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CPS120 Service Manual 1-4.vp

1. W m N E E FL LE O ISCREW 10 SCREW 9 OJ i i i i J2 i i i i w K i SGREW 8 LEJ 2 er LED1A LED2A LED3A LED4A LEDSA E B E E E E LED1 LED2 LED3 LED4 LEDS SCREW 3 PFMA 1 8 5 PUL1 PUL2 PUL3 N O O ma O DI le Y l EI lar u IN la 1 PuL4 Y PULS PULS l O O O PFMA 3 Hee JE BE alo ac ac BIE PUL7 PULS PUL9 Ji aL 33 a O o E O 8 E O IR n DI a u2 loc lo ler Ol lar m tn lg SEE PUL RR ON PULO PULY tat Eu 0 i OG ser Ol am IN N e ll da SCREW 1 SCREW 2 AC Wiring Diagram E Switching Cable Assy Power Supply e Main ON OFF Switch neno U M Chassis Ground CPS120 BOARDS CPS120 Service Manual CTS electronics 4 12 CPS120 Service Manu
2. RP4 RP6 RP10 RP3 RPS o o C4 PT2 PT1 R40 R39 R38 R37 J1 R13 R12 R11 C46 c45 C65 R10 R42 R41 R19 PT4 PT3 gt
3. SCREW5 RI179 R 18 14 N o R155 R109 E N R135 R111 u R 138 R133 R76 R63 R64 R88 R amp S R89 1 SCREW2 4 10 CPS120 Service Manual CTS electronics Consolle Control Board CPS DISPLAY 10764
4. R3S C82 R36 R33 C81 R34 gt LED4 LED3 LED2 CPS120 Service Manual 4 5 CTS electronics Input Output Reject Control Board Connections CPS CT 10761 J1 Near Empty Hopper Sensor J2 Empty Hopper Sensor J3 Eject Tray Door Open Sensor J4 Single Card Entry Motor J5 Single Card Entry Sensor J6 Eject Tray Full Sensor Emitter J7 Selection Tray Sensor UP J8 Selection Tray Sensor Down J9 Feeder Motor J10 Selection Tray Full Sensor J11 Reject Tray Full Sensor J12 Communication Port J13 24 V Power Supply rem SCREW4 SCREW3 SCREW2 4 6 CP
5. INPUT OUTPUT REJECT CONTROL BOARD Track 3 ISO JIS Input Hopper p Track 3 ISO JIS Write Head Input Hopper Selection Tray DC Motor Reject Tray Full p gt Single Card Input DC Motor Output Tray Full Feeder Home Selection Tray Single Card Input gt Feeder Step Motor 4 4 CPS120 Service Manual CTS electronics Main Control Board Connections CPS MASTER 10758 J7 J8 J9 J10 J11 J12 J13 J18 J19 J20 J22 J24 J26 Service Port Host Port Embosser Communication Port Encoder Communication Port Input Output Reject Communication Port Topper Communication Port Consolle Communication Port USB Port 24 V Power Supply Smart Card Contactless Power Supply Interlock Sensor Interlock Solenoid Smart Card Contact Solenoid TPS TPS
6. 1 JPS 38 1 JP4 Is 11 JP3 3 da JP2 8 1 JP1 3 4 V SCREW2 SCREW1 Contact Control Board Connections CPS SC USB 14025 J1 Photosensor J2 Contact J5 USB port CPS120 Service Manual 4 9 CTS electronics Embosser Control Board Connections CPS EBM 10759 J1 J2 J3 J5 J6 J7 J8 Die Motor Punch Motor Wheel Motor X Axis Motor Interconnection Front Indent Motor Front Indent Solenoid Rear Indent Motor Rear Indent Solenoid Die Home Sensor Punch Home Sensor Wheel Home Sensor Front Indent Ribbon Motion Sensor Rear Indent Ribbon Motion Sensor Synchronism Sensor Communication Port SCREW4 Ri18 R30 R43 R20 R42 R19 R46 R41
7. Daisy whell CPS120 Service Manual 5 13 CTS electronics Metal plate Character Daisy wheel si Tape on work FE N Tape on rest position rape on work position gt on rest position Fig 3 Fig 4 22 A s Ay R HU AN S gt TS S I E gt o 6 SS AN 5 14 CPS120 Service Manual CTS electronics CONTACT Chip contact station adjustment option Run a card on chip card reading position and verify that the contacts of the station are touching on the card contacts The adjustment on X axe is done by change the motor steps beside the adjustment on Y axe is done by adjusting the shaft 1 by the nut 2 CPS120 Service Manual 5 15 CTS electronics 5 16 CPS120 Service Manual CTS electronics Chapter 6 REMOVAL AND REPLACEMENT The CPS120 Card Personalization System operates as a standalone card embosser This chapter provides instruction for removal and replacement of assemblies and parts Introduction 2 ss amp 408 wa Kr a Ss an d a 6 3 Servicing Guidelines lt lt lt lt lt lt lt lt 6 3 FEEDER MODULE ASSEMBLY 6 4 Remove and replace input output reject module multi feeder lt lt 6 4 Remove and replace single card input drive
8. Less than 60dB 20 to 80 non condensing 1 195 BTU Hour 60 F to 90 F 15 C to 32 C The CPS120 can withstand an ESD discharge of 15KV 150pF storage and 330 ohm series resistance in test simulating a human discharge to the machine s outer surfaces EN61000 4 2 100 cards automatic card feed Up to 30 cards Up to 50 cards 700 cards 17 7 inches 450 mm Depth 25 9 inches 650 mm Height 11 6 inches 295 mm Weight 86 pounds 39 Kg Card Specifications Length 3 375 inches 85 7 mm Height 2 125 inches 54 0 mm Thickness 0 030 0 003 inches 0 762 mm 0 08mm Any gloss or matte finish 0 06 inches maximum from flat 1 5mm Dimensions Finish Color Any color Bow Material PVC IC Smart Card Optional Magnetic stripe Low Coercivity 300 Oe High Coercivity 4000 Oe CPS120 Service Manual 1 5 CTS electronics Magnetic Stripe Encoding Specifications The following table gives encoding specifications for magnetic stripe encoding used on the CPS120 Track Start Bit Position Skew Track Location BPI Number inches millimeters Angle Max Top Min Bottom in inches in inches Track1 IATA 0 293 0 020 7 44 0 51 0 20 0 223 0 333 210 8 Track2 ABA 0 293 0 020 7 44 0 51 0 20 0 353 0 463 75 5 Track3 TTS 0 293 0 040 7 44 1 02 0 20 0 493 0 603 210 8 NTT J2 0 236 0 020 6 00 0 51 0 10
9. Rear indent cartridge Front indent cartridge optional Consolle 3 4 CPS120 Service Manual CTS electronics Rear View of the CPS120 The following bulleted list identifies the components on the rear of the CPS120 See Figure for their location 1 Comunication ports Host Service LAN option USB option Smart card contact USB option Smart card contactless USB option 2 Power receptable 3 Power fuse 4 Power ON OFF ee O O O E a a a a T CPS120 Service Manual 3 5 CTS electronics Sequence of Reset PROCESS RESET CONSOLLE RESET No Yes TOPPER RESET Yes FEEDER RESET ENCODER RESET S a Yes EMBOSSER RESET o gt MOVE TO CLAMP RETURN POSITION ERROR CODE 3 6 CPS120 Service Manual CTS electronics TOPPER RESET Routine TOPPER RESET ERR CODE 0x77 Device Need Reset SW Sensor TOPPER HOME SENSOR Motor TOPPER MOTOR TOPPER MECHANICAL RESET ERR CODE 0x4A Topper moving is Lock Sensor TOPPER RIBBON MOTION SENSOR Motor RIBBON MOTOR RIBBON RESET ERR CODE 0x4B Topper Ribbon Ending or Broken ERR CODE 0x41 42 Topper Temperature Low High Yes RETURN OK RETURN ERROR CODE CPS120 Service Manual CTS electronics FEEDER RESET Routine FEEDER RESET HOPPER RESET Sensor UP SELECTION TRAT
10. Service Manual CTS electronics Cleaning the Magnetic Stripe Head 1 Unlock and lift up the Front and Supplies Covers 2 Power OFF the CPS120 and remove the power cord 3 Clean the following areas e Vacuum card dust from around the magnetic stripe head Remove remaining dust with a damp cloth e Clean roller with a cloth lightly moistened with rubber rejuvenator e Move an Encoder Cleaning Card back and forth over the magnetic stripe head 4 Plug in the power cord and power ON the CPS120 CPS120 Service Manual 2 7 CTS electronics 2 8 CPS120 Service Manual CTS electronics Chapter 3 THEORY OF OPERATION CPS120 CPS120 Overview eee eee eee ee 3 3 Component Identification lt lt lt lt lt lt lt lt 3 3 Inside View of the CPS120 3 4 Rear View of the CPS120 3 5 Sequence of Reset lt lt lt lt lt nn 3 6 Sequence of operation 3 11 Electrical Block Diagrams lt lt lt lt lt lt 3 12 Main Control Board lt lt lt lt 3 12 CPS120 Main Control Board Block Diagram 3 12 Microprocessor oaoa aa 3 13 Opla a p zas dokon 45044 Sed Bop aks a 3 13 Fl sh 2 as sea rase ete Git a 3 13 SOM aske se TUE AEG Sie a 3 13 Eeprom sag Sk keen Ge EE s g B GOR U E n n 3 13 485 Eines 4 sad sa re gale Glen sg 3 13 24 Volt Power Supply lt lt 3 14 5 Volt Regulator lt lt lt
11. Unlock the topper cartridge by turning lever counterclockwise and pulling the cartridge out of the module Remove the end tape from the supply spool and then unlock and remove the spool by pulling it out Unlock and remove the tape up spool by pulling it out Replace the topping ribbon by winding the new tape around the cartridge Insert the supply spool in the left core Thread the topper ribbon from the supply spool around the ribbon motion guide and insert the take up spool on the right core Wind the ribbon by turning the take up spool counterclockwise until it is tight Place the topper cartridge inside the topper module and press it firmly in place Lock lever by turning it clockwise Close the supplies cover 6 32 CPS120 Service Manual CTS electronics Take up spool Supply spool Left core Ta Guide rollers e Do not pull the ribbon from the supply spool when the spool is already inserted in the core Doing so might damage the holder spring If more tape G NOTE is needed press lever 3A and then pull ribbon as needed CPS120 Service Manual 6 33 CTS electronics EMBOSSER ASSEMBLY Remove and replace embosser module The Embosser Module is comprised of two rotating metal disks of punches and dies provides a means to make embossed characters on plastic card Use the following procedure to remove and replace the Embosser Module
12. e Any unscheduled maintenance is performed Task FRU Module Procedure Cleaning the CPS120 CPS120 Vacuum out the entire inside of the CPS120 and clean the outside ofthe cabinet with desk cleaner Clean The CPS120 CPS120 Clean O Rings and rubber drive rollers with O Rings Drive Rollers rubber rejuvenator Clean the CPS120 Sensors CPS120 Clean sensors with compressed air Clean Magnetic Stripe Head Magnetic Stripe Clean head using Encoding Cleaning Card Verify Adjustment and Operation of the CPS120 Card Transport Verify horizontal margin character height and vertical line location on customer setups Verify Start Sentinel and Track Locations for Magnetic Stripe Magnetic Stripe Run a Magnetic Stripe Test Card and verify start sentinel and track locations Verify Even and Uniform Topping Topper Run customer cards and verify cards are top coated evenly and uniformly CPS120 Service Manual 2 3 CTS electronics Tools and Material The following tools and supplies are required to perform preventive maintenance as specified in the PM schedule Can of compressed air Desk cleaner Encoder cleaning card Lint free cloth Magnetic stripe sight gauge Rubber rejuvenator Vacuum cleaner Vernier calipers Preventive Maintenance Procedures The following procedures are performed to complete the requirements of the PM schedule Cleaning the CPS120 Cleaning the O
13. 14029 Control Board Place a new motor in positon and hold in place with two screws 2 Place the drive motor pulley onto the shaft motor and hold in place with a grub screw 1 Reconnect the input motor cable J9 on the Topper code 14029 Control Board Replace the Input Output module on the CPS120 See Remove and replace input output module Single feeder Make sure to do not pinch the wires under the module A WARNING Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification 6 16 CPS120 Service Manual CTS electronics 6 17 CPS120 Service Manual CTS electronics Remove and replace card input drive o ring The Card Input Drive O Ring provides movement to transport a card to the picked area Use the following procedure to remove and replace the Card Input Drive O Ring Remove oP ON oO ND Replace aren gt Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Disconnect the input motor cable J9 from the Topper code 14029 Control Board Remove the input output module Remove and replace input output module Single feeder Loose grub screw 1 holding the drive motor pulley and remove it Slip the Input Drive O Ring
14. 2 off the Input drive motor pulley Remove the seeger 3 and slide out the shaft 4 Extract the the Card Input Drive O Ring 2 Place the new Input drive O Ring 2 in position Replace the shaft 4 and fix with the seeger 3 Place the drive motor pulley onto the shaft motor and hold in place with a grub screw 1 Reconnect the input motor cable J9 on the Topper code 14029 Control Board Replace the Input Output module on the CPS120 See Remove and replace input output module Single feeder Make sure to do not pinch the wires under the module A WARNING Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification 6 18 CPS120 Service Manual CTS electronics CPS120 Service Manual 6 19 CTS electronics Remove and replace Input Output module photosensors The photosensors that control the Input Ouput movement are e Card entry photosensor J7 e Card presence photosensor J8 Remove Card entry photosensor J7 1 Disconnect the Card entry photosensor cable J7 from Topper Module code 14029 control board 2 Remove one screw and remove the Card entry photosensor 1 Card presence photosensor J8 1 Disconnect the Card presence photosensor cable J8 from Topper Module code 14029 control board 2 Remove
15. 6 50 CPS120 Service Manual CTS electronics CHIP CARD ASSEMBLY option Remove and replace smart card module The Smart Card Module consists of a mechanism for write and read Contact and Contactless smart card Use the following procedure to remove and replace the Smart Card Module Remove 1 Unlock and lift up the Front Cover and the Supplies Cover 2 Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame 4 Disconnect the following cable from the Main Control board e Smart Card Contact Solenoid J26 e Smart Card Contactless Power Supply J20 5 Remove two screws 1 and remove the Smart Card Module from the CPS120 6 Lift the Smart Card Module from the CPS120 Replace 1 Place the new Smart Card Module in position and attach with two screws 2 Reconnect the Following Cable on the Main Control Board e Smart Card Contact Solenoid J26 e Smart Card Contactless Power Supply J20 Make sure wires are not pinched Make sure wires will not interfere WARNING with any mechanical movement inside the CPS120 Follow up Adjustments This remove and replace procedure affects the following adjustments which must be performed after this procedure produced cards for a final quality verification Smart Card Offset Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer
16. in inches in inches Track1 IATA 0 293 0 020 7 44 0 51 0 20 0 223 0 333 210 8 Track2 ABA 0 293 0 020 7 44 0 51 0 20 0 353 0 463 75 5 Track3 TTS 0 293 0 040 7 44 1 02 0 20 0 493 0 603 210 8 NTT J2 0 236 0 020 6 00 0 51 0 10 0 236 0 472 210 8 Start Bit Position is referenced from the right edge of the card as viewed from the magnetic stripe side Track Location is referenced from the top edge of the card Track 1 IATA 76 maximum data characters Track 2 ABA 37 maximum data characters Track 3 TTS 104 maximum data characters 5 8 CPS120 Service Manual CTS electronics Vertical position e Acton the nut 2 to lower or lift up the magnetic head group Clockwise rotation move up Anticlockwise rotation move down To verify the correct position of the encoder group it is necessary checking the input of the card during a standard operating phase The adjustment is reached when there are no hindrances to the passage of the card with respect to encoder group and the writing is successful ENCODER Adjustment card gap way Adjust the blocking nut 1 in order to verify a force of 150 50gr to move the card position between the wheel feed and the Encoder group By turning the blocking nut on clokwise it s increase the card gap way CPS120 Service Manual 5 9 CTS electronics TOPPE
