Service Manual

Module Control Board

Datacard MX Card Issuance Systems

MX9100
MX8100
MX6100

May 2022
527308-001, Rev. F
Notice
Please do not attempt to operate or repair this equipment without adequate
training. Any use, operation or repair you perform that is not in accordance
with the information contained in this documentation is at your own risk.
Trademark Acknowledgments
Entrust, Sigma and the hexagon design are trademarks, registered trademarks
and/or service marks of the Entrust Corporation in the United States and other
countries.

Datacard is a registered trademark and service mark of Entrust Corporation in

the United States and other countries.

MasterCard is a registered trademark of MasterCard International Incorporated.

Visa is a registered trademark of Visa International Service Association.

All other product names are the property of their respective owners.
Proprietary Notice
The design and information contained in these materials are protected by US
and international copyright laws.

All drawings and information herein are the property of Entrust Corporation. All
unauthorized use and reproduction is prohibited.

Entrust Corporation
1187 Park Place
Minneapolis, MN 55379
Phone: 952-933-1223
Fax: 952-933-7971
www.entrust.com

© 2013 - 2022 Entrust Corporation. All rights reserved.

ii
Safety
The following basic safety tips are given to ensure safe installation, operation
and maintenance of Datacard® equipment.
• Connect equipment to a grounded power source. Do not defeat or bypass
the ground lead.
• Place the equipment on a stable surface (table) and ensure floors in the work
area are dry and non-slip.
• 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. ABC type
extinguishers may be used on electrical fires.
• Know local procedures for first aid and emergency assistance at the
customer facility.
• Use adequate lighting at the equipment location.
• Maintain the recommended temperature and humidity range in the
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.

Warning: To avoid a possible electric shock, always unplug the system

before servicing.

Liability
The WARNING and CAUTION labels have been placed on the equipment for
your safety. 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.
California Prop
Warning: This product contains chemicals, including lead, known to the State of
California to cause cancer, and birth defects or other reproductive harm. Wash
hands after handling.

For more information on this warning, refer to:

www.datacard.com/califpropwarning.

iii
 Revision Log

Revision Date Description of Changes

A September 2013 First release of this document.

B June 2013 Added MX6100 module configurations and XE cover.

C October 2013 Added MX8100 module configurations.

D September 2017 Updated and converted manual. Added DX product

line.

E December 2017 Updated to comply with EDC internal structuring.

F May 2022 Added LC module control board.

iv
 Contents
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Control Board Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Node 1 (Legacy Electronics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Node 1 Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Replace the Node 1 Module Control Board Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Node 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Node 2 Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Node 2 Board Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Replace the Node 2 Module Control Board Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Stepper Motor Drive Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Node 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Node 3 Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Replace the Node 3 Module Control Board Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Node 4C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Node 4C Board Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Replace the Node 4C Module Control Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Thermal Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Thermal Print Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Replace the Thermal Print Module Control Board Assembly . . . . . . . . . . . . . . . . . . . . . . . 33
Servo Amplifier Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Laser Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Laser Power Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
LEDs and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Replace the Laser Module Control Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Activate a Replacement Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Node XE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Node XE Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Node XE Board Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Node XE Board LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Module Registration Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Module Registration Board Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Map the Module Registration Board Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Replace the Module Registration Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Configure the Replacement Module Registration Board . . . . . . . . . . . . . . . . . . . . . . 58
Activate the Replacement Module Registration Board. . . . . . . . . . . . . . . . . . . . . . . . 61
Module Control Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Module Control Board Assembly Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Replace the XE Module Control Board Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
External Expansion Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Card Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Magnetic Stripe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Multi-Card Buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

v
 Topping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Vision Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Node XE2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Node XE2 Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Multi-Point Laser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Drop on Demand Printing Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Color Label Printing Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
LC Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
LC Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Replace the LC Control Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
LC Control Board Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

vi
Description
The module control board processes individual module activities and system-
level communications. It powers all module functions with an integrated power
supply, and receives output from the registration or expansion board. It also
powers indicator lights and the module interlock. The module control board is
located within the frame of each module behind the front panel.

Buffer Flipper Module Service Manual 1-1

Control Board Types
The type of module control board used in a module varies depending on the
specific module function, system configuration, or age of the installed system.
The following table lists the different control boards that may be present in an
MX/DX Series or MPR3800 system.

Type of Control Board Used In These Modules

Node 1 (566379-001) Discontinued (previously used on Card Input,

Card Output, Card Rotation, Scanner/Buffer,
Smart Card, Cleaning, Magnetic Stripe,
Label); replaced by 4C

Node 2 (566347-001) DuraGard Laminate, Artista VHD, Laser

Engraving, CardGard, Vision Verification,
Basic Topcoat, Barrel Smart Card

Node 3 (566777-00x) Discontinued (previously used on Standard

Front and Back Graphics and Color);
replaced by Thermal Print

Node 4C Topping, Embossing/Indent, Card Input, Card

(571062-002) Output, Card Rotation, Bar Code Scanner,
Smart Card, Cleaning, Magnetic Stripe, Label,
Multi-Card Buffer, RFID/Scanner, MM

Thermal Print Gen 2 Graphics and Color

(569970-001)

Laser Power Gen 2 Laser Engraving, Laser 325, Laser 350

Distribution
(536947-00x)

Node XE Topping, Embossing/Indent, Card Input, Card

(503982-002) with Output, Card Rotation, Bar Code Scanner,
Module Registration Smart Card, Cleaning, Magnetic Stripe, Label,
Board (504388-002) Multi-Card Buffer, Single Card Buffer/RFID/
Scanner, Barrel Smart Card, Quality
Assurance

LC Cleaning, Standard Capacity Input, Standard

Capacity Output, Standard Capacity High
Speed Input, High Speed High Capacity
Input, High Speed High Capacity Output.

1-2
Node 1 (Legacy Electronics)
The Node 1 type module control board assembly was discontinued in 2009 and
replaced with the Node 4C type. It may be present on the following modules:

 Card Input  Smart Card  Bar Code Scanner

 Card Output  Cleaning  Label

 Card Rotation  Magnetic Stripe

Node 1 Board Connections

The following figure and tables show connections to the Node 1 module control
board and the attached stepper motor boards.

