Datacard
®
150i Desktop
Card Personalization System
Owner’s Manual
February 2008
Part No. 539782-001, Rev A
ii
Liability Statement
This product has been built to the high standards of Datacard Group. Please do
not attempt to operate or repair this equipment without adequate training. Any
use, operation, or repair in contravention of this document is at your own risk.
By acceptance of this system you hereby assume all liability consequent to your
use or misuse of this equipment. Datacard assumes no liability for incidental,
special, or consequential damage of any kind. Equipment specifications,
applications, and options are subject to change at the sole discretion of Datacard
without notice.
Proprietary Notice
All drawings and information herein are the property of DataCard Corporation.
All unauthorized use and reproduction is prohibited.
Trademark Acknowledgments
Datacard is a registered trademark and service mark of DataCard Corporation in
the US and other countries.
Windows is a registered trademark of Microsoft Corporation.
All other product names are the property of their respective owners.
Datacard Group
11111 Bren Road West
Minnetonka, MN 55343-9015
952.933.1223
Fax: 952.933.7971
www.datacard.com
© 2008 DataCard Corporation. All rights reserved.
Printed in the United States of America.
iii
Contents
Chapter 1: Introduction ____________________________________________________________ 1
Overview of the 150i System___________________________________________________________1
Internal Components of the 150i System________________________________________________2
Rear Components of the 150i System __________________________________________________3
Financial Card Access ________________________________________________________________4
Supplies/Options _____________________________________________________________________4
Chapter 2: Procedures _____________________________________________________________ 5
Powering On the 150i System__________________________________________________________5
Changing the Password_______________________________________________________________6
Opening the Top Cover_______________________________________________________________7
Loading Blank Cards in the Input Hopper_______________________________________________8
Loading a Single Card ________________________________________________________________9
Loading a Pre-Embossed Card ______________________________________________________ 10
Unloading Completed Cards________________________________________________________ 11
Unloading Reject Cards_____________________________________________________________ 12
Removing or Inserting the Topper Cassette___________________________________________ 13
Replacing the Topping Foil __________________________________________________________ 14
Replacing the Front Indent Ribbon___________________________________________________ 15
Replacing the Rear Indent Ribbon___________________________________________________ 16
Chapter 3: Troubleshooting________________________________________________________ 19
Identifying Errors Using Indicators_____________________________________________________ 19
Identifying Errors Using Error Codes___________________________________________________ 20
General System Errors_______________________________________________________________ 21
Magnetic Stripe Errors_______________________________________________________________ 25
Communication Errors ______________________________________________________________ 26
Troubleshooting Tips ________________________________________________________________ 27
Service Required Errors______________________________________________________________ 28
Obtaining Service __________________________________________________________________ 28
iv
Revision Log
150i Desktop Card Personalization System Owner’s Manual
Revision Date Description of Changes
A February 2008 Replaces Administrator’s Guide, Part No. 526638-001.
Regulatory Compliance
Notice for USA (FCC Notice)
This equipment generates, uses, and can radiate radio frequency energy. If it is
not installed and used in accordance with this instruction manual, it may
interfere with radio communications. This equipment has been tested and found
to be within the limits for Class A computing devices, pursuant to Title 47 CFR
Part 15 Subpart B of FCC rules, designed to provide reasonable protection
against radio interference in a commercial environment. Operation of this
equipment in a residential environment may possibly cause interference. In the
event of interference, the users, at their own expense, will be required to take
whatever measures are necessary to correct the problem.
Any changes or modifications to this device not expressly approved by the party
responsible for compliance could void the user's authority to operate the
equipment.
Notice for Canada
This digital apparatus does not exceed the Class A limits for radio noise for
digital apparatus set out in the Radio Interference Regulations of the Canadian
Department of Communications.
Le présent appareil numérique n’émet pas de bruits radioélectriques dépassant
les limites applicables aux appareils numériques de la classe A prescrites dans le
Règlement sur le brouillage radioélectrique édicté par le ministère des
Communications du Canada.
v
Safety
All Datacard products are built to strict safety and reliability specifications in
accordance with UL60950-1 and CUL requirements; therefore, safety issues
pertaining to operation and repair of Datacard equipment are primarily
environmental and human interface.
The following basic safety tips are given to ensure safe installation, operation and
maintenance of Datacard equipment and are not to be considered as
comprehensive on all matters of safety.
Safe Environment
•
Connect equipment to a grounded facility power source. Do not defeat or
bypass the ground lead.
• Place the equipment on a stable surface (table), and ensure floors in work area
are dry and non-slip. Insulated rubber floor mats are preferred.