17. 0 236 0 472 210 8 Start Bit Position is referenced from the right edge of the card as viewed from the magnetic stripe side Track Location is referenced from the top edge of the card Track 1 IATA 76 maximum data characters Track 2 ABA 37 maximum data characters Track 3 TTS 104 maximum data characters NOTE Maximum data characters do not include start end sentinels and LCR characters All magnetic stripe specifications are per ISO 7811 2 7811 4 and 7811 5 Standard Financial Emboss Line Locations L1 7CPI L2 10CPI L3 10CPI L4 10CPI L5 10CPI V 0 843 0 005 inches 21 412 0 127 mm OCR V 0 646 0 005 inches 16 408 0 127 mm 1st AN 12 395 0 127 mm 2nd AN V 0 332 0 005 inches 8 432 0 127 mm 3rd AN V 0 488 0 005 inches V 0 175 0 005 inches 4 445 0 127mm 4th AN NOTE All lines have a left margin of 0 401 0 010 inch 10 185 0 254mm V is the distance from the bottom of the card to the center of the character 1 6 CPS120 Service Manual CTS electronics Standard Emboss Character Height OCR Farrington 7B AN Indent Characters Indent Punctuation 7 Characters per inch 0 016 to 0 019 inches 0 40 to 0 48 mm 10 Characters per inch 0 015 to 0 018 inches 0 38 to 0 46 mm 0 001 to 0 005 inches 0 0254 to 0 127 mm 0 001 to 0 007 inches 0 0254 to 0 177 mm Standard Emboss Character Spa
18. 5 7 16 19 February 2007 Chapter 6 All 07 March 2007 Chapter 7 Spare parts list 7 8 7 9 30 March 2007 Chapter 3 Console Operation Description 3 17 CPS120 Service Manual CTS electronics FOREWORD NOTE The machine must be used solely for the purposes for which it was designed Any intervention modifying its original operating configuration must be authorized and certified beforehand by the manufacturer CTS electronicsis not liable for any damages caused by the use of non original spare parts CPS120 Service Manual I CTS electronics SYMBOLS This handbook uses the following conventions The note contains important information for the user K NOTE A Improperly using controls making adjustments or performing procedures not specified in this User Guide may be dangerous CPS120 Service Manual CTS electronics DECLARATION CE of CONFORMITY The Manufacturer C T S electronics S p A Corso Vercelli 332 10015 Ivrea To Italy Declares under its sole responsability that the product Equipment category Information Technology Equipment Product type Card issuance system Commercial name CPS120 Fulfils the essential requirements of Electromagnetic Compatibility and of Electrical Safety as prescribed by the Directives 89 336 EEC dated 3 May 1989 with subseguent amendments Directive 92 31 EEC dated 28th April 1992 and Directive 93 68 EEC dated 220d Ju
19. Card Module e Remove any jammed cards from the Smart Card Module e Attempt to resume printing When removing jammed card from the CPS120 care must be taken WARNING not to damage components CPS120 Service Manual 4 3 CTS electronics CPS120 Interconnect Diagrams The following diagrams show the CPS120 system cable connections 24V POWER SUPPLY Y Interlock Interlock Solenoid Smart Card Contatless Power Supply gt Smart Card Contact lg Solenoid MAIN CONSOLLE CONTROL CONTROL BOARD BOARD gt gt gt EMBOSSER CONTROL BOARD TOPPER CONTROL BOARD MAGNETIC STRIPE CONTROL BOARD Track 1 ISO Ez Be o p Die Step lt Die Home Motor p Wheel Step Wheel Home Motor gt X Axis Step 4 X Axis Home Motor 1 gt Y Axis Step Y Axis Home Motor p Rear Indent lt Rear Indent Ribbon Ribbon DC Motor gt Front Indent Front Indent Ribbon Ribbon DC Motor gr EE nism Sensor gt Front Indent Solenoid Topper Home Topper 4 Topper Ribbon gt DE Motor gt Topper Ribbon Heater Temperature DC Motor Sensor p Heater Write Read p Track 1 ISO Encoder Write Head Track 2180 Write Head Track 2 ISO Read Head
20. Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification 6 38 CPS120 Service Manual CTS electronics CPS120 Service Manual 6 39 CTS electronics Remove and replace punch die cam motors The Punch Die Cam Motor applies pressure to the Embossing Punch Die on the character wheel to form a character on plastic cards Use the following procedure to remove and replace the Punch Die Cam motors Remove PONS an Replace Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove the Embosser Module from CPS120 see Remove and Replace the Embosser Module Remove the Punch Die Cables from the motors Remove four screws 1 and remove the Punch Die motors 2 Loose one grub screw holding the drive motor pulley and remove it Place the drive motor pulley in the shaft motor and hold in place with one grub screw Place a new motor and the Punch Die Motor Belts in position and attach with four screws Replace the Punch Die cables on the motor Replace the Embosser Module on the CPS120 see Remove and Replace the Embosser Module Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produ
21. PONT a Replace Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove the Embosser Module from CPS120 see Remove and Replace the Embosser Module Remove the Indent cartridge Disconnect the Indent Motor cable J7 Front Indent J9 Rear Indent from the Embosser control board Remove cable ties Remove one grub screw 1 holding the Ribbon Traction Gear 3 and remove it Remove two screws 2 and remove the Indent Motor 4 Place the new Indent motor in position and attach with two screws Place the Ribbon traction gear on the shaft motor and hold in place with one grub screw Reconnect the Indent motor cable J7 Front Indent J9 Rear Indent on the Embosser control board Replace cable ties and the Indent cartridge Replace the Embosser Module on the CPS120 see Remove and Replace the Embosser Module Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final guality verification CPS120 Service Manual 6 45 CTS electronics 8 y per ISI y Io E Sg zu CPS120 Service Manual CTS electronics Remove and replace front rear indent ribbon motion senso
22. WARNING 4 Replace the Frame 5 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification 6 4 CPS120 Service Manual CTS electronics CPS120 Service Manual 6 5 CTS electronics Remove and replace single card input drive o ring The Single Card Input Drive O Ring provides movement to transport a single card to the picked area Use the following procedure to remove and replace the Single Card Input Drive Belt Remove 1 2 3 4 Replace 1 2 3 Unlock and lift up the Front Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove one seeger 1 holding the Input Guide Card Transport Drive Roller and partially remove the Input Guide Card Transport 2 Slip the Input Drive O Ring 3 off the Input drive motor pulley and remove the O Ring from the assembly Place the new Input drive O Ring in position Replace the Input Guide Card Transport in position and hold it in place with one seeger Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final guality verification CPS120 Service Manual CTS electronics Remove and replace feeder drive belt The feeder drive belt provide the motion to feed one card fr
23. energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this eguipment in a residential area is likely to cause harmful interference in which case the user will be reguired to correct the interference at his own expense Change or modification not expressly approved by the party responsible for compliance could void the user s aulhority to operate the eguipment Connecting of peripherals reguired the use of grounded shielded signal cables CANADA EMI REOUIREMENTS FOR CANADIAN MARKET This digital apparatus does not exceed the class A limits for radio noise emissions from digital apparatus as set out in the interference causing equipment standard entitled Digital Apparatus ICES 003 of the industry of Canada SPECIFICATIONS EMI POUR LE MARCH CANADIEN Cet appareil num rigue respecte les limites de bruits radio lectrigues applicables aux appareils num rigues de Classe A prescrites dans la norme sur le mat riel prouilleur Appareils Num rigues NMB 003 dict e par le Ministre des Communications CPS120 Service Manual V CTS electronics Information to the users SUPPLIED BY PARTNERS E The mmm symbol affixed on the equipment means that the refuse of this equipment must be collected separately Therefore the user shall deliver the related refuse to one of the special centres predisposed by the local administrations for the
24. lt lt varer lt 44 44 444444 3 14 3 3 Volt Regulator lt lt 3 14 The CPS120 Card Personalization System operates as a standalone card embosser This chapter provides general theory of operation for the CPS120 Service Manual CTS electronics RS232 Tranceiver LAN Tranceiver USB Tranceiver Input Output Reject Control Board Magnetic Stripe Control Board Topper Control Board Embosser Control Board Consolle Control Board Console Operation Description CPS120 Service Manual CTS electronics CPS120 Overview The CPS120 is a full featured single pass card personalization system The CPS120 embosses indents encodes and tops financial cards Depending on the options ordered the CPS120 is also capable of front indent printing and smart card personalization Component Identification The follow bulleted list identifies the major components of the CPS120 See Figure for their location Output hopper door Single card access entry Keyhole Keypad Display Front cover Power switch AO OV B N ES CPS120 Service Manual 3 3 CTS electronics Inside View of the CPS120 The following bulleted list identifies the major modules inside ofthe CPS120 See Figure for their location 1 2 3 4 5 6 r 8 Input output Reject module Card transport module Magnetic stripe encoding module Topper module Embosser module
25. o ring 6 6 Remove and replace feeder drive belt 6 7 Remove and replace single card input drive motor 6 8 Remove and replace feeder motor 6 10 Remove and replace selection tray motor 6 11 Remove and replace Input Output Reject module SENSOIS 44 sr aka Sa Das EET s sje ae 6 12 Remove and replace input output module Single feeder o 6 15 Remove and replace single card input drive motor 6 16 Remove and replace card input drive o ring 6 18 Remove and replace Input Output module photosensors6 20 ENCODER ASSEMBLY 6 21 Remove and replace encoder module 6 21 CPS120 Service Manual 6 1 CTS electronics Remove and replace encodersensor 6 23 TOPPER ASSEMBLY s s moat om a e opoe se d ar eee a 6 24 Remove and replace topper module 6 24 Remove and replace toppermotor 6 26 Remove and replace topper home sensor 6 27 Remove and replace ribbon motor drive belt 6 28 Remove and replace ribbon motor 6 29 Remove and replace ribbon motion sensor 6 30 Remove and replace topper platen 2 6 31 Replacing the topping ribbon 6 32 EMBOSSERASSEMBLY 6 34 Remove and replace embosser module 6 34 Remove and replace embosser sensor 6 36 Remove and replace punch die cam belts 6 38 Remove and replace X tran
26. performing and or observing a limited customer production run e DO NOT defeat the safety interlock CPS120 Service Manual 6 3 CTS electronics FEEDER MODULE ASSEMBLY E possibile installare su CPS 120 due differenti moduli feeder In opzione al modulo base multi feeder amp possibile installare Remove and replace input output reject module multi feeder The Input Output Reject Module is a main assembly used for stacking cards or a single card as an output receptacle for completed cards and as an reject receptacle for rejected cards Use the following procedure to remove and replace the Input Output Reject Module Remove 1 Unlock and lift up the Front Cover and the Supplies Cover 2 Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame 4 Manually move the Card Transport carriage to the center ofthe CPS120 5 Remove all loose cards from the CPS120 Input Output Reject Hoppers 6 Disconnect the following cables from the Feeder control board e Power supply J13 e Communication cable J12 7 Remove five screws and lift the module from the CPS120 Replace 1 Place the new module in position 2 Reconnect the following cables to the Input Output Reject Module control board e Power supply J13 e Communication cable J12 3 After connecting the inline cables attach the five screws 1 on the module Make sure to do not pinch the wires under the module A
27. quality verification 6 30 CPS120 Service Manual CTS electronics Remove and replace topper platen The Topper Platen places a colored layer on the top of embossed characters on a plastic card Use the following procedure to remove and replace the Topper Platen Remove 1 Unlock and lift up the Front Cover 2 Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame The Topper Platen May Be Very Hot A WARNING 4 Remove one screw 1 and remove the Topper Platen holding plate 2 5 Disconnect the Heater cable J15 and the Topper Temperature sensor cable J14 from the Topper Control board 6 Remove the Topper Platen 3 Replace 1 Place the new Topper Platen in position 2 Place the Topper Platen holding plate in position and attach with one screw 3 Reconnect the Heater Cable J15 and the Topper Temperature sensor cable J14 on the Topper Control board 4 Replace the Frame 5 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification CPS120 Service Manual 6 31 CTS electronics Replacing the topping ribbon Perform the following steps to replace the topping ribbon Use proper anti static grounding techniques when handling the WARNING Topper Control Board 10 Unlock and lift up the supplies cover
28. two screw and remove the Card presence photosensor 2 Replace Replace Card entry photosensor J7 1 Place the new Card entry photosensor 1 in place and attach with one screw 2 Reconnect the Card entry photosensor cable J7 on the Topper Module code 14029 control board Card presence photosensor J8 1 Place the new Card presence photosensor 2 in place and attach with screws 2 Reconnect the Card presence photosensor cable J8 on the Topper Module code 14029 control board 6 20 CPS120 Service Manual CTS electronics ENCODER ASSEMBLY Remove and replace encoder module The Encoder Module head reads and writes data on the magnetic stripes on a card Use the following procedure to remove and replace the Encoder Module Remove of en Le Replace 1 2 a Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Unscrew the screw 1 and extract the metal plate protection boad 2 Remove four screws and partially remove the Encoder from the base to gain access to the cable connectors Disconnect the following cables from the Encoder control board Power supply J4 Communication cable J5 Lift the Encoder from the CPS120 Partially place the new Encoder in position Reconnect the following cables on the Encoder control board Power supply J4 Communication cable J5 After co