Buffer Flipper Module Service Manual 1-3

Card Input

Module Control Board Connector

Component Assignment

Transport J2 (Motor A)

Card Picker J3 (Motor B)

Card Output

Module Control Board Connector

Component Assignment

Card Transport J2 (Motor A)

Tray 2 Paddle J3 (Motor B)

Tray 1 Paddle J10 (Motor C)

Card Rotation (Flipper)

Module Control Board Connector

Component Assignment

Turret Pivot J2 (Motor A)

Turret Transport J3 (Motor B)

Card Entry (Roller) J10 (Motor C)

Transport Arm J13 (Motor D)

Bar Code Scanner

Module Control Board Connector

Component Assignment

Exit Transport J3 (Motor B)

Entry Motor J10 (Motor C)

Transport Arm J13 (Motor D)

1-4
Smart Card

Module Control Board Connector

Component Assignment

Card Entry J2 (Motor A)

Card Pusher/Carriage J3 (Motor B)

Magazine Transport J10 (Motor C)

Station Arm Actuator J13 (Motor D)

Cleaning

Module Control Board Connector

Component Assignment

Transport J2 (Motor A)

Turret J3 (Motor B)

Take-Up J10 (Motor C)

Magnetic Stripe

Module Control Board Connector

Component Assignment

Card Input J2 (Motor A)

Transport J3 (Motor B)

Label

Module Control Board Connector

Component Assignment

Supply J2 (Motor A)

Take-Up J3 (Motor B)

Infeed J10 (Motor C)

Transport J13 (Motor D)

Buffer Flipper Module Service Manual 1-5

Replace the Node 1 Module Control Board Assembly
Replace module control boards when troubleshooting indicates they are
defective. The module control board assembly is located behind the front panel
of the module.

The module power supply is on the module control board. Therefore,

when the control board is removed, the power supply is also removed
and VPD information is lost.

Removal Procedure
Follow standard ESD procedures whenever you touch a
ESD! circuit board.

1. Back up (export) the Vital Product Data (VPD) information for the module
using the Diagnostics program. For detailed steps, refer to the System and
Controller Service Manual.

2. Power off the system and unplug the power cord.

3. Remove the front panel from the module. For details, refer to the System
and Controller Service Manual.
Warning: High voltage is present in the control board. Even with
power off the caps are charged and dangerous. Leave board covers
on and do not touch anything under them.

4. Disconnect all cables and connectors from the face of the control board.

Note how the cables are routed so you can route them properly
during replacement.

5. Loosen the two mounting screws at the bottom of the control board
mounting bracket.

6. Lift and pull out the control board and place it on an anti-static mat.

Replacement Procedure
1. Align the tabs of the control board mounting bracket with the slots in the
frame.

2. Carefully slide the board into the frame. Keep the board straight. If the
board is tilted, it will jam.

3. Tighten the mounting screws at the bottom of the control board mounting
bracket.

1-6
 4. Press firmly against the front of the faceplate to make sure that it is fully
seated.

5. Reinstall the cables and connectors as described in “Node 1 Board

Connections” on page 1-3.

6. Reload the VPD data from the backup. For detailed steps, refer to the
System and Controller Service Manual.
C

Buffer Flipper Module Service Manual 1-7

Node 2
The Node 2 module control board is an assembly that is partially covered and
houses a series of stepper motor boards. It is used on the following modules:

 DuraGard Laminate  CardGard  Barrel Smart Card

 Artista VHD  Vision Verification

 Laser Engraving  Basic Topcoat

Node 2 Board Connections

The following figure and tables show connections to the Node 2 module control
board and the attached stepper motor boards.

1-8
DuraGard Laminate

Module Control Board Connector

Component Assignment

Tack Entry Slot 4, Position 1 (2-Channel Boards)

Slot 3, Position 1 (3-Channel Boards)

Tack Actuator Slot 5, Position 1 (2-Channel Boards)

Slot 3, Position 3 (3-Channel Boards)

Tack Exit Slot 4, Position 4 (2-Channel Boards)

Slot 3, Position 2 (3-Channel Boards)

Carrier Take-Up Slot 5, Position 4 (2-Channel Boards)

Slot 2, Position 3 (3-Channel Boards)

Laminate Transport Slot 2, Position 1 (2-Channel Boards)

Slot 2, Position 1 (3-Channel Boards)

Laminate Actuator Slot 2, Position 4 (2-Channel Boards)

Slot 2, Position 2 (3-Channel Boards)

Laminate Roller Slot 3, Position 1 (2-Channel Boards)

Slot 1, Position 3 (3-Channel Boards)

Debow Actuator Slot 1, Position 4 (2-Channel Boards)

Slot 1, Position 2 (3-Channel Boards)

Debow Transport Slot 1, Position 1 (2-Channel Boards)

Slot 1, Position 1 (3-Channel Boards)

Tack and Laminate J20

Heater

Unused J13

Buffer Flipper Module Service Manual 1-9

CardGard
Earlier CardGard modules had six 2-channel stepper motor boards,
newer modules have four 3-channel boards.

Module Control Board Connector

Component Assignment

Card Entry Slot 6, Position 4 (2-Channel Boards)

Slot 4, Position 3 (3-Channel Boards)

Tab Belt (Card Slot 4, Position 1 (2-Channel Boards)

Transport) Slot 4, Position 1 (3-Channel Boards)

Heated Roller Slot 3, Position 4 (2-Channel Boards)

Slot 3, Position 1 (3-Channel Boards)

Platen Roller Slot 5, Position 1 (2-Channel Boards)

Slot 2, Position 3 (3-Channel Boards)

Platen Advance Slot 6, Position 1 (2-Channel Boards)

Slot 4, Position 2 (3-Channel Boards)

Interstage Transport Slot 5, Position 4 (2-Channel Boards)

Slot 3, Position 3 (3-Channel Boards)

Cover Take-Up Slot 4, Position 4 (2-Channel Boards)

Slot 3, Position 2 (3-Channel Boards)

Supply Film (Feed) Slot 2, Position 1 (2-Channel Boards)

Slot 2, Position 1 (3-Channel Boards)

Carrier Take-Up Slot 3, Position 1 (2-Channel Boards)

Slot 2, Position 2 (3-Channel Boards)

Cure Transport Slot 2, Position 4 (2-Channel Boards)

Slot 1, Position 2 (3-Channel Boards)

Cure Shutter Slot 1, Position 1 (2-Channel Boards)

Slot 1, Position 1 (3-Channel Boards)

Card Exit Slot 1, Position 4 (2-Channel Boards)

Slot 1, Position 3 (3-Channel Boards)

