and newer ones

Starting and Stopping the System

Turn off the hardware by turning the switch counterclockwise.

MX2000 Card Issuance System Owners Manual

Pausing and Resuming the System

MX2000 Card Issuance System Owners Manual

3. Unplug the power cord(s) from the AC power source.

Interpreting Module Status Lights

FlashingModule error or failure in

MX2000 Card Issuance System Owners Manual

Computer BIOS Battery

Datacard Web Site (www.datacard.com)

CardGard Module Safety Information

CardGard Supply Film Precautions

MX2000 Card Issuance System Owners Manual

Ultraviolet (UV) Light Warning