29. 0710 ST03 03 Emitt E2 1 R34 CAB 0803 Cable 2way x Photo Em L400mm 1 20 R34 10761 CPS CT Input Output Board 7 2 CPS120 Service Manual CTS electronics TABLE 1 13 14 2 J8 Feeder board gt J9 Feeder board J10 Feeder board J6 Feeder board CPS120 Service Manual 7 3 18 gt J3 Feeder board Pu M CTS electronics m 18 14 gt J11 Feeder board gt J1 Feeder board gt J16 Feeder board 7 4 CPS120 Service Manual CTS electronics ENCODER TAB Nr 2 Encoder Q RIE CODE DESCRIPTION 1 1 R34 10790 Magnetic Head Group R W 3T Support 1 2 R34 10795 Encoder Heds 5500 A12 Cable 1 3 R34 CAB 0716 Cable photo TLP802L 250 Writing Synchronism photo 1 4 R34 10763 CPS BM Encoder board TABLE 2 3 FG JT Encoder board P 1 2 J1 J2 J3 Encoder board CPS120 Service Manual CTS electronics TAB Nr 3 Topper Q RIF CODE DESCRIPTION 1 1 R34 20828 Topping cartridge group 2 2 R34 01326 Traction Spring 1 3 R34 01360 Traction Spring 1 4 R34 01136 Belt Tooth 480MXL Z60 L025 1 5 R34 10791 Reduction Motor Group 24V Fimo1 Cable 1 6 R34 10887 Gr M rid L149 12 90 MODU2 L280 1 7 R34 10786 Heater Group 2 8 R34 CAB 0715 Cable 3way photo TLP802 L150 P2 1 9 R34 10762 CPS CT Topping Board TABLE 3 7 6 CPS120 Service Manual CTS electronics gt J14 J15 Topper board 7 A 8 5 gt J11 Topper board gt
30. 120 Service Manual CTS electronics INPUT OUTPUT REJECT Metal Plate high adjustment The adjustment of the little moving plate is done operating only on one side of the INPUT OUTPUT REJECT module right side in fact the height of the plate on the left side of the module depends on the presence of the cam that grants the correct height Right side e Loosen the fixing dowel 3 e Put the moving plate 1 at the same height of the upper side of the internal metal plate 2 e Keep this adjustment and fix it tightening the fixing dowel 3 CPS120 Service Manual 5 7 CTS electronics ENCODER Encoder adjustment It is possible to adjust both the horizontal position of the magnetic head and the input height of the cards into the encoder module in order to allow the correct position of the writing with respect to the magnetic stripe Orizzontal position e Work on the dowel 1 to move away or bring nearer the magnetic head group Clockwise rotation move backward Anticlockwise rotation move forward To verify the position of the writing is correct place the encoder group again into the machine and perform a writing then check the values of the magnetic stripe with the following table The following table gives encoding specifications for magnetic stripe encoding used on the CPS120 Track Start Bit Position Skew Track Location BPI Number inches millimeters Angle Max Top Min Bottom
31. CPS120 Service Manual 6 51 CTS electronics Remove and replace smart card contact sensor The Smart Card Contact sensor control that the contact is on the card Use the following procedure to remove and replace the sensor Remove 1 Unlock and lift up the Front Cover and the Supplies Cover 2 Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame 4 Remove the Smart Card Module from CPS120 see Remove and Replace the Smart Card Module 5 Disconnect the Smart Card Contact sensor cable from the Smart Card Contact Control board 1 6 Remove one screw 2 holding the Smart Card Contact sensor 3 and remove it Replace 1 Place the new Smart Card Contact sensor in position and attach with one screw 2 Reconnect the Smart Card Contact sensor cable on the Smart Card Contact control board 3 Replace the Smart Card Module on the CPS120 see Remove and Replace the Smart Card Module 4 Replace the Frame 5 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification 1 3 b y 6 52 CPS120 Service Manual CTS electronics Remove and replace smart card contact solenoid The Smart Card Contact Solenoid is used to place the Contact on the card Use the following procedure to remove and replace the Smart Card Contact Solenoi
32. CTS electronics SERVICE MANUAL CPS120 Card issuance system CPS120 Service Manual CTS electronics PUBLISHED BY O 0 electronics CTS electronics Corso Vercelli 332 10015 IVREA ITALY Tel 0125 235611 Telefax 0125 235623 http www ctsgroup it Copyright No part of this publications may be reproduced or transmitted in any form or any means electronic or mechanical including photocopying and recording or by any information storage or retrieval system without the prior written permission of CTS Electronics Disclaimers The information in this document is subject to change without notice CTS Electronics makes NO warranty of any kind with regard to this material either express or implied expect as provided herein including without limitation thereof warranties as to marketability merchantability fitness for a particular purpose of use or non infringement CTS Electronics shall not be liable for any direct incidental or consequential damages of any nature or losses or expenses resulting from the use of this material Edition 24 april 2007 Codice MAN 1217 Previous issue Subjects covered in the new issue New pages introduced or amended 03 August 2006 Topper Cartridge Capacity 1 5 Chapter 7 Spare parts list 16 January 2007 Contact Control Board Connections 4 8 Chapter 7 Spare parts list 7 14 30 January 2007 Chapter 7 Spare parts list 7
33. J10 Topper board CPS120 Service Manual 7 7 CTS electronics EMBOSSER TAB Nr 4 Embosser Q RIF CODE DESCRIPTION 1 1 R34 01028 Bearing 120x150x16 2 2 R34 01094 Belt Tooth XL Z 40 L025 1 3 R34 022221 Wheel Tooth Z 192 1 4 R34 022223 Daisy wheel Upper A 1 5 R34 022261 Daisy wheel Upper B 1 6 R34 022262 Daisy wheel Lower B 1 7 R34 022263 Daisy wheel Lower A 2 8 R34 022265 Cam Shaft Group 2 9 R34 022266 Punch Arm Group 2 10 R34 022267 Punch Group 1 11 R34 10896 GR MOT STEP CAMM Super L300 Upper Punch Motor 1 12 R34 10897 GR MOT STEP CAMM Infer L150 Lower Punch Motor 1 13 R34 10797 MOTSTEP 05 Group Cabmot 017 Daisy Motor 2 14 R34 CAB 0716 Cable 3way Photo TLP822 L 250 P2 Upper lower Punch Zeroing Photo 1 15 R34 CAB 0740 Cable 3way Photo TLP802 L 285 P2 Daisy wheel Zeroing Photo 1 16 R34 CAB 0755 Cable Photo High STO7 p 2 L 380 Synchronism Photo 1 17 R34 10759 CPS EMB Board 7 8 CPS120 Service Manual CTS electronics TABLE 4 10 15 J14 Embosser board J21 Embosser board 5 J1 Embosser board 16 1 UPPER gt J13 Embosser board CPS120 Service Manual 7 9 CTS electronics INDENT TAB Nr 5 Indent Q RIF CODE DESCRIPTION 2 1 R34 10793 Gr Cartridge indent 2 2 R34 022282 Leaf spring 1 3 R34 10890 Gr motrid 24V V fimo cavo L300 isolan front 1 4 R34 10891 Gr motrid 24V V fimo cavo L300 rear 2 5 R34 10788 Gr e magn
34. OCK SOLENOID CARD SOLENOID CONTACT CHIP 3 12 CPS120 Service Manual CTS electronics Microprocessor Cpld Flash Sdram The microprocessor is the controlling element of CPS120 system the connectivity two serial port LAN and Usb and the comunication with other module of CPS120 through 485 lines It is a Motorola COLDFIRE MCF5272 a 32 bit microprocessor clocked at 66MHz The processor power is supplied by filtered 3 3 volt supply The microprocessor support the address bus A0 A23 and it generate eight chip select CS0 CS7 that are used as follow CS0 for flash memory CS1 for cpld CS2 for future expansion CS3 for external uart CS4 unused CS5 unused CS6 unused CS7 for SDRAM Additionally the microprocessor have two serial port the SDRAM controller the MAC controller of LAN and the controller of USB 1 1 ABDM JTAG connector allows a host development system the ability to control the processor debug the hardware and programming the Flash memory This component M4A3 32 32 perform the enable of all module of CPS120 the control of data buffer the I O of EEPROM memory and the administration of signal TX RX of 485 lines for the comunication of all modules The Flash memory chip AMD29LV160 is 2 MB with 16 bit wide 1M X 16 and contain the firmware code that control and operates the CPS120 system The Flash is selected by chip select 0 CS0 and address and data signal are buffered By using t
35. R The topper group can be adjusted to allow inserting positioning and fixing the cartridge correctly e Operate on the nut to obtain the distance of 10 mm between the end of the threaded pivot and the front face of the metal plate e Repeat this operation for each of the three spacing pivots e Insert the cartridge onto the topper group and close the stopper 2 e Verify that the cartridge is blocked e Differently work on the nut 1 to move away or nearer the fixing slot 5 10 CPS120 Service Manual CTS electronics ENCODER Hunting control by the encoder Check on the diagnostic graph Test on the two direction and adjust the belt tension see page 6 6 X Axis Transport Drive Belt Adjustment eventually increase the card gap way see page 6 9 Adjustment card gap way EMBOSSER Embosser adjustment Initial punch die adjustment Lower part Adjust the screw control 1A in order to get the head of the screw on the same line with the lateral arms profile 2A Fig 1 Upper part Adjust the screw control 1 in order to get the quote of 2 7 3mm between the screw head and the internal bush Fig 1 Daisy wheel rotation reset position adjustment Run a complete reset and verify that the punch die internal cone has to be true in comparison with the character projecting cone Fig 3 if not act on the reset steps see wheel offset Character projecting adjustment After downlo
36. Remove 1 Unlock and lift up the Front Cover and the Supplies Cover 2 Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame 4 Remove the Rear and Front Indent Cartridges if available 5 Disconnect all cables from the Embosser control board B Le Uncrew two screws A and remove the control board support 8 Remove two screws C 9 Remove two screws D by pushing fowar and remove the embosser module Replace 1 Place the new module in position 2 Reconnect the following cables to the Embosser control board e Interconnection Flat cable J6 e Power supply J13 e Communication cable J12 e X axis motor cable J5 3 After connecting the inline cables attach the three screws 2 on the module Make sure to do not pinch the wires under the module A WARNING 4 Replace the Frame 5 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification 6 34 CPS120 Service Manual CTS electronics Front side sa a ET CPS120 Service Manual 6 35 CTS electronics Remove and replace embosser sensor The sensors that control the Embosser movement are e Punch and Die Home sensors e Wheel Home sensor e Synchronism sensor Use the following procedure to remove and replace the sensors Remove PONS Unlock and lift up the Front Cover and
37. Rings Drive Rollers Cleaning the Sensors Clean of the Magnetic Stripe Head Verifying Embossing Line Locations and Margins Verifying Start Sentinel and Track Locations for Magnetic Stripe Verifying Even and Uniform Topper coating 2 4 CPS120 Service Manual CTS electronics Cleaning the CPS120 1 Unlock and lift up the Front Cover and the Supplies Cover 2 Power OFF the CPS120 and remove the power cord e Vacuum out the inside of the CPS120 e Clean the outside of the cabinet with either a damp lint free cloth or desk cleaner Cleaning the O Rings 1 Unlock and lift up the Front and Supplies Covers 2 Power OFF The CPS120 and remove the power cord 3 Clean the following O Rings or drive rollers with rubber rejuvenator e Magnetic Stripe Encoder roller 1 e Single Card Input drive rollers 2 e Single Card Input drive belt 3 PR OTE Inspect all O Rings and drive rollers for cracks or cuts Replace if necessary CPS120 Service Manual 2 5 CTS electronics Cleaning the Sensors Unlock and lift up the Front and Supplies Covers Power OFF the CPS120 and remove the power cord Use a can of compressed air to clean the following sensors Single Card Input Sensor X Home sensor Y Home sensor Reject Full sensor Input Hopper Empty sensor Input Hopper Nearly Empty sensor Magnetic Stripe Synchronism sensor Emboss Synchronism sensor Indent Ribbon Motion sensor 2 6 CPS120
38. S Boh SE GA es 7 10 TAB Nr 5 Indent 2 2222 Emm nn 7 10 CARRIAGE 2 5 coa aaa a Era 7 12 TAB Nr 6 Carriage o 7 12 CONTACT STATION SMART CARD 7 14 TAB Nr 7 Contact s s teaca m m nme 7 14 COVER va gs s AG e pE m AG Ed EG 7 15 TAB Nr 8 Cover Cable connection 7 15 OPTIONS 245 6 500 Sara ew SM MEG aa avs 7 18 INPUT OUTPUT MODULE Single feeder 7 18 TAB Nr 9 Single feeder 7 18 Legend gt XXX board name Connect to CPS120 Service Manual 7 1 CTS electronics INPUT OUTPUT REJECT MODULE TAB Nr 1 Input Leafing Q RIF CODE DESCRIPTION 4 1 R34 01015 Bearings 6x10x3 9balls 1 2 R34 01136 Belt Tooth 480MXL Z60 L025 1 3 R34 01150 Belt Tooth 1200MXL Z150 1 4 R34 01207 O ring CB86 3030 2 109 Silicon 1 5 R34 01267 O ring CB85 D 7 60 SEC 2 62 1 6 R34 01246 O ring 2 028 070x4 19 32 83A 1 7 R34 022098 Tooth Leafer Group 1 8 R34 022099 Input Cam Group 1 9 R34 022100 Lever Bridge Group 1 10 R34 022101 Knob Group 1 11 R34 10714 Reduc Motor Group 24v Fimo Cable 400mm 1 12 R34 10751 Reduc Motor Group L149 12 43 MODU2 L280 1 13 R34 10794 Step Motor Group T17 0 33A Cable 4 14 R34 CAB 0716 Cable 3way Photo TLP802 L 250 P2 1 15 R34 CAB 0740 Cable 3way Photo TLP802 L285 P2 1 16 R34 CAB 0804 Cable 2way ST03xPhoto ricev 1 17 R34 CAB 0806 Cable photo medium ST17 P2 L350 2 18 R34 CAB 0866 Cable 3way Photo TLP822 L350 P2 1 19 R34 1
39. S electronics Console Operation Description Console display gives informations on the machine across two lines structured in the following way machine name and release locked keypad online offline printed cards Keypad unlocking The first operation to perform to have access to the console is unlocking the keyboard For this purpose the user is required to digit a key the message Please enter pin will be displayed followed by a correct seguence of 4 digits the keypad pin and followed by an Enter The factory initial pin is set to 3450 At every reset the keypad will be locked again and will need to be unlocked After the keypad has been unlocked every key is associated with a specific operation to be performed on the peripheral Every operation will reguire the user confirmation before being executed to avoid accidental errors in key pressing Key 1 Set IP address and address mask Both operations can be skipped pressing the key 2 and executed by pressing key 1 At the end of the operations a chance of resetting the machine is offered to the user Key 2 Get IP address and address mask The current IP address followed by the current address mask are shown to the user Key 3 DES3 encryption The current encryption mode YES DES3 enabled NO DES3 disabled is shown and a chance to change it is given to the user Press key 1 to enable DES3 key 2 to disable it key 9 to exit to the main d
40. S120 Service Manual CTS electronics Topper Control Board Connections CPS CT 10762 J2 J4 J5 J10 J11 J12 J13 J14 J15 Ribbon Motion Senor Ribbon Motor Not used Topper Motor Topper Home Sensor Communication Port 24 V Power Supply Heater Temperature Sensor Heater SCREW4 SCREW3 SCREW2 Carriage Control Board Connection CPSINTX 10760 J1 Photosensor FOT1 J2 Interconnection 00 1 J1 J3 Y Axis Motor l a rl CPS120 Service Manual 4 7 CTS electronics Topper Control Board Connections CPS CT 14029 Optional only for Single Feeder module installed J2 Ribbon Motion Senor J4 Ribbon Motor J5 Not used J7 Card entry photosensor J8 Card presence photosensor J9 Feeder module motor J10 Topper Motor J11 Topper Home Sensor J12 Communicat