AC Opt J20

Unused J13

1-10
Basic Topcoat

Module Control Board Connector

Component Assignment

Card Entry Slot 1, Position 1

Heated Roller Drive Slot 1, Position 2

Platen Roller Drive Slot 1, Position 3

Supply Feed Slot 2, Position 1

Platen Advance Slot 2, Position 2

Interstage Transport Slot 2, Position 3

Supply Take-Up Slot 3, Position 1

Debow Transport Slot 3, Position 2

Debow Advance Slot 3, Position 3

Heater Lamp Circuit J20

Fans J13

Barrel Smart Card

Module Control Board Connector

Component Assignment

Card Entry Transport Slot 1, Position 1

Placement Arm Slot 1, Position 2

Horizontal Rack Slot 1, Position 3

Card Rotation Slot 2, Position 1

Card Exit Transport Slot 2, Position 2

Supply Take-Up Slot 3, Position 1

Debow Transport Slot 3, Position 2

Unused J20

Unused J13

Buffer Flipper Module Service Manual 1-11

Vision Verification

Module Control Board Connector

Component Assignment

Card Entry Transport Slot 1, Position 1

Placement Arm Slot 1, Position 2

Horizontal Rack Slot 1, Position 3

Card Rotation Slot 2, Position 1

Card Exit Transport Slot 2, Position 2

Light Box Slot 6, Position 3

Light Box Slot 6, Position 4

Unused J20

Unused J13

Laser Engraving

Module Control Board Connector

Component Assignment

Card Input Transport Slot 1, Position 1

Card Output Transport Slot 1, Position 2

Card Indexer Slot 2, Position 1

Turret Rotation Slot 2, Position 2

Turret Z-Position Slot 2, Position 3

Camera Light Slot 3, Position 1

AC Opt J20

Unused J13

1-12
Artista VHD (Applicator)

Applicator Control Board Connector

Component Assignment

Elevator Roller Slot 1, Position 1

Elevator Slot 1, Position 2

Exit Roller Slot 1, Position 3

Card Pass-through Slot 2, Position 1

Roller

Debow Slot 2, Position 2

Debower Roller Slot 2, Position 3

Heated Roller Position Slot 3, Position 1

Hot Roller Slot 3, Position 2

Track A Slot 4, Position 1

Track B Slot 4, Position 2

Track Select Slot 4, Position 3

Gantry X Slot 5, Position 1

Gantry Y Slot 5, Position 2

Card In Slot 6, Position 1

Head Fan J20

Expansion Board 2 J13

Power

Buffer Flipper Module Service Manual 1-13

Artista VHD (Printer)

Printer Control Board Connector

Component Assignment

Head 1 Ribbon Slot 1, Position 1

Head 1 Load Slot 1, Position 2

Head 2 Ribbon Slot 1, Position 3

Head 2 Load Slot 1, Position 4

Head 3 Ribbon Slot 2, Position 1

Head 3 Load Slot 2, Position 2

Head 4 Ribbon Slot 2, Position 3

Head 4 Load Slot 2, Position 4

Head 5 Ribbon Slot 3, Position 1

Head 5 Load Slot 3, Position 2

Head 6 Ribbon Slot 3, Position 3

Head 6 Load Slot 3, Position 4

Drum Slot 4, Position 1

RTM Slot 4, Position 2

RTM/Head 1 Brake Slot 5, Position 1

Head 2/Head 3 Brake Slot 5, Position 2

Head 4/Head 5 Brake Slot 5, Position 3

Head 6 Brake Slot 5, Position 4

AC OPT J20

Unused J13

1-14
Node 2 Board Fuses
Datacard does not support field repair of electronic boards, or provide repair
processes or electrical parts for repair. The following table lists the fuse ratings
for the Node 2 module control boards only to show UL compliance.

Fuse Part Number # of Fuses Description

808496-022 1 FUSE, RL, TIME LAG, 250V, 5.0A

808496-011 1 FUSE, RL, TIME LAG, 250V,

400MA

808496-021 1 FUSE, RL, TIME LAG, 250V, 4.0A

Replace the Node 2 Module Control Board Assembly

Replace the module control board when troubleshooting indicates it is
defective. The module control board assembly is located behind the front panel
of the module.

Removal Procedure
Follow standard ESD procedures whenever you touch a
ESD! circuit board.

1. Back up (export) the Vital Product Data (VPD) information for the module
using the Diagnostics program. For detailed steps, refer to the System and
Controller Service Manual.

2. Power off the system and unplug the power cord.

3. Remove the front panel from the module. For detailed steps, refer to the
System and Controller Service Manual.
Warning: High voltage is present in the control board. Even with
power off the caps are charged and dangerous. Leave board covers
on and do not touch anything under them.

4. Disconnect all cables from the face of the control board and all stepper
motor boards.

Note how the cables are routed so you can route them properly
during replacement.

5. Loosen (but do not remove) the two mounting screws that attach the
control board mounting bracket to the module chassis.

Buffer Flipper Module Service Manual 1-15

 6. Carefully lift and pull out the control board. Place it on an anti-static mat.

Replacement Procedure
1. Align the tabs of the control board mounting bracket with the slots in the
module frame.

2. Carefully insert and lower the mounting bracket tabs into the frame while
making sure that the slots at the bottom line up with the two mounting
screws. Keep the board straight. If the board is tilted, it will jam.

3. Press firmly against the front of the faceplate to make sure that it is seated.

4. Tighten the mounting screws at the bottom of the board mounting bracket.

5. Reinstall the connectors to locations as described in “Node 2 Board

Connections” on page 1-8.

6. Reload the VPD information from the backup file. For detailed steps, refer to
the System and Controller Service Manual.
Caution: While loading VPD information or flash updates to the
control board of a module with a heated roller, always open the
module cover to avoid damaging the roller. After system
initialization, power is applied to the lamp, but the heater roller does
not turn.

1-16
 CardGard module: If the UV Lamp pulse count value did not get
restored from VPD backup file, manually set the counter in the VPD to
the value from the system log book.

Stepper Motor Drive Board

Stepper motor drive boards are connected to the module control board. When
a board is operational, its LED is lit. Use this procedure to replace one or more
nonfunctional motor drive boards.

Earlier CardGard modules had six 2-channel stepper motor boards;

newer modules have four 3-channel boards.

Caution: A module can have only one type of stepper motor board. If
you must replace a 2-channel board in a module, change all the
boards in that module to 3-channel boards at the same time. A
module requires fewer 3-channel boards, and the motor connections
change.

Removal Procedure
Follow standard ESD procedures whenever you touch a
ESD! circuit board.

1. Power off the system, unplug the power cord, and lift the hood.

2. Remove the front panels from the module. For instructions, refer to the
Operator’s Manual.

3. Disconnect the motor cables from the motor drive board that is to be
removed. For motor cable connections, refer to “Node 2 Board
Connections” on page 1-8.
4. Loosen the two captive screws that secure the motor drive board to the
control board, and pull out the motor drive board as indicated in the
following figure.