• Know the location of equipment branch circuit interrupters or circuit breakers
and how to turn them on and off in case of emergency.
• Know the location of fire extinguishers and how to use them. Use only ABC
type extinguishers on electrical fires.
• Know local procedures for first aid and emergency assistance at the customer
facility.
• Use adequate lighting at the equipment.
• Maintain recommended range of temperature and humidity in equipment area.
Safe Human Interface
•
Use proper lifting techniques when moving or installing the equipment.
• Use standard electrostatic discharge (ESD) precautions when working on or
near electrical circuits.
• Do not defeat or disconnect safety interlocks on covers.
vi
150i Desktop Card Personalization System 1
Chapter 1: Introduction
The Datacard® 150i Desktop Card Personalization System delivers high quality,
ready-to-use cards in a fast, secure, single pass operation.
This manual describes the components of the 150i System and the basic operating
procedures. Information on troubleshooting, obtaining service and ordering
supplies is also included.
Overview of the 150i System
The 150i system includes the following components.
• Output Hopper Door
• Single Card Access Door
• Keyhole
• Keypad
• Display
• Indicators
• Top Cover
• Power Switch
2 Owner’s Manual
Internal Components of the 150i System
The assemblies inside the 150i system include the following Modules.
• Card Transport Module
• Embossing Module
• Rear Indent Printing Module
• Front Indent Printing Module
(Optional)
• Output Tray
• Input Hopper
• Magnetic Stripe Encoding Module
• Reject Tray
• Smart Card Personalization Module
(Optional)
• Topper Module
150i Desktop Card Personalization System 3
Rear Components of the 150i System
The following components are located on the back of the 150i system.
• On/Off Switch
• Communication Ports
• Host
• Service
• Smart Card 1 (Option)
• Power Receptacle
• Fan
4 Owner’s Manual
Financial Card Access
The 150i system contains security features to restrict the generation of financial
cards during shipment. If the security requirements are not met, the system will
display an error. Your Datacard Authorized Service provider will assist in
ensuring that the security requirements are correctly enabled for your
application.
Supplies/Options
The following table lists supplies that may be ordered.
Description Part Number
Cassette, Reusable 596666-002
Topping Foils*
Dark Blue 597950-001
Black 597950-002
Gold 597950-003
White 597950-004
Red 597950-006
Silver 597950-015
Indent Module Ribbons*
Black
596805-001,
case of 10, 715227
White
596805-002,
case of 10, 715228
*With average use, a ribbon equals approximately 1,800 cards.
150i Desktop Card Personalization System 5
Chapter 2: Procedures
Use the following procedures to operate the 150i System.
Powering On the 150i System
Connect the power cord from the wall outlet socket to the 150i system. To power
ON the 150i system, switch the on/off switch to ON.
• 1 = ON
• 0 = OFF
The 150i system will display a “Ready” message on Line 1 after power up.
Line 2 will display the current version of the internal software, followed by
the current total number of good cards produced. If an error occurs, an error
code is displayed.
6 Owner’s Manual
Changing the Password
The command for unlocking the cover is *0. The default password for the system
as shipped from the factory is 000. The cover can be unlocked by keying the
following sequence *0 0000.
To change the password, do the following:
*1[0000][5555]
Old Password New Password
Change Password Code
Enter *1 (change password code) followed by the current password and then the
new password. For example, to change the default password 0000 to 5555, enter
*100005555. In this example, the keystrokes to open the Top Cover again using
the new password would be *05555.
If you do not remember your current password, use the key or contact your
Datacard Service Representative to reset it.
150i Desktop Card Personalization System 7
Opening the Top Cover
The Top Cover can be opened with either a four-digit password or a key. The
default password shipped from the factory for the 150i system is *00000. This
password should be changed upon receipt of the machine.
• To open the Top Cover using a password, using the keypad, enter *0 (unlock
code) followed by your 4-digit password (XXXX). The solenoid to open the
Top Cover will be energized for 5 seconds.
• The message “OPEN COVER!” is displayed. If the password is entered
incorrectly, “ACCESS DENIED!” is displayed. To reenter the correct
password, press *0 followed by the correct password.
• To open the Top Cover using a key, insert the key in the keyhole and turn it
clockwise a quarter turn.
8 Owner’s Manual
Loading Blank Cards in the Input Hopper
To load the Input Hopper, perform the following steps:
1. Unlock and lift up the Top Cover.
2. Remove the Input Hopper Card Weight.
3. Insert up to 100 blank cards in the Input Hopper, with the front of the card
up and the top edge of the card toward the rear of the 150i system.