41. SENSOR DOWN SELECTION TRAY SENSOR Motor SELECTION TRAY MOTOR ERR CODE 0x30 Feeder Group in mechanical Error Sensor FEEDER HOME SENSOR Motor FEEDER MOTOR FEEDER RESET ERR CODE 0x30 Feeder Group in mechanical Error OR WARN CODE 0x17 Card can be Feed Sensors REJECT FULL SENSOR EJECT FULL SENSOR Motor NONE WARNING CODE 0x33 34 Reject Eject Stack Full RETURN ERROR CODE Yes RETURN OK 3 8 CPS120 Service Manual CTS electronics EMBOSSER RESET Routine DIE Sensor DIE HOME SENSOR RESET Motor DIE MOTOR No ERR CODE 0x51 Die On Error Yes PUNCH Sensor PUNCH HOME SENSOR RESET Motor PUNCH MOTOR No ERR CODE 0x51 Punch On Error Yes DAISY Sensor WHEEL HOME SENSOR RESET Motor WHEEL MOTOR ERR CODE 0x52 Daisy On Error OR Yes CARRIAGE Y Sensor Y AXIS HOME SENSOR RESET Motor Y AXIS MOTOR ERR CODE 0x54 Carriage Y On Error Yes CPS120 Service Manual 3 9 CTS electronics CARRIAGE X Sensor X AXIS HOME SENSOR RESET Motor X AXIS MOTOR ERR CODE 0x53 Carriage X On Error Sensor FRONT INDENT RIBBON MOTOR SENSOR Motor FRONT INDENT MOTOR ERR CODE 0x59 Indent UP On Error Sensor REAR INDENT RIBBON MOTOR SENSOR Motor REAR INDENT MOTOR ERR CODE 0x5A Indent DOWN On Error RETURN ERROR CODE 3 10 CPS120 Service Manual CTS ele
42. TS electronics Wheel home sensor 1 Place the new Wheel Home sensor in place and attach with one screw 2 Reconnect the Wheel Home sensor cable J14 on the Embosser Control board 3 Replace Cable Tie Synchronism sensor 1 Place the new Synchronism sensor in place and attach with two screws 2 Reconnect the Synchronism sensor cable J21 on the Embosser Control board 3 Replace Cable Tie 1 Replace the Embosser Module on the CPS120 see Remove and Replace the Embosser Module 2 Replace the Frame see Remove and Replace the Frame 3 Run a Standard Test Card to confirm proper operation of the CPS120 If successful run a limited number of customer produced cards for a final quality verification Follow up Adjustments The following adjustments must be performed after replacing the Wheel sensor e Wheel Offset VA A APF LA A A Nm 0 OK d BP A lt a NG u CPS120 Service Manual 6 37 CTS electronics Remove and replace punch die cam belts The Punch Die Cam belts transfers motion from the Punch Die Cam Motors to the cams which in turn applies pressure to the embossing punch die on the characters wheel Use the following procedure to remove and replace the Punch Die cam belts Remove 1 Unlock and lift up the Front Cover and the Supplies Cover 2 Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame 4 Remove the Embos
43. ad the steps table for punch die control run a card to get a standard embossing on it and measure if the character projection is in according with ISO standard Act on the two regulation screw 1 and turn always the same distance on lower part and upper part till obtain the projection needed Tight the upper and lower grub screw Fig 1 Card bow adjustment The Card support metal plate 3 drive the lower indent tape and mainly it control the card bow just embossed If the card embossed show a bow with the two side towards down need to move up the Card support metal plate 3 by loosing the three screw V1 and the grub screw G and screw clockwise the cam 4 till get the proper adjustment Then tight the grub screw G and the screws V1 Fig 2 If the card embossed show a bow with the two side towards up lt need to move down the Card support metal plate 3 by loosing the three screw V1 and the grub screw G and screw anticlockwise the cam 4 till get the proper adjustment Then tight the grub screw G and the screw V1 Fig 2 Move the Card support metal plate even of few 0 1mm can make a considerable changes so adjust it with care The Card support metal plate 5 is present only if the Upper Indent group is available if it s so adjust by the screws V2 in order to hold a embossed card thickness plus 0 3 0 5mm Embossing parallelism adjustment Run a card by embossing with three 8 characters on the two card opposite position and verify the
44. al CTS electronics Chapter 5 ADJUSTMENTS CPS120 Introduction am 3 eee ANE Ge en nen Ek 5 3 Mechanical Adjustments lt lt lt lt lt lt lt 5 3 CARRIAGE Pliers carriage adjustment 5 4 CARRIAGE Carriage high adjustment 5 5 CARRIAGE X Axis Transport Drive Belt Adjustment 5 6 HOPPER Adjusting for Card Thickness 5 6 INPUT OUTPUT REJECT Metal Plate high adjustment 5 7 ENCODER Encoder adjustment 5 8 Orizzontal position lt lt lt lt lt lt lt lt 0200004 5 8 ENCODER Adjustment card gap way 5 9 Vertical position lt lt lt lt lt lt lt lt lt nn 5 9 TOPPER ges A ee eg fn Gear ig 5 10 ENCODER Hunting control by the encoder 5 11 EMBOSSER Embosser adjustment 5 11 Initial punch die adjustment 5 11 Daisy wheel rotation reset position adjustment 5 11 Character projecting adjustment 5 11 Card bow adjustment lt lt lt lt lt lt 5 11 Embossing parallelism adjustment 5 11 INDENT Indent adjustment 5 13 Lower indent Tape position adjustment 5 13 Upper indent Tape position adjustment 5 13 CONTACT Chip contact station adjustment option 5 15 The CPS120 Card Personalization System operates as a standalone card embosser This chapter provides information for ad
45. al plate 2 Fix the metal plate with three screws 2 3 Reconnect the X Home sensor cable on the Axis interconnection control board 4 Place the seeger 1 Y Home sensor 1 Place the new Axis interconnection control board 5 in place and attach with two screws 4 2 Reconnect all cables on the Axis interconnection control board 1 Replace the Card transport Module on the CPS120 see Remove and Replace the Card Transport Module 2 Replace the Frame see Remove and Replace the Frame 3 Run a Standard Test Card to confirm proper operation of the CPS120 If successful run a limited number of customer produced cards for a final guality verification Follow up Adjustments These remove and replace procedures affect the following adjustments which must be performed after these procedures e X Offset e Y Offset CPS120 Service Manual 6 61 CTS electronics X Home sensor Y Home sensor CPS120 Service Manual CTS electronics Remove and replace power supply The Power Supply delivers DC power to the stepper and DC motors and powers the Main Control Board Use the following procedure to remove and replace the Power Supply Remove de m Replace DL DB M Unlock and lift up the Covers Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove two screws 1 and partially remove the Power Supply Remove the protection plate and rem
46. andard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification 6 48 CPS120 Service Manual CTS electronics CPS120 Service Manual 6 49 CTS electronics Replace the indent ribbon To change the indent ribbon perform the following steps A WARNING The topper platen may be very hot 1 Unlock the Supplies Cover and lift it see opening the Front and Supplies Covers Unlock the indent cartridge by pushing the two levers and pulling the cartridge out of the embosser module 3 Unlock the cartridge lever and open the cartridge Take up spool i Unlock Lever _ fe Supply spool Retainer take up Supply retainer Supply retainer metal pin Ribbon foil motion Ribbon guide rollers 4 Remove the empty ribbon core from the supplies spool and the full ribbon core from the take up spool 5 Place the new ribbon core on the supply spool as shown below 6 Wrap the indent ribbon around the ribbon motion guide and ribbon guide rollers 7 Place the empty core on the take up spool 8 Tape the edge of the ribbon dull side out to the empty core as shown below and lock the lever Take up spool Supply spool Tape the edge of the ribbon dull side out to the core Shiny side Dul side 9 Insert the cartridge into the printer and close the supplies cover
47. ble ST07 High P 2 L 380 1 8 R34 CAB 0994 Photoxensor Cable ST17 Medium P 2 L 400 1 9 R34 014029 CPS CT Topping Single feeder board 1 10 R34 022081 Input output contrast roller gt J9 Topper board 6 014029 Ng gt J8 Topper board 014029 GEL OG EG Fae 7 18 CPS120 Service Manual
48. ced cards for a final quality verification 6 40 CPS120 Service Manual CTS electronics 5 o e S Y RE Le 2 RO 7 l lin y l j gt O o n u oj C Ip AN a a bt CPS120 Service Manual 6 41 CTS electronics Remove and replace wheel motor The Wheel Motor is a stepper motor used for select a caracter to emboss Use the following procedure to remove and replace the Wheel motor Remove PORS o a Replace gi DVD Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove the Embosser Module from CPS120 see Remove and Replace the Embosser Module Remove the Wheel Cable from the motor Remove four screws 1 and remove the Wheel motor 2 Loose one grub screw holding the drive motor pulley and remove it Place the drive motor pulley in the shaft motor and hold in place with one grub screw Place a new motor in position and attach with four screws but do not fully tighten Press the mo
49. chapter of the manual provides information and procedures to isolate a fault to the part and or component level It includes symptoms fault isolation procedures use of diagnostic tools and error codes CPS120 Service Manual 4 1 CTS electronics 4 2 CPS120 Service Manual CTS electronics Troubleshooting Tips When correcting errors it is a good idea to perform the following Always power OFF the CPS120 Load the Input Hopper if the card stock is low Clear any rejected cards from the Reject Tray Replace the Topper Ribbon if it is getting low Replace the Indent Ribbon if it is getting low Make sure the Front Cover and the Supplies Cover are closed and locked Output Hopper door is fully closed Use these tips to correct the following problems If a Card is Loose in the CPS120 e Check the inside of the CPS120 for cards that may have fallen from the Card Transport module e Remove the cards and attempt to resume printing Ifthe Card is Jammed in the Input Hopper e Remove any jammed cards from the Input Hopper module by pulling cards from the back of the Input Hopper through the card throat e Attempt to resume printing Ifthe Card is Jammed in the Embosser Module e Remove any Jammed cards from the Embosser module e Attempt to resume printing If the Card is Jammed in the Topper Module e Remove any Jammed Cards from the Topper module e Attempt to resume printing If the Card is Jammed in the Smart
50. cing OCR Ferrington 7B AN Indent Characters Indent Punctuation 7 Characters per inch 0 143 0 006 inches 3 632 0 152 mm 10 Characters per inch 0 100 0 006 inches 2 540 0 152 mm 0 006 inches 0 152 mm 0 006 inches 0 152 mm CPS120 Service Manual 1 7 CTS electronics 1 8 CPS120 Service Manual CTS electronics Chapter 2 PREVENTIVE MAINTENANCE The CPS120 Card Personalization System operates as a standalone card embosser This chapter provides instructions for performing preventive maintenance on the CPS120 Preventive Maintenance lt lt 2 lt lt 22 lt 2 nn nn 2 3 Tools and Material lt lt lt lt Emm nn 2 4 Preventive Maintenance Procedures 2 4 Cleaning the CPS120 2 5 Cleaning the O Rings lt lt lt 22 2 5 Cleaning the Sensors lt lt lt lt nr rn 2 6 Cleaning the Magnetic Stripe Head 2 7 CPS120 Service Manual 2 1 CTS electronics 2 2 CPS120 Service Manual CTS electronics Preventive Maintenance The following table lists the periodic cleaning and adjustment verification requirements for the CPS120 A complete procedure for each item in the table is given in this chapter Preventive Maintenance PM should be performed at 12 month intervals and after any of the following activities e Any adjustement to a FRU or sub assembly e Any replacement to a FRU or sub assembly
51. ctronics Sequence of operation 1 After the CPS120 initializes on power up cards can be produced a Once the system detects that a block of data has been received acknowledges the data and signals the topper platen heater to turn on 2 The CPS120 senses cards in the Input Hopper by checking the Input Hopper Empty sensor a The card is feed and the pick mechanism picks a card 3 The card is tranported to the Encoder Module a Depending on the Magnetic Stripe setup the card make as many as one or two passes one for LO CO two for HI CO to read and write to the card s magnetic stripe tracks If the magnetic stripe can not be written to or read from the card is transported to the reject tray 4 The card transport mechanism moves the card to the Embossing Wheel a The Embossing Wheel senses the home position Wheel Home sensor the first time a character is reguested to print The Embossing Wheel will move either clockwise or counter clockwise depending on how guickly the Embossing character can be moved to be embossed on the card The card will move in four directions as the punch and dies emboss characters on the card The die cam home sensor and the punch cam home sensor detect when both cams are in their home position both the die and the punch cams work simultaneously to emboss characters on a card 5 After a card is embossed it is transported to the Topper Module where the bottom half of the car
52. d Remove POD Replace Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove the Smart Card Module from CPS120 see Remove and Replace the Smart Card Module Remove two screws 1 and remove the Smart Card Contact Solenoid 2 Place a new Solenoid in position and attach with two screws Replace the Smart Card Module on the CPS120 see Remove and Replace the Smart Card Module Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification CPS120 Service Manual 6 53 CTS electronics CARRIAGE ASSEMBLY Remove and replace card transport module The Card Transport consists of a mechanism for moving a card through different stages of production to produce a final card Use the following procedure to remove and replace the Card Transport Module Remove 1 Unlock and lift up the Front Cover and the Supplies Cover 2 Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame 4 Remove eight screws 1 and partially remove the Card Transport from the base to gain access to the cable connectors 5 Disconnect the X axis cable from the X axis motor and the Card Transport Flex Cable fr
53. d is topped a The topper platen sensor detects that the platen is in its home position and up to temperature and ready to top cards The topping foil is advanced and the platen is moved to the ready position As a card is moved in to the topper module a topper motor is activated to apply platen pressure and heat to the topping foil This topping foil adheres to the raised embossed characters on the card 6 After a card is topped the completed card is transported to the eject tray for delivery to the operator CPS120 Service Manual 3 11 CTS electronics Electrical Block Diagrams The following section provides a brief description of the CPS120 Main Control Board and module s boards Main Control Board The Main Control Board hold communication data to all modules and provides the electronics to control Interlock Solenoid and Interlock Sensor CPS120 Main Control Board Block Diagram CPS EMB CPS TOP CPS ENC CPS FEEDER CPS CONS I on em CONTACTLESS CHIP CARD OSC 3 072 MHz EEPROM N POWER SUPPLY SVE 33V LU z ert x 52 I ll lt lt x 7 FO a a 2 o Za Ss OT xx 83 2 Be OG 33 sq ES a l s X 193 a 3 lt 185 I O O m Im O m X 3 KA E u z o N O De in E z w2 a LL N Ge og 2 lt ro o w gt 2 LU EA 2 fal 3 F x Ox rz wu zo INTERL