Buffer Flipper Module Service Manual 1-17

2-Channel Stepper Boards

3-Channel Stepper Boards

1-18
Node 3
The Node 3 type module control board assembly has been inactivated/
obsoleted and replaced with the Thermal Print type. The Node 3 type may be
present on older Standard Front and Back Graphics and Color modules.

Node 3 Board Connections

The following figure shows connections to the Node 3 module control board.

Buffer Flipper Module Service Manual 1-19

Replace the Node 3 Module Control Board Assembly
Replace the module control board when troubleshooting indicates it is
defective. It is located behind the front panel of the module.

Removal Procedure
Follow standard ESD procedures whenever you touch a
ESD! circuit board.

1. Back up (export) the Vital Product Data (VPD) information for the module
using the Diagnostics program. For detailed steps, refer to the System and
Controller Service Manual.

2. Power off the system and unplug the power cord.

3. Remove the front panel from the module. For detailed steps, refer to the
System and Controller Service Manual.
Warning: High voltage is present in the control board. Even with
power off, the caps are charged and dangerous. Leave board covers
on and do not touch anything under them.

4. Disconnect all cables from the face of the control board.

Note how the cables are routed so you can route them properly
during replacement.

5. Loosen, (but do not remove) the two mounting screws that attach the
control board mounting bracket to the module chassis.

6. Gently lift and pull out the control board. Place it on an anti-static mat.

1-20
Replacement Procedure
1. Align the tabs of the control board mounting bracket with the slots in the
module frame.

2. Carefully insert and lower the mounting bracket tabs into the frame while
making sure that the slots at the bottom line up with the two mounting
screws. Make sure that you keep the board straight. If the board is tilted, it
will jam.

3. Press firmly against the front of the faceplate to make sure that it is seated.

4. Tighten the mounting screws at the bottom of the control board mounting
bracket.

5. Reinstall the connectors to their locations as described in “Node 3 Board

Connections” on page 1-19.

6. Reload the VPD information from the backup file. For detailed steps, refer to
the System and Controller Service Manual.

Buffer Flipper Module Service Manual 1-21

Node 4C
The Node 4C board is part of an assembly that is partially covered and houses
a series of stepper motor boards. It may be present on the following modules:
 Topping

 Embossing/Indent
 Card Input
 Card Output

 Card Rotation
 Bar Code Scanner
 Smart Card
 Cleaning
 Magnetic Stripe
 Label
 Multi-Card Buffer
 RFID/Scanner
 MM

1-22
Node 4C Board Connections
The following figure and tables show connections to the Node 4C module
control board.

Buffer Flipper Module Service Manual 1-23

Topping

Module Control Board Connector

Component Assignment

Platen Cam Drive J8 (Motor A)

Foil Advance J9 (Motor B)

Card Transport J10 (Motor C)

Card Entry J11 (Motor D)

Heater/Thermocouple J21

Emboss\Indent

Module Control Board Connector

Component Assignment

Card Transport J8 (Motor A)

Wheel J9 (Motor B)

Card Entry J10 (Motor C)

Vertical Lift J11 (Motor D)

Indent I/O Board J19

Power Supply J21

Die (Front) Solenoid J22

Punch (Rear) Solenoid J23

Card Input

Module Control Board Connector

Component Assignment

Transport J8 (Motor A)

Card Picker J9 (Motor B)

1-24
Card Output

Module Control Board Connector

Component Assignment

Card Transport J8 (Motor A)

Tray 2 Paddle J9 (Motor B)

Tray 1 Paddle J10 (Motor C)

Card Rotation (Flipper)

Module Control Board Connector

Component Assignment

Turret Pivot J8 (Motor A)

Turret Transport J9 (Motor B)

Card Entry (Roller) J10 (Motor C)

Transport Arm J11 (Motor D)

Bar Code Scanner

Module Control Board Connector

Component Assignment

Exit Transport J9 (Motor B)

Entry Motor J10 (Motor C)

Transport Arm J11 (Motor D)

Smart Card

Module Control Board Connector

Component Assignment

Card Entry J8 (Motor A)

Card Pusher/Carriage J9 (Motor B)

Magazine Transport J10 (Motor C)

Station Arm Actuator J11 (Motor D)

Buffer Flipper Module Service Manual 1-25

Cleaning

Module Control Board Connector

Component Assignment

Transport J8 (Motor A)

Turret J9 (Motor B)

Take-Up J10 (Motor C)

Magnetic Stripe

Module Control Board Connector

Component Assignment

Card Input J8 (Motor A)

Transport J9 (Motor B)

Label

Module Control Board Connector

Component Assignment

Supply J8 (Motor A)

Take-Up J9 (Motor B)

Infeed J10 (Motor C)

Transport J11 (Motor D)

Multi-Card Buffer

Module Control Board Connector

Component Assignment

Transport Arm J8 (Motor A)

Card Entry J9 (Motor B)

Rack J10 (Motor C)

Card Exit J11 (Motor D)

1-26
RFID/Scanner

Module Control Board Connector

Component Assignment

Card Entry Motor J9 (Motor B)

Card Exit Motor J10 (Motor C)

Transport Arm Motor J11 (Motor D)

RFID Reader/Writer Box J21

Power

Buffer Flipper Module Service Manual 1-27

Replace the Node 4C Module Control Board Assembly
Replace the module control board when troubleshooting indicates it is
defective. The module control board assembly is located behind the front panel
of the module.

Removal Procedure
Follow standard ESD procedures whenever you touch a
ESD! circuit board.

1. Back up (export) the Vital Product Data (VPD) information for the module
using the Diagnostics program. For detailed steps, refer to the System and
Controller Service Manual.

2. Power off the system and unplug the power cord.

3. Remove the front panel from the module. For detailed steps, refer to the
System and Controller Service Manual.
Warning: High voltage is present in the control board. Even with
power off the caps are charged and dangerous. Leave board covers
on and do not touch anything under them.

4. Disconnect all cables from the module control board assembly.

Note how the cables are routed so you can route them properly
during replacement.

5. Loosen, (but do not remove) the two mounting screws that attach the
control board mounting bracket to the module chassis.

6. Carefully lift and pull out the control board assembly. Place the control
board assembly on an anti-static mat.

1-28
Replacement Procedure
1. Align the tabs of the control board mounting bracket with the slots in the
module frame.

2. Carefully insert and lower the mounting bracket tabs into the frame while
making sure that the slots at the bottom line up with the two mounting
screws. Keep the board straight. If the board is tilted, it will jam.
3. Press firmly against the front of the faceplate to make sure that it is seated.

4. Tighten the mounting screws at the bottom of the control board mounting
bracket.

5. Reinstall the connectors to their locations as described in “Node 4C Board

Connections” on page 1-23.