If you are encoding Magnetic Stripe cards, place the Magnetic Stripe face
down and oriented toward the rear of the 150i system. If the optional front
Smart Card module is being used, insert the Smart Card so the chip is facing
up and to the left as shown. If the optional rear Smart Card Module is being
used, insert the Smart Card so the chip is facing down and to the right.
Contactless cards can be encoded with the card positioned either way.
4. Replace the Input Hopper Card Weight oriented as shown.
5. Close the Top Cover.
150i Desktop Card Personalization System 9
Loading a Single Card
A single card loaded in the Single Card Track will be personalized by the 150i
system before any cards loaded in the Input Hopper. To manually load a single
card, perform the following steps:
The 150i system must be in the Ready Mode before loading a single card. Do
not insert a card while the 150i system is processing cards. Do not place more
than one card in the Single Card Track. The Input Hopper Card Weight must
be present for the reliable feeding of cards.
1. Open the Single Card Access Door.
2. Place a single card on the Single Card Track, with the front of the card up and
the top edge of the card toward the back of the 150i system.
If you are encoding Magnetic Stripe cards, place the Magnetic Stripe face
down and toward the rear of the 150i system. If the optional front Smart Card
Module is being used, insert the Smart Card so the chip is facing up and to
the left as shown. If the optional rear Smart Card Module is being used, insert
the Smart Card so the chip is facing down and to the right. Contactless cards
can be encoded with the card positioned either way.
3. Close the Single Card Access Door. The single card is the next card in the
stack to be personalized.
10 Owner’s Manual
Loading a Pre-Embossed Card
A pre-embossed card loaded in the Single Card Track will be personalized by the
150i system before any cards loaded in the Input Hopper. To manually load a
pre-embossed card, perform the following steps:
The 150i system must be in the Ready Mode before loading a pre-embossed
card. Do not insert a pre-embossed card while the 150i system is processing
cards. Do not place more than one pre-embossed card in the Single Card
Track. Pre-embossed cards must not be loaded in the Input Hopper. The
Input Hopper Card Weight must be present for the reliable feeding of cards.
1. Open the Single Card Access Door.
2. Place a pre-embossed card on the Single Card Track, with the front of the
card up and the top edge of the card toward the back of the 150i system.
3. Close the Single Card Access Door. The pre-embossed card is the next card in
the stack to be personalized.
150i Desktop Card Personalization System 11
Unloading Completed Cards
Remove completed cards from the 150i system by opening the Output Door and
removing the card(s). The Output Tray can hold up to 15 cards.
The 150i system will not process cards when the Output Door is open. Do not
open the Output Door while a card is being processed.
12 Owner’s Manual
Unloading Reject Cards
The Reject Tray holds up to 10 rejected cards. To remove rejected cards from the
150i system, perform the following steps:
1. Unlock and lift up the Top Cover.
2. Remove all rejected cards from the Reject Tray.
3. Close the Top Cover.
Keep loose objects, such as jewelry or clothing, away from parts inside the
150i system; they may become caught.
The Topper Platen may be very hot.
150i Desktop Card Personalization System 13
Removing or Inserting the Topper Cassette
To replace the Topper Cassette, perform the following steps:
The Topper Platen may be very hot.
1. Unlock and lift up the Top Cover.
2. Lift the Topper Cassette Release Ring and pull the Topper Cassette out of the
Topper Module (toward the front of the 150i System).
3. Lift the Topper Cassette Release Ring and insert the new Topper Cassette in
the Topper Module until it is firmly in place.
4. Close the Top Cover.
14 Owner’s Manual
Replacing the Topping Foil
To replace the Topping Foil, perform the following steps:
1. Unlock and lift the Top Cover.
2. Lift the Topper Cassette Release Ring and pull the Topper Cassette out of the
Topper Module (toward the front of the 150i system).
3. Pull the Take-up Pin out of the Topper Cassette and remove any used
Topping Foil from the Take-up Spool.
4. Pull the Feed Spool from the Topper Cassette and remove the core and any
unused foil from the Topper Cassette Feed Spool.
5. Insert the Topper Cassette Feed Spool into the core of the new topping foil.
6. Insert the Feed Spool with the new Topping Foil so it feeds from the top with
the shiny side up and snap into place in the cassette.
7. Wrap the Topping Foil with the shiny side toward the Topping Foil Roller.
8. Wrap the end of the Topping Foil, shiny side out, around the Take-up Spool
and replace the Take-up Pin so it holds the topping foil securely in place.
Remove slack in the Topping Foil either by winding either the Take-up Spool
gear or the Supply Spool.
9. Replace the Topper Cassette by lifting the Topper Cassette Release Ring and
inserting the Topper Cassette in the Topper Module until it is firmly in place.
10. Close the Top Cover.
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