54. e two screws 2 holding the input motor to its support Disconnect the input motor cable J4 from the Input Output Reject Control Board Place a new motor into the support and hold in place with two screws 2 Place the drive motor pulley onto the shaft motor and hold in place with one grub screw Place the input drive o ring in position Place the motor group in positon and hold in place with two nuts Reconnect the input motor cable J4 on the Input Output Reject Control Board Replace the Input Output Reject module on the CPS120 see Remove and Replace the Input Output Reject module Make sure to do not pinch the wires under the module A WARNING Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification 6 8 CPS120 Service Manual CTS electronics CPS120 Service Manual 6 9 CTS electronics Remove and replace feeder motor The Feeder motor provide traction for feed a card from the input hopper Use the following procedure to remove and replace the Feeder motor Remove PPD a Replace 1 2 3 Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove the Input Output Reject Module from CPS120 see Remove and Replace the Input Output Rejec
55. emove it Place the new Y Transport drive belt in position and hold in the up side of the Card Transport with one stirrup and two nuts Partially place the Up side of the Card Transport in position place the belt around the drives belt 3 Attach with four screws the Up side of the Card Transport Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification CPS120 Service Manual 6 59 CTS electronics Remove and replace Y transport motor The Y Transport Motor drives the transport mechanism for moving cards through the CPS120 Use the following procedure to remove and replace the Y Transport Drive belt Remove ALO O B ODS Replace 1 2 3 Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove four screws 1 and remove the up side of the Card transport Disconnect the cable from the Y Transport motor Remove two nuts 3 and remove the Y Transport motor 4 Loose one grub screw and remove the Y Transport drive motor pulley 5 Replace the Y Transport drive motor pulley 5 on the shaft motor and hold in place with one grub screw Place the new Y Transport drive motor 4 in position and attach with two nuts Partially place the Up side of the Card Transport in p
56. emove one screw and remove the Feeder home sensor 7 Eject tray door open sensor 1 Disconnect the Eject Tray Door Open sensor cable J3 from Input Output Reject Module control board 2 Remove one screw and remove the Eject Tray Door Open sensor 8 CPS120 Service Manual 6 13 CTS electronics Replace Single card input sensor 1 Place the new Single Card Input sensor 1 in place and attach with one screw 2 Reconnect the Single Card Input sensor cable J5 on the Input Output Reject Module control board Selection tray sensor UP 1 Place the new Up Selection Tray sensor 2 in place and attach with one screw 2 Reconnect the Up Selection Tray sensor cable J7 on the Input Output Reject Module control board Selection tray sensor DOWN 1 Place the new Down Selection Tray sensor 3 in place and attach with one screw 2 Reconnect the Down Selection Tray sensor cable J8 on the Input Output Reject Module control board Reject tray full sensor 1 Place the new Reject Tray Full sensor 4 in place and attach with one screw 2 Reconnect the Reject Tray Full sensor cable J11 on the Input Output Reject Module control board 3 Replace the Input Output Reject Module on the CPS120 see Remove and Replace the Input Output Reject Module 4 Replace the Frame see Remove and Replace the Frame 5 Run a Standard Test Card to confirm proper operation of the CPS120 If successful run a limited numb
57. eneral information about this document and service data for the CPS120 Chapter 2 Installation Provides information for site preparation unpacking inspection setup configuration and initial checkout of a CPS120 Chapter 3 Preventive Maintenance Provides a preventive maintenance schedule with procedures and tool requirements for periodic maintenance of the CPS120 Chapter 4 Theory of Operation Provides basic electrical theory for the CPS120 Chapter 5 Troubleshooting Provides a Troubleshooting guide to determine which FRU needs to be replaced or what adjustment needs to be performed for proper operation of the CPS120 Chapter 6 Adjustments Provides detailed procedures for mechanical electrical and software adjustments Chapter 7 Removal and Replacement Provides removal and replacement procedures for field replaceable items in the CPS120 1 4 CPS120 Service Manual CTS electronics Product Specifications Electrical 100 240V AC at 3 2A 50 60Hz Single phase 3 wire grounded receptable only Environmental Noise level Relative Humidity Maximum heat dissipation Operating temperature range ESD Susceptibility Communications RS 232 service port RS 232 host port LAN port USB port Smart Card Contact port Smart Card Contactless port Card Capacities Input Hopper Capacity Reject Hopper Capacity Output Hopper Capacity Topper Cartridge Capacity Physical Specifications Width
58. er of customer produced cards for a final quality verification Empty hopper sensor 1 Place the new Empty Hopper sensor 5 in place and attach with one screw 2 Reconnect the Empty Hopper sensor cable J2 on the Input Output Reject Module control board Nearly empty hopper sensor 1 Place the new Nearly Empty Hopper sensor 6 in place and attach with one screw 2 Reconnect the Nearly Empty Hopper sensor cable J1 on the Input Output Reject Module control board Feeder home sensor 1 Place the new Feeder Home sensor 7 in place and attach with one screw 2 Reconnect the Feeder Home sensor cable J16 on the Input Output Reject Module control board Eject tray door open sensor 1 Place the new Eject Tray Door Open sensor 8 in place and attach with one screw 2 Reconnect the Eject Tray Door Open sensor cable J3 on the Input Output Reject Module control board 6 14 CPS120 Service Manual CTS electronics Remove and replace input output module Single feeder The Input Output Module is a main assembly used for stacking single card as an output receptacle for completed card Use the following procedure to remove and replace the Input Output Module Single card Remove 1 Unlock and lift up the Front Cover and the Supplies Cover 2 Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame 4 Manually move the Card Transport carriage to the center of the CPS120 5 Disconnect the f
59. et 7 31 24V 660hm L300 2 6 R34 CAB 0866 Cable 3way photo TLP822 L 350 P2 Photo encoder TABLE 5 7 10 CPS120 Service Manual CTS electronics FRONT p En CPS120 Service Manual 7 11 CTS electronics CARRIAGE TAB Nr 6 Carriage Q RIF CODE DESCRIPTION 1 1 R34 01093 Belt Tooth MXL Z591 L025 1 2 R34 01092 Belt Tooth MXL Z85 L025 2 3 R34 022371 Shaft guide 1 4 R34 022382 Plier Group Axis Y Card Movement 1 5 R34 022383 Plier Group Axis X Card Movementer 1 6 R34 022384 Transport Card support group 1 7 R34 022385 Release Command group 1 8 R34 10760 CPSINTX board 1 9 R34 10794 Step Motor T17 0 33A Cable group 1 10 R34 10798 Gr Motstep 13 Cabmot 016 1 11 R34 CAB 0715 Cable 3way Photo TLP802 L 150 P2 1 12 R34 CAB 0813 FCC 10wayx890mm P 2 54mm TABLE 6 7 12 CPS120 Service Manual CTS electronics 8 9 gt J1 Carriage board gt J3 Carriage board CPS120 Service Manual 7 13 CTS electronics CONTACT STATION SMART CARD TAB Nr 7 Contact RE CODE DESCRIPTION O 1 1 R34 10792 Contact station group 1 2 R34 CAB 0716 Cable 3way photo TLP822 L250 P2 1 3 R34 10578 Gr E mag T 31 24V 660hm L160 1 4 R34 14025 CPS SC USB Board TABLE 7 7 14 CPS120 Service Manual CTS electronics COVER TAB Nr 8 Cover Cable connection RIF CODE DESCRIPTION O 1 1 R34 00812 Lock box5 sx 16 onc Fast Loc 1 2 R34 10892 Gr E mag E5499 24V 60ohm Thermal pro
60. ge will occur 3 Reconnect the Ribbon Motor cable J4 on the Topper Control board 4 Replace the Frame 5 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification CPS120 Service Manual 6 29 CTS electronics Remove and replace ribbon motion sensor The Ribbon Motion sensor detects physical motion of a slotted wheel insuring that the topper ribbon has advanced Use the following procedure to remove and replace the Ribbon Motion sensor Remove 1 Unlock and lift up the Front Cover and the Supplies Cover 2 Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame The Topper Platen May Be Very Hot A WARNING 4 Remove two screws 1 holding the Ribbon Motion sensor group and remove it 5 Remove one screw 2 holding the Ribbon Motion sensor 3 and remove it 6 Disconnect the Ribbon Motion sensor cable J2 from the Topper Control Board Replace T Place a new sensor in position and hold in place with one screw 2 Place the Ribbon Motion sensor group in position and attach with two screws 3 Reconnect the Ribbon Motion sensor cable J2 on the Topper Control Board 4 Replace the Frame 5 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final
61. gulated supply from 5 0 volts The 3 3 volts 3 3V is supplied to all IC s via a discrete plane within the printed circuit board RS232 Tranceiver The CPS120 service port support a 2 driver and 2 receiver RS232 tranceiver configuration the RS232 trainceiver input and output are tied directly to the microprocessor Comm port1 The CPS120 host port support the modem control signal the trainceiver input and output are tied to an external Uart TL16C550 controlled by the microprocessor LAN Tranceiver The MCF5272 integrated fast Ethernet media access controller MAC performs the full set of IEEE 802 3 Ethernet CSMA CD media access control The microprocessor interface an external 100 10 BaseT Ethernet tranceiver LXT971L and the isolation trasformer HALO TG110 The tranceiver requires a 25 MHz oscillator In default configuration mode the LAN is auto negotiation of 10 or 100 baseT full duplex operation There are three LED that indicated the status of the Ethernet tranceiver and the meaning of each LED is software configurable Default settings meaning e LED2 display 1 If link is not connected the LED2 is off 2 Iflink is connected the LED2 is on 3 Iflink is connected and there is activity on the lines the LED2 blinking e LED3 display the state of link if the link is connected LED3 is on e LED4 display the state of receiver USB Tranceiver The integrated USB controller on COLDFIRE MCF5272 support device mode data co
62. he BDM JTAG connector of the microprocessor is possible programming the firmware in flash memory There are two memory SDRAM MT48LC4M16A2 each by 8 MByte 4M X 16 arranged to provide 16MByte in a 32 bit wide data bus configuration 8M X 32 of main memory for the microprocessor These devices are controlled directly by the microprocessor by chip select 7 CS7 Eeprom The EEPROM Elettrically Erasable Programmable Read Only Memory can be written to and changed many times and it is used for data storage This device organized as 128 byte 64 X 16 is accessed through a serial data input and output Configuration offset setting and history of machine are stored in this chip 485 Lines The board Cps Master communicate with the other module of CPS120 with this channel This is a line of two differential wire controlled by the chip SN75176 It used the microprocessor Comm port2 and communicate at 19200 baud CPS120 Service Manual 3 13 CTS electronics 24 Volt Power Supply The power supplies 24V DC supplies all driver of stepper motors DC motors solenoids the resistor of topping and the magnetic stripe driver circuit 5 Volt Regulator A switching regulator is utilized to create the 5 0 volt supply about 3A from the 24 Volts The 5 volts Vcc is used to supply all board of module of CPS120 and the board of contacless option 3 3 Volt Regulator Alinear regulator LD1117DT330 is utilized to create 3 3 volts re
63. he CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification CPS120 Service Manual 6 23 CTS electronics TOPPER ASSEMBLY Remove and replace topper module The Topper Module places a colored layer on the top of embossed characters on a plastic card Heat is used to affix this layer to the plastic card Use the following procedure to remove and replace the Topper Module Remove 1 Unlock and lift up the Front Cover and the Supplies Cover 2 Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame The Topper Platen May Be Very Hot A WARNING 4 Remove four screws 1 and partially remove the Topper from the base to gain access to the cable connectors 5 Disconnect the following cables from the Topper control board e Power supply J13 e Communication cable J12 6 Lift the Topper Module from the CPS120 Replace 1 Place the new Topper Module in position and attach with four screws 2 Reconnect the following cables to the Topper control board e Power supply J13 e Communication cable J12 3 Replace the Frame 4 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification 6 24 CPS120 Service Manual CTS electronics CPS120 Service Manual 6 25 CTS e
64. he Main Control Board 1 Unlock and lift up the Front Cover and the Supplies Cover 7 Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Use proper anti static grounding techniques when handling the Main WARNING Control Board Disconnect all cables from the Main Control Board 1 E Remove four screws 2 and four studs 3 and remove the Main Control Board Replace Use proper anti static grounding techniques when handling the Main WARNING Control Board 1 Place the new Main Control Board in position and hold in place with four screws and four studs 2 Reconnect all cables on the Main Control Board 3 Reload the saved configurations into the CPS120 4 Replace the Frame 5 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final guality verification CPS120 Service Manual 6 69 CTS electronics 6 70 CPS120 Service Manual CTS electronics Chapter 7 SPARE PARTS LIST INPUT OUTPUT REJECT MODULE 7 2 TAB Nr 1 Input Leafing 7 2 ENCODER br ay 3 2 0 2 Bed ROG ET 7 5 TAB Nr 2 Encoder 2222 7 5 TOPPER 2 2 ae Saa DR Rot oto 7 6 TAB Nr 3 TOPper 2 sa sje kvele 2 a ee ne 7 6 EMBOSSER 4 2 ach wo a ra a ek 7 8 TAB Nr4 Emb sser a oa 4444 but s slede 7 8 INDENT x 4 sara EO
65. include the following e 32 K byte user program FLASH memory e 512 byte of on chip EEPROM for user data storage e 1 K byte of on chip RAM The microprocessor support a CPLD that manage the enable rotations and the phases of four motor step the full step of punch and die and the half step of wheel and the X axis The Embosser Board provides the electronics to control e Embosser Motors Wheel Step motor Punch Step motor Die Step motor Rear Indent Ribbon DC motor Rear Indent solenoid Front Indent Ribbon DC motor and Front Indent solenoid e Axis motors X Axis Step motor and Y Axis Step motor e Embosser sensors Wheel Home sensor Punch Home sensor Die Home sensor Rear Indent Ribbon Motion sensor and Front Indent Ribbon Motion sensor e Axis sensors X Axis Home sensor Y Axis Home sensor and Synchronism sensor Consolle Control Board The microprocessor Motorola MC68HC908GT8 is the module controlling element of CPS120 system Itis a 8 bit microprocessor at 8 MHz internal bus freguency it communicate with the master board through 485 lines at 19200 baud Features of the microprocessor include the following e 8 K byte user program FLASH memory e 512 byte of on chip RAM e internal oscillator The Consolle Board incorporates a 2X24 LCD display Five indipendently controlled LED s provide visual status and control functions A 12 digit keypad allows user input from the front panel 3 16 CPS120 Service Manual CT