6. Reload the VPD information from the backup file. For detailed steps, refer to
the System and Controller Service Manual.

Buffer Flipper Module Service Manual 1-29

Thermal Print
The thermal print type module control board assembly is used on the Gen 2
Graphics and Color modules.

Thermal Print Connections

The following figure and tables show connections to the thermal print module
control board.

1-30
Gen2 Graphics

Module Control Board Connector

Component Assignment

Ribbon Take-Up J4 (Step Motor 3)

Printhead Actuator J7 (Step Motor 4)

Ribbon Supply J29 (Step Motor 5)

Gen2 Color

Module Control Board Connector

Component Assignment

Ribbon Take-Up J2 (Step Motor 1)

Printhead Actuator J1 (Step Motor 2)

Ribbon Supply J4 (Step Motor 3)

Cam Motor J7 (Step Motor 4)

Entry/Exit Transport J29 (Step Motor 5)

Sensor Rack Motor J28 (Step Motor 6)

Buffer Flipper Module Service Manual 1-31

Durable Graphics

Module Control Board Connector

Component Assignment

Ribbon Take-Up J4 (Step Motor 3)

Printhead Actuator J7 (Step Motor 4)

Ribbon Supply J29 (Step Motor 5)

Print Servo J2 and J6 on Servo Amplifier to J30 on MCB

Input Rollers MTR1 (Slot 1)

Turret One Rollers MTR5 (Slot 1)

Turret One Rotate MTR3 (Slot 1)

Lamp Transport Rollers MTR9 (Slot 1)

Lamp Shutter MTR7 (Slot 1)

Turret Two Rollers MTR3 (Slot 2)

Turret Two Rotate MTR1 (Slot 2)

Exit Rollers MTR5 (Slot 2)

1-32
Replace the Thermal Print Module Control Board Assembly
Replace the module control board when troubleshooting indicates it is
defective. The module control board assembly is located behind the front panel
of the module.

Removal Procedure
Follow standard ESD procedures whenever you touch a
ESD! circuit board.

1. Back-up (export) the Vital Product Data (VPD) information for the module
using the Diagnostics program. For detailed steps, refer to the System and
Controller Service Manual.

2. Power off the system and unplug the power cord.

3. Remove the front panel from the module. For detailed steps, refer to the
System and Controller Service Manual.
Warning: High voltage is present in the control board. Even with
power off, the caps are charged and dangerous. Do not remove
node board covers and do not touch anything under them,
unless necessary.

4. Disconnect all cables from the face of the module control board assembly.

Some versions of the module control board assembly contain a

cover that must be removed prior to accessing cable connections.
Loosen the retaining screws as shown to remove the housing
cover.

Buffer Flipper Module Service Manual 1-33

 Note how the cables are routed so you can route them properly
during replacement.

1-34
 1. Loosen, (but do not remove) the two mounting screws (1 in the following
figure) that attach the control board mounting bracket (2) to the module
chassis.

2. Carefully lift and pull out the control board. Place the module control board
assembly on an anti-static mat.

The module control board assembly housing may have a different

appearance from the figure shown above. Some versions of the
assembly contain a cover that must be removed prior to accessing
cable connections.

Replacement Procedure
1. Transfer the compact flash memory card from the old module control board
to the new board.

2. Align the tabs (3 in the previous figure) of the control board mounting
bracket with the slots in the module frame.

3. Carefully insert and lower the mounting bracket tabs into the frame while
making sure that the slots at the bottom line up with the two mounting
screws. Make sure that you keep the board straight. If the board is tilted, it
will jam.

4. Press firmly against the front of the faceplate to make sure that it is seated.

Buffer Flipper Module Service Manual 1-35

 5. Tighten the mounting screws at the bottom of the control board mounting
bracket.

6. Reinstall the connectors to locations as described in “Thermal Print

Connections” on page 1-30.

7. If equipped, install the module control board assembly housing cover and
tighten the eight mounting screws.

8. If the VPD needs to be erased or the board converted to generic, use the
following steps.

a. Open a Telnet session to the module (telnet 172.27.0.x where x equals the
module number).

b. Type root at the login prompt and press Enter.

c. Type cd/fcm/bin/ and press Enter.

d. Type ./flashGeneric and press Enter.

9. Reload the VPD information from the backup file. For detailed steps, refer to
the System and Controller Service Manual.

1-36
Servo Amplifier Fuse
If the servo motor does not turn, you may need to replace the fuse on the
module control board that protects power to the servo amplifier board.

Removal Procedure
Follow standard ESD procedures whenever you touch a
ESD! circuit board.

1. Power off the system and unplug the power cord.

2. Remove the front panel from the module. For detailed steps, refer to the
System and Controller Service Manual.
Warning: High voltage is present in the control board. Even with
power off, the caps are charged and dangerous. Leave board covers
on and do not touch anything under them.

3. Replace the F1 fuse located in the lower left corner of the board below the
K4 relay.

4. Access system Diagnostics for the module.

5. Display the Exerciser tab, select FlashServoAmp, and then click Run.

6. Reboot the module by cycling the E-stop switch on the Controller.

Buffer Flipper Module Service Manual 1-37

Laser Power Distribution
The laser power distribution board is used exclusively on the Gen 2 Laser, Laser
325, and Laser 350 Engraving modules. The module control board assembly is
composed of the laser power distribution board, a laser control board, and a
power supply board.

Laser Power Board Connections

The following figure shows the cable connections, located behind the front
panel and the laser power supply.

1-38
LEDs and Fuses
The following figure shows the laser power distribution board LED indicators,
replaceable fuses, and dip switch settings.

Buffer Flipper Module Service Manual 1-39

Replace the Laser Module Control Board Assembly
The Gen 2 Laser module control board assembly is composed of a laser power
distribution board, a laser control board, and a power supply board. Replace
the module control board when troubleshooting indicates it is defective. It is
located behind the front panel of the module.

Removal Procedure
Follow standard ESD procedures whenever you touch a
ESD! circuit board.

1. Back up (export) the Vital Product Data (VPD) information for the module
using the Diagnostics program. For detailed steps, refer to the System and
Controller Service Manual.

2. Power off the system and unplug the power cord.

3. Remove the front panel from the module.

Warning: High voltage is present in the control board. Even with
power off, the caps are charged and dangerous. Allow 60 seconds
to elapse after removing power before accessing any board
connectors.

4. Disconnect the laser power and control cables from the top of the laser
power supply (1 in the following figure).

5. Remove the two nuts that secure the laser power supply mounting bracket
to the posts (2) in the bottom of the module frame.