66. ines at 19200 baud Features of the microprocessor include the following e 32 K byte user program FLASH memory e 512 byte of on chip EEPROM for user data storage e 1 K byte of on chip RAM The microprocessor support two CPLD that manage the contemporaneous writing of three tracks one and zero bit sincronized by encoder of 210 BPI and in reading mode the sincronized of count of tracks for the jitter control The Magnetic Stripe Board provides the electronics to control the Magnetic Head and synchronism sensor Topper Control Board The microprocessor Motorola MC68HC908GT8 is the module controlling element of CPS120 system Itis a 8 bit microprocessor at 8 MHz internal bus freguency it communicate with the master board through 485 lines at 19200 baud Features of the microprocessor include the following e 8 K byte user program FLASH memory e 512 byte of on chip RAM e internal oscillator The Topper Board provides the electronics to control e Heater e Topper motors Topper DC Motor and Ribbon DC Motor e Topper Sensors Topper Temperature sensor Topper Home sensor and Ribbon Motion sensor CPS120 Service Manual 3 15 CTS electronics Embosser Control Board The microprocessor Motorola MC68HC908AB32 is the module controlling element of CPS120 system Itis a 8 bit microprocessor at 8 MHz internal bus freguency it communicate with the master board through 485 lines at 19200 baud Features of the microprocessor
67. inter or use the correct command sent from PC Key 0 Read Topping Temperature The topping temperature is shown on the display Key ENTER reset Pressing this key a warm reset is performed An alternate way to reset the peripheral is obtained by turning around the cover key 3 18 CPS120 Service Manual CTS electronics Chapter 4 TROUBLESHOOTING Troubleshooting Tips lt lt lt lt lt lt lt lt lt 4 enn enn 4 3 If a Card is Loose in the CPS120 4 3 If the Card is Jammed in the Input Hopper 4 3 If the Card is Jammed in the Embosser Module 4 3 If the Card is Jammed in the Topper Module 4 3 If the Card is Jammed in the Smart Card Module 4 3 CPS120 Interconnect Diagrams 4 4 Main Control Board Connections CPS MASTER 10758 4 5 Input Output Reject Control Board Connections CPS CT 10761 o se s EEE 4 6 Topper Control Board Connections CPS CT 10762 4 7 Topper Control Board Connections CPS CT 14029 Optional only for Single Feeder module installed 4 8 Magnetic Stripe Control Board Connections CPS BM 10763 4 9 Contact Control Board Connections CPS SC USB 14025 4 9 Embosser Control Board Connections CPS EBM 10759 4 10 Consolle Control Board CPS DISPLAY 10764 4 11 AC Wiring Diagram 22 arv vr vr 4 11 The CPS120 Card Personalization System operates as a standalone card embosser This
68. ion Port J13 24 V Power Supply J14 Heater Temperature Sensor J15 Heater SCREWA SCREW3 SCREW2 4 8 CPS120 Service Manual CTS electronics Magnetic Stripe Control Board Connections CPS BM 10763 J1 J2 J3 Magnetic head group J7 Synchronism Sensor J11 Encoder TP3STP32 o a
69. isplay Key 4 Unlock cover If the user confirms his choice pressing the key 1 the printer cover is unlocked even without turning around its key After a timeout of about 15 seconds the cover is locked again If the cover is yet locked the printer goes Off Line After closing the cover the printer will reset itself Key 5 not used Key 6 not used CPS120 Service Manual 3 17 CTS electronics Key 7 Start Eject Loop Cards are taken from the feeder and ejected one after the other until a key is pressed to stop the loop Key 8 Start Reject Loop Cards are taken from the feeder and rejected one after the other until a key is pressed to stop the loop Key 9 Make Demo card The task is divided in three subtasks encoding the magnetic stripe embossing the card and moving to Chip Contact Each of these subtasks can be enabled or disabled If encoding the stripe is enabled the user is asked what is the reguired coercitivity high or low if embossing the card is reguested a further topping step can be enabled or disabled After having embossed the card and eventually moved it to Chip Contact a further option can be printing the indent on the rear face in that case the user must specify if the indent must be OCRB or Slanted Key DEL Enable Diagnostic Mode The channel is asked RS232 or LAN Once entered Diagnostic Mode the only way to go back to Normal mode is switch off and again on the pr
70. justing the CPS120 Service Manual CTS electronics 5 2 CPS120 Service Manual CTS electronics Introduction This chapter presents mechanical and software adjustment procedures for the CPS120 These procedures are not part of preventive maintenance and are only performed as unscheduled maintenance requirements identified during fault isolation Mechanical Adjustments The following pages describe the mechanical adjustments for the CPS120 The software offset adjustments appear after the mechanical adjustments CPS120 Service Manual 5 3 CTS electronics CARRIAGE Pliers carriage adjustment Verify that bridge 1 pulled by the spring 6 is leading on the point P1 Verify that the pin 2 is leading on the levers A pulled by the hook 3 Ifthese conditions are correct verify that the distance from the theets 5 to the plier support 6 is from 0 2 mm up to 0 3 mm Ifthe distance is different bend the levers A Then insert a card between the theets 5 and the plier support 6 and verify that the card stay in position if pulling it whit a certain force If the card slip out the plier easy adjust by the nut 4 Fig 1 Fig 2 Fig 1 Fig 2 5 4 CPS120 Service Manual CTS electronics CARRIAGE Carriage high adjustment Put the carriage to the end of stroke in this position move the carriage to the working points 1 and 2 and verify that the height with respect to the base is 127 mm Differen
71. lectronics Remove and replace topper motor The Topper motor provides traction for moving the platen to the card Use the following procedure to remove and replace the Topper motor Remove 1 2 3 Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame The Topper Platen May Be Very Hot A WARNING NOG Replace Remove the Topper from CPS120 see Removing the Topper Assembly Remove one pin 1 holding the Topper Motor gear 2 Remove the Topper motor gear Disconnect the Topper motor cable J10 from the Topper Control Board and remove cable ties Remove three screws 3 holding the Topper Motor and remove it Place a new Topper motor in position and attach with three screws Place the Topper motor gear onto the shaft motor and hold in place with one pin Reconnect the Topper motor cable J10 on the Topper Control Board and replace cable ties Replace the Topper Assembly on the CPS120 see Replacing the Topper Assembly Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification 6 26 CPS120 Service Manual CTS electronics Remove and replace topper home sensor The Topper Home sensor detects when the platen has reached its home position Use the follo
72. lt Place the new X Transport drive belt in position as shown in Figure B and hold in the Card Transport Module with one stirrup and two nuts Place the X Transport drive belt around the backstand gear place the backstand gear in place and attach with two screws Replace the X Transport drive belt backstand in position and hold with one nut Replace the Card Transport Module CPS120 see Remove and Replace the Card Transport Module Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 Ifthe test is successful run a limited number of customer produced cards for a final quality verification Follow up Adjustment This remove and replace procedure affects the following adjustments which must be performed after this procedure e X Transport drive belt backstand regulation 6 56 CPS120 Service Manual CTS electronics CPS120 Service Manual 6 57 CTS electronics Remove and replace X transport motor The X Transport motor provides traction for moving cards through the CPS120 Use the following procedure to remove and replace the X Transport motor Remove POD a Replace 1 2 Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove
73. ly 1993 73 23 EEC dated 19 February 1973 with subsequent amendments Directive 93 68 EEC dated 220d July 1993 since designed and manufactured in compliance with the following European Harmonised Standards EN 55022 Limits and method of measurements of radio interference characteristics of Information Technology Equipment EN 61 3 2 Electromagnetic Compatibility Part 3 Limit Section 2 Limits for harmonic current emission eguipment input current lt 16 A per phase EN 61000 3 3 Electromagnetic Compatibility Part 3 Limit Section 3 Limitation of voltage fluctuations and flicker in low voltage supply system for equipment with rated current lt 16 A EN 55024 Limits and method of measurements of Immunity characteristics of Information Technology Eguipment EN 60950 1 Safety of Information Technology Equipment including electrical business equipment Compliance with the above mentioned essential reguirements is shown by affixing the CE marking on the product U S A U S FEDERAL COMMUNICATIONS COMMISSION RADIO FREQUENCY INTERFERENCE STATEMENT INFORMATION TO THE USER This eguipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference when the eguipment is operated in a commercial enviroment This eguipment generates uses and can radiate radio freguency
74. me 5 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final guality verification CPS120 Service Manual 6 65 CTS electronics Remove and replace encoder control board The Encoder Control Board provide the electronic to write and read the magnetic stripe on the cards Use the following procedure to remove and replace the Encoder Control Board Remove Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove the Encoder Module from CPS120 see Remove and Replace the Encoder Module gt AN WARNING Encoder Control Board A Use proper anti static grounding technigues when handling the 5 Disconnect all cables from the Encoder Control board 6 Remove four screws holding the Encoder Control Board 1 and remove it Replace Use proper anti static grounding techniques when handling the WARNING Encoder Control Board 1 Place the new Encoder Control Board in position and attach with four screws 2 Reconnect all cables on the Encoder control board 3 Replace the Encoder Module in the CPS120 see Remove and Replace the Encoder Module 4 Replace the Frame 5 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited
75. mmunication between itself and a USB host device typically a PC Itis fully compatible with the Universal Bus Specification 1 1 and support full speed 12 Mbps USB device and low speed 1 5 Mbps devices The controller required a 48 MHz oscillator and data communication is internally synchronized The USB trainceiver PDIUSB11APW is an external component to be USB 1 1 compliant controlled by microprocessor 3 14 CPS120 Service Manual CTS electronics Input Output Reject Control Board The microprocessor Motorola MC68HC908GT8 is the module controlling element of CPS120 system Itis a 8 bit microprocessor at 8 MHz internal bus freguency it communicate with the master board through 485 lines at 19200 baud Features of the microprocessor include the following e 8 K byte user program FLASH memory e 512 byte of on chip RAM e internal oscillator The Input Output Reject Board provides the electronics to control e Feeder Motors Feeder Step motor Selection Tray DC motor and Single Card Input DC motor e Feeder sensors Feeder Home sensor Single Card Input sensor Nearly Empty Hopper sensor Empty Hopper sensor Selection Tray sensors Eject Tray Door open sensor Reject Tray Full sensor Magnetic Stripe Control Board The microprocessor Motorola MC68HC908AB32 is the module controlling element of CPS120 system Itis a 8 bit microprocessor at 8 MHz internal bus frequency it communicate with the master board through 485 l
76. nnecting the inline cables place the new Encoder in position and attach with four screws Replace the metal plate protection boad 2 and screw the fixing screw 1 Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification CPS120 Service Manual 6 21 CTS electronics 6 22 CPS120 Service Manual CTS electronics Remove and replace encoder sensor The Encoder sensor provide the synchronism to write the magnetic stripe on the cards Use the following procedure to remove and replace the sensors Remove SONA a Replace 1 RR Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove the Encoder Module from CPS120 see Remove and Replace the Encoder Module Disconnect the Synchronism sensor cable J7 from the Encoder Control board Remove screw 1 and extract the metal plate holding the synchronism sensor 2 remove it Place the new Synchronism sensor on the metal plate 2 in position with emitter pointing down and attach with screw 1 Reconnect the Synchronism sensor cable J7 on the Encoder board Replace the Encoder on the CPS120 see Remove and Replace the Encoder Replace the Frame Insert a Standard Test Card to confirm the proper operation of t
77. not fully tighten Reconnect the Indent solenoid cable J8 Front J10 Rear on the Embosser control board Replace the Embosser Module on the CPS120 see Remove and Replace the Embosser Module Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification Follow up Adjustments This remove and replace procedure affects the following adjustments which must be performed after this procedure e Indent adjustment CPS120 Service Manual 6 43 CTS electronics 6 44 CPS120 Service Manual CTS electronics Remove and replace front rear indent motor The Front and Rear Indent Motors are a DC motors used to advance the Front if is available and Rear Indent ribbon in the Indent cartridge Use the following procedure to remove and replace the Front and Rear Indent Motors The procedure is the same for both Front and Rear Motors Remove
78. number of customer produced cards for a final quality verification 6 66 CPS120 Service Manual CTS electronics Remove and replace topper control board The Topper Control Board provides the electronic to places a colored layer of embosser characters on a plastic card Use the following procedure to remove and replace the Topper Control Board Remove 1 Unlock and lift up the Front Cover and the Supplies Cover 2 Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame 4 Remove the Topper Assembly from CPS120 see Removing the Topper Assembly Use proper anti static grounding technigues when handling the WARNINGI Topper Control Board Disconnect all cables from the Topper Control board Remove four screws holding the Topper Control Board 1 and remove it Replace Use proper anti static grounding technigues when handling the WARNINGI Topper Control Board 1 Place the new Topper Control Board in position and attach with four screws 2 Reconnect all cables on the Topper control board 3 Replace the Topper Assembly on the CPS120 see Replacing the Topper Assembly 4 Replace the Frame 5 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final guality verification CPS120 Service Manual 6 67 CTS electronics Remove and re