6. Remove the grounding strap (3) from the power supply mounting bracket.

7. Remove the two nuts that secure the laser power supply mounting bracket
to the posts on the intermediate mounting bracket (4) in front of the
module control board.

8. Gently lift and remove the laser power supply and place it on a cart or stable
surface.
Caution: Do not crimp or over-bend the laser assembly’s fiber
optic cable. Maintain a soft loop for any cable slack. If necessary,
remove the cable tie that secures the cable loop to the front of
the laser amplifier.

9. If necessary, remove the entire laser assembly as described in the Gen 2

Laser Engraving Module Service Manual.

10. Remove the two screws that secure the intermediate mounting bracket to
the module control board (5). Retain the intermediate mounting bracket
and hardware.

1-40
 11. Disconnect all cables from the face of the control board.

Note how the cables are routed so you can route them
properly during replacement.

12. Loosen (but do not remove) the two mounting screws that attach the
control board mounting bracket to the module chassis.

13. Gently lift and pull out the control board. Place it on an anti-static mat.

Buffer Flipper Module Service Manual 1-41

 The Laser module control board assembly contains a laser control
board (7 in the following figure), power supply board (8), and
laser power distribution board (9). Remove the mounting screws
and standoffs that secure the boards to the module control board
mounting bracket.

8 9
7

Replacement Procedure
1. Attach the intermediate mounting bracket and hardware to the new module
control board prior to installation of the module control board.

2. Align the tabs (6) of the control board mounting bracket with the slots in
the module frame.

3. Carefully insert and lower the mounting bracket tabs into the frame while
making sure that the slots at the bottom line up with the two mounting
screws. Keep the board straight. If the board is tilted, it will jam.

4. Press firmly against the front of the faceplate to make sure that it is seated.

5. Tighten the mounting screws at the bottom of the control board mounting
bracket.

6. Reinstall the connectors to locations as described in “Laser Power Board

Connections” on page 1-38.

1-42
 7. Carefully move the laser power supply onto the mounting posts of the
module frame and intermediate mounting bracket.

8. Secure the laser power supply to the mounting posts with four retaining
nuts.

9. Connect the laser power and control cables to the connectors on top of the
laser power supply.

10. The Laser Engraving module control board is preloaded with a VPD file.
When the MX6000 system is initialized, the VPD is saved automatically.
Reload the last known functioning VPD file.

11. Run the Flash update.

12. Run exercises within Diagnostics to verify that all Gen 2 Laser module
components are functional.

Buffer Flipper Module Service Manual 1-43

Activate a Replacement Power Supply Board
For non-MX6000 systems with Controller software version 5.9 Build 1166
Service Pack 1 or higher, the Controller module production screen (in idle state)
displays a message reporting that the Gen 2 Laser module power supply board
is not authorized (non-activated mode) and provides a card count remaining
message for the replacement board.

Use the following procedure to write the authorization code to the replacement
Gen 2 Laser security power supply board.

This procedure is not required for:

 MX6000 systems.

 MX Series systems with Controller software versions lower than 5.9 Build
1166 Service Pack 1.

1-44
Procedure
1. Stop card production and access system Diagnostics.

2. Select the Controller module from the list of system modules.

3. Select the Utilities tab and click MRB Utility.

4. Select the module that requires authorization from the list and then click
OK.

5. Select whether to type in the code or import it from an external file.

If you cut and paste the authorization code from an email or text
file, remove any dashes when pasting the data.

Buffer Flipper Module Service Manual 1-45

 6. Enter the module serial number. If necessary, click on the (help)
button for serial number rules and information.

7. Enter the 44-character authorization code (or paste it) and then click OK.
The software verifies that the code is valid.

8. An authorization status window displays. When authorization is complete,

click OK.

9. Power-cycle the modules and reset the Controller.

10. Access system Diagnostics, navigate back to the Utilities, and click MRB
Utility.

11. If the key code is properly registered, it displays in the list without a warning
or limited card count.

12. The software writes the authorization code to the replacement board. If the
write operation fails, power-cycle the module and reenter the key code.

If the authorization code does not successfully write to the

replacement power supply board after two attempts, a new board
is required. Obtain another board and re-initiate the replacement
procedure.

13. Make sure that the message no longer displays on the operator screen. If the
card count message remains after the authorization code has been written,
a new Gen2 Laser power supply board is required. Obtain another board
and re-initiate the replacement procedure.

14. Run test jobs on the system to make sure that all modules are functioning
properly.

1-46
Node XE
The Node XE module control board assembly processes all module activity and
system-level communication and powers all module functions with an
integrated power supply. The Node XE board powers the attached registration
board and receives registration board output. Some modules also require a
special expansion board that is mounted below the Node XE board.

A Node XE module control board assembly may be present on the following

modules:
 Topping
 Embossing/Indent
 Card Input (Standard/High Capacity)
 Card Output (Standard/High Capacity)
 Card Rotation
 Label
 Card Cleaning
 Smart Card (Rack)
 Barrel Smart Card

 Bar Code Scanner

 Multi-Card Buffer
 Vision Verification
 MX1100 Graphics
 Magnetic Stripe (Standard/Dual Head)

 Quality Assurance

Node XE Control Board

The Node XE module control board is contained within the module control
board enclosure in the front of the module frame. It serves as a motherboard
for the module registration board.

Buffer Flipper Module Service Manual 1-47

Node XE Board Connectors

The following figure displays connectors on the Node XE module control board.

1-48
Node XE Board LEDs

The following figure displays the Node XE module control board LED
indicators.

Buffer Flipper Module Service Manual 1-49

Module Registration Board
The module registration board connects to the front of the XE module control
board. This board defines the modules in the existing module set and system.
The module registration board also powers the motors and receives input from
all sensors and encoders in the module set.

On some systems, a single XE module control board with module

registration board can be shared by two adjacent modules. The
upstream module houses the boards and is referred to as the
physical module in the set. The downstream module is referred to
as the logical module.

Module Registration Board Connectors

You can reassign the module registration board connectors when

troubleshooting indicates that a circuit is defective. The sensor and motor
connectors on the board can be mapped within Diagnostics as described in
“Replace the XE Module Control Board Assembly” on page 1-92. The sensor
connector pairs can accommodate one cable with either a 3-pin or a 5-pin
connector. The following illustration shows the connectors on the module
registration board.

1-50
Map the Module Registration Board Connectors

The sensor and motor connectors on the module registration board can be
verified or reassigned within Diagnostics. Use the following procedure to view/
change current connector mapping assignments for modules that contain the
XE module control board and module registration board.