79. ollowing cables from the Topper code 14029 control board Motor connection J9 Photosensors cable J7 J8 6 Remove two screws and lift the module from the CPS120 Replace 1 Place the new module in position 2 Reconnect the following cables from the Topper code 14029 control board Motor connection J9 Photosensors cable J7 J8 3 After connecting the inline cables attach the five screws 1 on the module Make sure to do not pinch the wires under the module A WARNING 4 Replace the Frame 5 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality Verification CPS120 Service Manual 6 15 CTS electronics Remove and replace single card input drive motor The input motor provide traction for moving a single card into the picked area Use the following procedure to remove and replace the input motor Remove gt PAN o a Replace gt BD Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove the input output module See Remove and replace input output module Single feeder Loose grub screw 1 holding the drive motor pulley and remove it Remove two screws 2 holding the input motor to its support Disconnect the input motor cable J9 from the Topper code
80. om the Axis Interconnection 6 Lift the Card Transport Module from the CPS120 Replace 1 Partially place the new Card Transport Module in position 2 Reconnect the X axis cable on the X axis motor and the Card Transport Flex Cable on the Axis Interconnection 3 After connecting the inline connectors place the new Card Transport Module in position and attach with eight screws 1 4 Replace the Frame 5 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification 6 54 CPS120 Service Manual CTS electronics CPS120 Service Manual 6 55 CTS electronics Remove and replace X transport drive belt The X Transport Drive belt drives the transport mechanism for moving cards through the CPS120 Use the following procedure to remove and replace the X Transport Drive belt Remove PON On Replace 1 Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove the Card Transport Module from CPS120 see Remove and Replace the Card Transport Module Remove one nut 1 holding the X Transport Drive belt backstand 2 Remove two screws 3 holding the backstand pulley Remove two nuts 4 and one stirrup holding the X Transport drive belt 5 on the Card Transport Remove the X Transport drive be
81. om the input hopper Use the following procedure to remove and replace the feeder drive belt Remove 1 Unlock and lift up the Front Cover and the Supplies Cover Ze Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame 4 Remove manually the two plastic washers 1 from the two gears and remove the Feeder Drive Belt 2 Replace 1 Place the new Feeder Drive Belt in position and replace the two plastic washer 1 2 Replace the Frame 3 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final guality verification CPS120 Service Manual 6 7 CTS electronics Remove and replace single card input drive motor The input motor provide traction for moving a single card into the picked area Use the following procedure to remove and replace the input motor Remove gt PAN a Replace DOT M Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove the Input Output Reject module from the CPS120 see Remove and Replace the Input Output Reject module Remove two nuts 1 holding the Input Motor group Slip the input drive o ring 5 off the Input drive motor pulley and remove the Input Motor group Loose one grub screw 4 holding the drive motor pulley and remove it Remov
82. osition place the belt around the drives belt 2 Make sure belt tension is sufficient to ensure that no slippage will occur Attach with four screws the Up side of the Card Transport Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification 6 60 CPS120 Service Manual CTS electronics Remove and replace card transport sensor The sensors that control the Card Transport movement are e X Home sensor e Y Home sensor Use the following procedure to remove and replace the sensors Remove 1 Unlock and lift up the Front Cover and the Supplies Cover see Opening the Covers 2 Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame see Remove and Replace the Frame 4 Remove the Card Transport Module from CPS120 see Removing the Card Transport Module X Home sensor 1 Remove the seeger 1 2 Remove three screws 2 and extract the support metal plate 3 Disconnect the X Home sensor cable from Axis Interconnection control board 4 Remove the X home sensor 3 Y Home sensor 1 Disconnect all cables from Axis Interconnection control board 2 Remove two screws 4 and remove the Axis interconnection control board 5 Replace X Home sensor 1 Place the new X Home sensor 3 in place and attach with one screw on the support met
83. otor cable J10 from the Input Output Reject Module Control Board and remove cable ties Remove two screws 4 holding the Selection Tray Motor and remove it Place a new motor in position and attach with two screws Place the motor Cam in the shaft motor and hold in place with one grub screw Place the Selection Tray Sensors and hold in place with two screws Reconnect the selection tray motor cable J10 on the Feeder Control Board and replace cable ties Replace the Input Output Reject Module on the CPS120 see Remove and Replace the Input Output Reject Module Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final guality verification CPS120 Service Manual 6 11 CTS electronics Remove and replace Input Output Reject module sensors The sensors that control the Input Ouput Reject movement are Single Card Input sensor 1 Selection Tray sensors 2 3 Reject Tray Full sensor 4 Empty Hopper sensor 5 Nearly Empty Hopper sensor 6 Feeder Home sensor 7 Eject Tray Door Open sensor 8 Use the following procedure to remove and replace the sensors Remove 1 Unlock and lift up the Front Cover and the Supplies Cover see Opening the Covers 2 Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame see Remove and Replace the Frame 4 Rem
84. ove six red wires from the V side of the Power Supply Remove six black wires from the V side of the Power Supply and three AC line wires from the AC Input side of the Power Supply Remove the Power Supply Attach six red wires to the V side of the new Power Supply Attach six black wires to the V side of the new Power Supply Attach three AC line wires to the AC input side of the new Power supply Place the protection plate Place the new Power Supply in position and attach with two screws Replace the Frame Plug in the power cord and power ON the CPS120 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final guality verification SP 200 24 DC OUTPUT AC INPUT V v N L alelajalalale CPS120 Service Manual 6 63 CTS electronics Remove and replace fuse The Fuse protects the electronic components inside the CPS120 Use the following procedure to remove and replace the Fuse Remove 1 Power OFF the CPS120 and remove the power cord from the wall outlet Zi Use a flat blade screwdriver to pry out the Fuse Holder as shown Replace 1 Place the new fuse in the Fuse Holder and press the Fuse Holder back in place 2 Plug in the power cord and power ON the CPS120 3 Insert a Standard Tes
85. ove the Input Output Reject Module from CPS120 see Remove and Replace the Input Output Reject Module Single card input sensor 1 Disconnect the Single Card Input sensor cable J5 from Input Output Reject Module control board 2 Remove one screw and remove the Single Card Input sensor 1 Selection tray sensor UP 1 Disconnect the Up Selection Tray sensor cable J7 from Input Output Reject Module control board 2 Remove one screw and remove the Up Selection Tray sensor 2 Selection tray sensor DOWN 1 _ Disconnect the Down Selection Tray sensor cable J8 from Input Output Reject Module control board 2 Remove one screw and remove the Down Selection Tray sensor 3 Reject tray full sensor 1 Disconnect the Reject Tray Full sensor cable J11 from Input Output Reject Module control board 2 Remove one screw and remove the Reject Tray Full sensor 4 Empty hopper sensor 1 Disconnect the Empty Hopper sensor cable J2 from Input Output Reject Module control board 2 Remove one screw and remove the Empty Hopper sensor 5 6 12 CPS120 Service Manual CTS electronics Nearly empty hopper sensor 1 Disconnect the Nearly Empty Hopper sensor cable J1 from Input Output Reject Module control board 2 Remove one screw and remove the Nearly Empty Hopper sensor 6 Feeder home sensor 1 Disconnect the Feeder Home sensor cable J16 from Input Output Reject Module control board 2 R
86. pacing 1 7 The CPS120 Card Personalization System operates as a standalone card embosser This chapter provides a system description of the CPS120 Service Manual 1 1 CTS electronics 1 2 CPS120 Service Manual CTS electronics Audience This document is intended for use by authorized representatives of CTS Group Corporation who are responsible for the maintenance service and repair of the CTS CPS120 Card Personalization System which is also referred to in this document as the CPS120 Repair Ability The authorized CTS representative must possess the following ability e Ability to set up the CPS120 communication parameters e Ability to check CPS120 configuration against purchase order agreement and if necessary change configuration e Ability to run and interpret software diagnostics e Ability to remove and replace all FRUs Field Replaceable Units e Ability to diagnose mechanical and electrical failures and correctly adjust all mechanical components including software adjustments Serial Numbers Information in this document applies to all CPS120 Card Personalization Systems beginning with Serial number xxxxxxx and higher CPS120 Service Manual 1 3 CTS electronics Use of this Document This document contains the following chapters to assist the service representative in the maintenance service and repair of the CPS120 Chapter 1 System Description Provides g
87. parallelism between the two 8 characters of the same line A1 and Q2 Fig 4 the difference between the two quote do not change over 0 1mm If not act on the screws V3 Fig 5 on the carriage upper group The upper metal plate is available only if the upper indent group is installed and need to be adjusted on parallel at the lower metal plate Check the free movement of the card between the two metal plate CPS120 Service Manual 5 11 CTS electronics Upper group Calg TY Character Character Fig 5 C N Q1 8 Some a QD _ J Fig 4 5 12 CPS120 Service Manual CTS electronics INDENT Indent adjustment Lower indent Tape position adjustment The tape on reset position must be like shown in the Fig 1 if not act on the column by the screw A The tape on work position must be like shown on Fig 2 and it s in the middle of character if not act on the position of the solenoid 1 by the screw B Check after run a card with indent the matching of the characters on the tape Upper indent Tape position adjustment The adjustment is like the Lower indent on the Upper indent group Tape on rest position Tape on work position l eS E Tape on rest position gt
88. place embosser control board The Embosser Control Board provides the electronic to make embossed characters on a plastic card Use the following procedure to remove and replace the Embosser Control Board Remove 1 Unlock and lift up the Front Cover and the Supplies Cover 2 Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame 4 Disconnect all cables from the Embosser Control board 5 Remove three screws holding the Embosser Control Board 1 and remove it Replace Use proper anti static grounding techniques when handling the WARNING Embosser Control Board 1 Place the new Embosser Control Board in position and attach with three screws 1 2 Reconnect all cables on the Embosser control board 3 Replace the Frame 4 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification JAN ar 6 68 CPS120 Service Manual CTS electronics Remove and replace Main control board The Main Control Board is the main processorboard of the CPS120 Use the following procedure to remove and replace the Main Control Board Remove Before replacing the Main Control Board backup all stored setting WARNING using the CPS120 Diagnostic Install Utility This program will give you step by step instructions for backing up t
89. r The Front Rear Indent Ribbon Motion Sensors detects physical motion of a slotted wheel insuring that the Front Rear Indent ribbons has advanced Use the following procedure to remove and replace the Front Rear Indent Ribbon motion sensors The procedure to remove and replace the Front and Rear Indent Ribbon Motion Sensors is the same for both Front and Rear Indent Ribbon Motion Sensors Remove Po ONS a 0 10 Replace 1 2 3 Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove the Embosser Module from CPS120 see Remove and Replace the Embosser Module Remove the Rear Front Indent cartridges if available Disconnect the Indent Ribbon Motion Sensor cable J15 Front Indent J16 Rear Indent from the Embosser control board Remove cable ties Remove two screws 1 holding the Cartridge Support 2 Partially remove the Cartridge Support to have access at the Indent Ribbon Motion sensor 3 Remove one screw 4 holding the Indent Ribbon Motion sensor and remove it Place the new Indent Ribbon Motion sensor in position and attach with one screw Place the cartridge in position and hold in place with two screws Reconnect the Indent Ribbon Motion cable J15 Front Indent J16 Rear Indent on the Embosser control board Replace cable ties and Rear Front Indent cartridge if available Replace the Embosser Module on
90. separate refuse collection In alternative the user shall give the equipment back to the retailer in exchange for a new equivalent equipment The separate collection of the refuse and the related operations for the treatment recycling and waste disposal promote the manufacturing of new equipment using recycled materials thus limiting the damages to the environment and the negative effects to the health due to an inadequate waste management The unauthorized waste disposing of the product will be submitted to the administrative penalties in conformity to the article 50 and subsequent articles of the D lgs number 22 1997 According to the article 13 D Lgs dated 25 July 2005 n 151 Enforcing of the directives 2002 95 CE 2002 96 CE e 2003 108 CE related to reduce the use of dangerous substances in electric and electronic equipment and to the refuse disposal For more information visit www ctsgroup it VI CPS120 Service Manual CTS electronics Chapter 1 SYSTEM DESCRIPTION CPS120 embosser AUdlenCeu ao s k Av AG kr ar ee a 1 3 Repair Ability lt lt lt 3 lt sex ae ka nenn 1 3 Serial Numbers sva rak 4 as ann ae ss GE le A 1 3 Use of this Document 1 4 Product Specifications 1 5 Magnetic Stripe Encoding Specifications 1 6 Standard Financial Emboss Line Locations 1 6 Standard Emboss Character Height 1 7 Standard Emboss Character S
91. ser Module see Remove and Replace the Embosser Module di Remove the Rear Front indent cartridge if available 6 Disconnect the Indent cable from the Embosser Control board e Indent Ribbon Motion sensor J15 Front J16 Rear e Indent Ribbon Motor J7 Front J9 Rear e Indent Solenoid J8 Front J10 Rear 7 Remove four screws 1 and remove the Front Indent Module 8 Disconnect the Punch Die motor cables from the Punch Die motors 9 Remove nine screws 2 and remove the Punch Die motors module 10 Uncrew the two screws 3 and open the module 11 Remove the Die Cam belt 4 12 The procedure to remove the Punch Cam belt are the same of the Die Cam Belt on the Rear Indent Module Replace 1 Place the new Punch Die Belt 4 in position around the idler pulley 2 Partially place the Punch Die motor support in position and place the Punch Die Cam belt around the cam motor 3 Attach the Punch Die motor support with two screws 3 4 Replace the Punch Die motors module and attach with ninw screws 2 4 Replace the Indent Module in position and attach with four screws 1 5 Reconnect the Indent cables on the Embosser Control board e Indent Ribbon Motion sensor J15 Front J16 Rear e Indent Ribbon Motor J7 Front J9 Rear e Indent Solenoid J8 Front J10 Rear 6 Replace the Embosser on the CPS120 see Remove and Replace the Embosser T Replace the Rear Front indent cartridge if available 8 Replace the Frame 9
92. sport motor 6 58 Remove and replace Y transport drive belt 6 59 Remove and replace Y transport motor 6 60 Remove and replace card transport sensor 6 61 Remove and replace power supply 6 63 Remove and replace fuse 6 64 Remove and replace Input Output Reject module control board 3 z ak s EG GR ea AR Ge Eee Aird 6 65 Remove and replace encoder control board 6 66 Remove and replace topper control board 6 67 Remove and replace embosser control board 6 68 Remove and replace Main control board 6 69 CPS120 Service Manual CTS electronics Introduction This section gives procedures for the removal and replacement of the CPS120 Card Personalization System Field Replaceable Units FRUs and sub assemblies P OTE Some FRU replacements may require self tapping screws to be used Servicing Guidelines Use the following guidelines when servicing the CPS120 e Observe warning and caution labels affixed to various areas of the equipment e Use only the recommended tools as specified to perform service e Replacement of certain assemblies and parts requires follow up adjustments Make sure these adjustments are performed after replacement e Always perform preventive maintenance as described in Chapter 3 Preventive Maintenance of this manual after replacement procedures e Verify the CPS120 functions after replacement by
93. t 5 6 Slip the Ribbon Motor Belt 3 off the Ribbon drive shaft pulley and remove the belt from the assembly Replace U Place the new Ribbon Motor belt in position 2 Replace the Ribbon drive shaft in position and hold in place with one seeger 1 Replace the Ribbon Motor in position and attach with two screws Make sure belt tension is sufficient to ensure that no slippage will occur 3 Replace the Frame 4 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification 6 28 CPS120 Service Manual CTS electronics Remove and replace ribbon motor The Ribbon Motor is a DC motor used to advance the topping ribbon in the Topping cartridge Use the following procedure to remove and replace the Ribbon Motor Remove 1 Unlock and lift up the Front Cover 2 Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame The Topper Platen May Be Very Hot A WARNING 4 Remove two screws 1 holding the Ribbon Motor and slip the Ribbon Motor Belt 3 off the Ribbon drive shaft pulley then remove the Ribbon Motor 2 5 Disconnect the Ribbon Motor cable J4 from the Topper Control board Replace 1 Place the Ribbon Motor belt in position P Place the new Ribbon Motor in position and attach with two screws Make sure belt tension is sufficient to ensure that no slippa
94. t Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification 6 64 CPS120 Service Manual CTS electronics Remove and replace Input Output Reject module control board The Input Output Reject Control Board provides the electronics to control the Input Output Reject module Use the following procedure to remove and replace the Input Output Reject Control Board Remove Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove the Input Output Reject Module from CPS120 see Remove and Replace the Input Output Reject Module PON WARNING Input Output Reject Control Board A Use proper anti static grounding technigues when handling the 5 Disconnect all cables from the Input Output Reject Control Board 1 6 Remove four screws and remove the Input Output Reject Module Control Board Replace Use proper anti static grounding technigues when handling the WARNINGI Input Output Reject Control Board 1 Place the new Input Output Reject Module Control Board in position and hold in place with four screws 2 Reconnect all cables on the Input Output Reject Control Board 3 Replace the Input Output Reject Module on the CPS120 see Remove and Replace the Input Output Reject Module 4 Replace the Fra
95. t Module Remove two nuts 1 holding the Feeder Motor 4 and remove it Loose one grub screw 2 holding the drive motor pulley 3 and remove it Place the drive motor pulley in the shaft motor and hold in place with one grub screw Place a new motor and the Feeder Motor Belt in position and attach with two nuts Make sure belt tension is sufficient to ensure that no slippage will occur Replace the Input Output Reject Module on the CPS120 see Remove and Replace the Input Output Reject Module Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification CPS120 Service Manual CTS electronics Remove and replace selection tray motor The Selection Tray motor provide traction for select the Reject Tray or the Eject Tray Use the following procedure to remove and replace the Selection Tray Motor Remove PORN A Replace PORN Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove the Input Output Reject Module from CPS120 see Remove and Replace the Input Output Reject Module Remove two screws holding the Selection Tray Sensors 1 up 2 down and remove the Sensors Loose one grub screw 3 holding the motor cam and remove it Disconnect the selection tray m
96. tection 1 3 R34 10764 CPS Display Board 1 4 R34 10758 CPS Master Full Option 1 5 R34 CAB 0797 Cable 5way 1 1 Molex P2 5L 1200 3 6 R34 CAB 0798 Cable 5way 1 1 Molex P2 5L 650 1 7 R34 CAB 0799 Cable 5way 1 1 Molex P2 5L 350 2 8 R34 CAB 0800 Cable Power 2way Modu2 L 450 2 9 R34 CAB 0801 Cable Power 2way Modu2 L 300 1 10 R34 CAB 0802 Cable Power 4 2way Modu2 L 150 1 11 R34 CAB 0805 Cable 2way Power Switch L 300 1 12 R34 CAB 0910 Cable Tond 4V Photo LTP802 L800 P2 1 13 R34 INPUL18551108 8 Switch 4A 250V Green Light 1 14 R34 PRESAPANN 01 1 Socket Male P Fuse 1 15 R34 TR 0085 Ali SW O F 200W 8 4A SP 200 24 TAB Nr 8 gt GS 322 Main board Main board 20 G 324 Main board gt Main board CPS120 Service Manual 7 15 CTS electronics g C2 Power supply J12 C gt J12 Topper 4 Main Control Board i J10 Magnetic stripe Board 6 J11 Input Board 6 G 312 Fede 7 16 CPS120 Service Manual CTS electronics Jtg Owy de PT Magnetic stripe Board Input Board CPS120 Service Manual 7 17 CTS electronics OPTIONS INPUT OUTPUT MODULE Single feeder TAB Nr 8 Cover Cable connection Q RIF CODE DESCRIPTION 1 1 R34 01246 O Ring 2 028 070x4 19 32 1 2 R34 01207 O Ring CB86 30302 109 silicon 1 3 R34 01267 O Ring CB85 D 6 02 S 2 62 Silicon 1 4 R34 01351 Spring 1 5 R34 01321 Traction spring 1 6 R34 10893 GR M RID L149 12 43 Modu2 L400 1 7 R34 CAB 0755 Photosensor Ca
97. the CPS120 see Remove and Replace the Embosser Module Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification CPS120 Service Manual 6 47 CTS electronics Remove and replace The Embosser Module is comprised of two rotating metal disks of punches and dies every metal disk is subdivided in two parts for an easy extraction from the module Use the following procedure to remove and replace a single part of metal disk of the Embosser Module Remove R D Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Uncrew the two screws 1 and remove the main control board with support 2 Manually rotate the metal disks on the free zone until you can see two pins that indicate a central line A Uncrew the three fixing screws that fix the part to be remove Remove only one half at a time to maintain the correct module adjustment Before extracting another part of a metal disck replace the first one A WARNING Replace 1 Place the half of metal disk 3 in the correct position 2 Insert without impediment and fix three fixing screws 3 Replace the main control board with support 2 and fix two screws 1 4 Replace the Frame 5 Insert a St
98. the Card Transport Module from CPS120 see Remove and Replace the Card Transport Module Remove two screws 1 holding the X Transport motor 2 Slip the X Transport Drive Belt 3 off the X Transport drive motor pulley and remove X Transport motor Loose one grub screw holding the X Transport drive motor pulley and remove it Place the Drive motor pulley on the shaft motor and hold in place with one grub screw Place the X Transport drive belt and the new X Transport motor in position and attach with two screws Replace the Card Transport Module on the CPS120 see Remove and Replace the Card Transport Module Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final guality verification 6 58 CPS120 Service Manual CTS electronics Remove and replace Y transport drive belt The Y Transport Drive belt drives the transport mechanism for moving cards through the CPS120 Use the following procedure to remove and replace the Y Transport Drive belt Remove NPS EE Replace 1 Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove four screws 1 and remove the up side of the Card transport Remove two screws 4 and one stirrup holding the Y Transport drive belt 2 and r
99. the Supplies Cover see Opening the Covers Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame see Remove and Replace the Frame Remove the Embosser Module from CPS120 see Remove and Replace the Embosser Module Punch or die home sensors 1 BEA BERND Disconnect the Punch or Die Home sensor cable J13 Punch J12 Die from the Embosser control board Remove Cable Tie Remove four screws 1 holding the Front Indent module to remove Die sensor Partially Remove the Indent Module Remove one screw 3 holding the Punch or Die Home sensor 4 and remove it To remove the Punch sensor follow the same procedure of Die sensor but on the Rear Indent module Wheel home sensor 1 2 3 Disconnect the Wheel Home sensor cable J14 from the Embosser Control Board Remove Cable Tie Remove one screw 5 and remove the Wheel Home sensor 6 Synchronism sensor 1 2 3 Replace Disconnect the Synchronism sensor cable J21 from the Embosser Control board Remove Cable Tie Remove two screws 7 and remove the Synchronism sensor 8 Punch or die home sensor 1 2 3 Place the new Punch or Die Home sensor in place and attach with one screw Reconnect the Punch or Die Home sensor cable J13 Punch J12 Die on the Embosser control board Replace Cable Tie Place the Front Rear Indent module in position and hold in place with four screws 6 36 CPS120 Service Manual C
100. tly operate on the respective dowels shown in figure 1 Transport position 2 Work position CPS120 Service Manual 5 5 CTS electronics CARRIAGE X Axis Transport Drive Belt Adjustment Connect the dynamometer 5Kg max to the X Transport Drive Belt backstand 1 Pull the dynamometer and observe the X Transport Drive Belt backstand when this start to move check the face of the dynamometer The correct adjustment is around 3Kg If the adjustment does not correspond to the required one intervention on the nut 2 will be necessary Rotating the nut 2 clockwise increase the adjustment HOPPER Adjusting for Card Thickness The card thickness adjustment is set for the standard card thickness at the factory You can adjust the gauge on the e The card thickness knob has to be adjusted anytime the cards in the input hopper are too thick for the card to move into the entrance of the input hopper gate Perform the following steps to adjust the input hopper gate e Insert one blank card into the input hopper e Slide the card in the gate and out as you rotate ntrance input hopper gate for cards of other thicknesses Unlock the supplies cover and lift it up see Opening the Front and Supplies Covers the knob until the card moves inside the gate smoothly Move the knob clockwise to widen L the gate opening or NOTE counterclockwise to narrow the gate opening 5 6 CPS
101. tor pulley against the wheel gear then completely tighten the screws Replace the Wheel cable on the motor Replace the Embosser Module on the CPS120 see Remove and Replace the Embosser Module Replace the Frame Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final guality verification o 6 ES O 1 5 o 6 42 CPS120 Service Manual CTS electronics Remove and replace front rear indent solenoids The Front Rear Indent Solenoids are used to place the Front Rear Indent Ribbon under the Punch Die characters Use the following procedure to remove and replace the Front Rear Indent Solenoids Remove PONS an Replace Unlock and lift up the Front Cover and the Supplies Cover Power OFF the CPS120 and remove the power cord from the wall outlet Remove the Frame Remove the Embosser Module from CPS120 see Remove and Replace the Embosser Module Disconnect the Indent cable J8 Front J10 Rear from the Embosser control board Remove the Cable Tie Remove two nuts 1 and remove the Front Rear Indent Solenoids 2 Place a new Solenoid in position and attach with two nuts but do
102. wing procedure to remove and replace the Topper Home sensor Remove 1 Unlock and lift up the Front Cover and the Supplies Cover 2 Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame The Topper Platen May Be Very Hot A WARNING 4 Remove one screw 1 holding the Topper Home sensor and remove it 5 Disconnect the Topper Home sensor cable J11 from the Topper Control Board Replace T Place the new Topper home sensor in position and attach with one screw 2 Reconnect the Topper Home sensor cable J11 on the Topper Control Board 3 Replace the Frame 4 Insert a Standard Test Card to confirm the proper operation of the CPS120 If the test is successful run a limited number of customer produced cards for a final quality verification CPS120 Service Manual 6 27 CTS electronics Remove and replace ribbon motor drive belt The Ribbon Motor Belt provides movement to advance the topping ribbon in the Topping cartridge Use the following procedure to remove and replace the Ribbon Motor Belt Remove 1 Unlock and lift up the Front Cover and the Supplies Cover 2 Power OFF the CPS120 and remove the power cord from the wall outlet 3 Remove the Frame The Topper Platen May Be Very Hot A WARNING 4 Remove two screws 1 holding the Ribbon Motor and partially remove the Ribbon Motor 4 5 Remove one seeger 2 and partially remove the Ribbon Motion shaf

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