1. Stop card production and access system Diagnostics.

2. Select the Controller module from the list of system modules.

3. Select the Utilities > Run SysCon tab.

A blank white diagram workspace displays with a series of command icons

and drop-down menu options.

Buffer Flipper Module Service Manual 1-51

 4. Select File > Import and type in the IP address of the desired module
(172.27.0.x). Click OK.

5. The current connector mapping diagram for the module displays inside the
diagram workspace. You can switch the diagram style between Default
Style and Basic Style by selecting Options > Stylesheet.

On some systems, a single XE module control board with module

registration board may be shared by two adjacent modules. The
following diagram shows the module registration board and its
connections to an upstream (physical) module and downstream
(logical) module.

1-52
 6. Examine the current sensor and motor connector mapping by highlighting
the diagram wire paths between the MRB connectors and the module
components. The wire path lines highlight as the mouse passes over them.

Buffer Flipper Module Service Manual 1-53

 7. To remap or reassign a connector, use one of the following two methods:
 Select a wire path line and drag it to a different MRB connector.

 Delete an existing wire path line and create a new one.

8. To apply the changes to the current module, select File > Export and type in
the IP address of the module (172.27.0.x). Click OK.

9. Verify that the sensor and motor connector mapping matches the physical
connections on the module registration board by highlighting the diagram
paths between the MRB connectors and the module components.

10. To save the current configuration as a backup, select File > Save. Navigate
to a backups directory, and type in the name of the file. Click Save.

The backup configuration file contains a snapshot of VPD settings.

If a backup file is restored to the module, it overwrites the existing
module VPD settings.

1-54
Replace the Module Registration Board
Follow standard ESD procedures whenever you touch a
ESD! circuit board.

All the sensors and motors connect to the module registration board, which is
connected to the module control board in the front of the module.

Removal Procedure
1. Power off the system and unplug the power cord.

2. Remove the front panel as described in the System and Controller Service
Manual.
Warning: High voltage is present in the control board. Even with
power off the caps are charged and dangerous. Leave node board
covers on and do not touch anything under them, unless
necessary.

3. Disconnect all connectors on the module registration board (1) and connect
them to the corresponding connectors on the replacement board.

Some versions of the module control board assembly contain a

full-length cover that must be removed prior to accessing cable
connections. Loosen the retaining screws as shown to remove the
housing cover.

If necessary, move one cable connector at a time to make sure

that the connections are identically mapped.

Buffer Flipper Module Service Manual 1-55

 4. Remove the five screws that secure the module registration board to the
module control board (4).

The module control board assembly housing may have a different

appearance than the figure shown above. Some versions of the
assembly contain a full-length cover that must be removed prior
to accessing cable connections. The possible full-length cover
types may differ as shown in the following figure:

1-56
 5. Disconnect the module registration board from the module control board
assembly.

Replacement Notes
 Connect the sensors and motors into the new board as described in “Node
XE Control Board” on page 1-47.
 Reload Vital Product Data (VPD) information from the backup. For detailed
steps, refer to “Reloading VPD” in Chapter 2 of the System and Controller
Service Manual.
 Make sure that the cables are routed through cutouts or access doors.

Buffer Flipper Module Service Manual 1-57

Configure the Replacement Module Registration Board

After a module registration board has been physically replaced, the module
VPD that resides on the board must be configured for the correct module type.
The module type must be established before the board is fully activated. Use
the following procedure to initially configure the VPD.

Procedure
1. Power off the MX Series system.

2. For Modules that require VLAN connectivity (i.e. Barrel Smart Card):
Disconnect the module VLAN cable from the Controller switch and move it
to a different position (any ports except 21-23). Record the original port
number to be reconnected later.
3. Restore power to the system. The Controller module production screen
displays the Machine in an Off-line state.

4. Access system Diagnostics. The suspect module should appear in the list of
system modules on the left side of the screen as “Generic”. Select the
Controller module from the list.

5. Select the Utilities > Run SysCon tab.

6. Select File > Open and navigate to the Configs folder. Select the
configuration file for the suspect module type and click OK.

1-58
 7. The default connector mapping diagram for the suspect module will display.

8. Verify that the sensor and motor connector mapping matches the physical
connections on the replacement MRB. If differences exist, move the cables
connected to the MRB to match the default mapping diagram.

9. Select File > Export and type in the IP address of the suspect module
(172.27.0.x). Click OK.

10. Select Yes to overwrite the existing file.

Buffer Flipper Module Service Manual 1-59

 11. Click OK to verify that the operation was successful.

12. Power-cycle the system and return to system Diagnostics. The suspect
module type should now display in the list of system modules.

13. Select the suspect module from the list.

14. Select File > Reload module VPD from file. Navigate to the most recent VPD
snapshot zip file and select Save.

15. Click OK to overwrite the existing file.

16. Click OK to verify that the operation was successful.

17. If necessary, select the Adjust and Test tab and run exercises to verify that
all module components are functional.

18. For Modules that require VLAN connectivity (i.e. Barrel Smart Card):
Connect the module VLAN cable to its original position on the Controller
switch and Power-cycle the system.

1-60
Activate the Replacement Module Registration Board

The Controller module production screen in idle state displays a message

reporting that the suspect module is not authorized (non-activated mode) and
provides a card count remaining message for the replacement board.

Use the following procedure to write the authorization code to the replacement
module registration board.

Procedure
1. Stop card production and access system Diagnostics.
2. Select the Controller module from the list of system modules.

3. Select the Utilities tab and click MRB Utility.

Buffer Flipper Module Service Manual 1-61

 4. Select the module that requires authorization from the list and then click
OK.

5. Select whether to type in the code or import it from an external file.

 Select Type in the code to manually enter the authorization code. You
may also cut and paste the authorization code from an email or text file.
Remove dashes when pasting the data.
 Select Import code(s) from a file to automatically retrieve the
authorization data from an external file. Navigate to the authorization file
location and select it.

6. The following code entry window displays. If the authorization code has
been imported from an external file, the window will already be filled in with
the correct data.

7. If necessary, enter the module serial number. If necessary, click on the

(help) button for serial number rules and information.

1-62
 8. If necessary, enter the 44-character authorization code (or paste it) and
then click OK. The software will check to verify that a valid code has been
used.

If the data is entered incorrectly, acknowledge the following

window (or similar) and re-enter the data.

9. When the date has been successfully entered, an authorization status

window displays. When authorization is complete, click OK.

10. Power-cycle the modules and reset the Controller.

11. Access system Diagnostics, navigate back to the Utilities tab, and click MRB
Utility.

12. If the key code is properly registered, it displays in the list without a warning
or limited card count.

13. The software writes the authorization code to the replacement board. If the
write operation fails, power-cycle the module and reenter the key code.

If the authorization code does not successfully write to the

replacement power supply board after two attempts, a new board
is required. Obtain another board and re-initiate the replacement
procedure.

14. Make sure that the message no longer displays on the operator screen. If the
card count message remains after the authorization code has been written,

Buffer Flipper Module Service Manual 1-63

 a new Gen2 Laser power supply board is required. Obtain another board
and re-initiate the replacement procedure.

15. Run test jobs on the system to make sure that all of the modules are
functioning properly.

Module Control Board Assembly

The module control board assembly consists of the module control board, the
module registration board, special expansion boards, and the electrical
enclosure.
Module Control Board Assembly Connections

The following tables and graphics list the module registration board, expansion
board, and power supply connector assignments within the module control
board assembly. For a list of the standard connections to the XE control board,
refer to “Node XE Board Connectors” on page 1-48.

The following tables show default connector assignments for the

module registration board. These assignments can be remapped or
modified as described in “Map the Module Registration Board
Connectors” on page 1-51.

Standard Card Input

Component Connector Board

Transport Motor MOTOR 1 MRB

Card Picker Motor MOTOR 2 MRB

Cleaning Sleeve Actuator MOTOR 3 MRB

Card Entry Sensor (Pass-through SEN 8 MRB

Only)

Card Exit Sensor SEN 9 MRB

Picker Home Sensor SEN 10 MRB

Vacuum Valve/Vacuum Pump/ J7 MRB

Module Interlock

Vacuum Sensor Board (SYS IN) SPECIAL MRB

1-64
MX6100/MX8100 High Capacity Card Input

Component Connector Board

Card Entry Motor MOTOR 1 MRB

Tab Belt Motor MOTOR 2 MRB

Card Separator Motor 1 MOTOR 3 MRB

Card Separator Motor 2 MOTOR 4 MRB

Card Picker Motor 1 MOTOR 5 MRB

Card Picker Motor 2 MOTOR 6 MRB

Card Entry Sensor (Pass-through SEN 0 MRB

Only)

Card Exit Sensor SEN 1 MRB

Door (Track) Sensor SEN 2 MRB

Tab Belt Home Sensor SEN 3 MRB

Card Picker Home Sensor 1 SEN 4 MRB

Card Picker Home Sensor 2 SEN 5 MRB

Stack Pusher Home Sensor 1 SEN 6 MRB

Stack Pusher Home Sensor 2 SEN 7 MRB

Tray Present 1 SEN 8 MRB

Tray Present 2 SEN 9 MRB

Tray Empty 1 SEN 10 MRB

Tray Empty 2 SEN 11 MRB

Servo Interlock Board EXP2 MRB

Servo/Encoder Feedback 1 ( RFID 0 MRB

Servo/Encoder Feedback 2 RFID 1 MRB

Buffer Flipper Module Service Manual 1-65

 Component Connector Board

Vacuum Valve/Vacuum Pump/Module J7 MRB

Interlock

Vacuum Sensor Board SPECIAL

The High Capacity Card Input module control board assembly includes a servo
interlock board and servo drivers to control the servo motors. The expansion
board/servo drivers and their connections are shown below.

1-66
Buffer Flipper Module Service Manual 1-67
Card Cleaning

Component Connector Board

Transport Motor MOTOR 1 MRB

Turret Motor MOTOR 2 MRB

Take-Up Motor MOTOR 3 MRB

Card Entry Sensor SEN 8 MRB

Card Exit Sensor SEN 9 MRB

Turret Home Sensor SEN 10 MRB

Supply Ribbon Present (Tape Break) SEN 11 MRB

Sensor

RFID RFID 0 MRB

Supply Encoder ENC 0 MRB

Single Card Buffer/Bar Code Scanner

Component Connector Board

Entry Motor MOTOR 1 MRB

Transport Arm Motor MOTOR 2 MRB

Exit Motor MOTOR 4 MRB

Card Entry Sensor SEN 8 MRB

Transport Arm Home Sensor SEN 9 MRB

Card Interim Sensor SEN 10 MRB

Card Exit Sensor SEN 11 MRB

Bar Code Scanner (Optional) RFID 0 MRB

1-68
Card Rotation

Component Connector Board

Turret Pivot Motor MOTOR 1 MRB

Turret Transport Motor MOTOR 2 MRB

Card Entry Motor MOTOR 3 MRB

Transport Arm Motor MOTOR 4 MRB

Card Entry Sensor SEN 8 MRB

Track 1 Sensor SEN 9 MRB

Track 2 Sensor SEN 10 MRB

Turret Home Sensor SEN 11 MRB

(Transport) Arm Home Sensor SEN 12 MRB

Card Interim Sensor SEN 13 MRB

Buffer Flipper Module Service Manual 1-69

MX1100 Graphics (Front and Back)

Component Connector Board

Entry/Exit Motor MOTOR 1 MRB

Transport Motor MOTOR 2 MRB

Cam Drive Motor MOTOR 3 MRB

Roller Lift Solenoid MOTOR 4 MRB

Cleaning Actuator Solenoid

Entry Sensor SEN 8 MRB

Exit Sensor SEN 9 MRB

Registration Sensor SEN 10 MRB

(Front Graphics module only)

Swingarm Sensor SEN 12 MRB

Cam Home Sensor SEN 13 MRB

Graphics Expansion Board EXP 1 MRB

1-70
Smart Card (Rack)

Component Connector Board

Card Entry/Roller Transport Motor MOTOR 1 MRB

Card Pusher/Carriage Motor MOTOR 2 MRB

Magazine Motor MOTOR 3 MRB

Station Arm Actuator MOTOR 4 MRB

Card Exit Sensor SEN 0 MRB

Card Pusher/Carriage Home Sensor SEN 1 MRB

Magazine Home Sensor SEN 2 MRB

Card Entry Sensor SEN 3 MRB

Station Arm Home Sensor SEN 4 MRB

Station Arm Open Sensor SEN 5 MRB

Card Pusher/Carriage Encoder ENC 0 MRB

Magazine Encoder ENC 1 MRB

Smart Card Flex Power EXP 1 MRB

Buffer Flipper Module Service Manual 1-71

Barrel Smart Card

Component Connector Board

Carriage Motor MOTOR 1 MRB

Barrel Motor MOTOR 2 MRB

Head Opener Motor MOTOR 3 MRB

Exit Roller Motor MOTOR 6 MRB

Entry Roller Motor MOTOR 7 MRB

Card Stop Home Sensor SEN 0 MRB

Exit Track Entry Sensor SEN 1 MRB

Exit Track 1 Sensor SEN 2 MRB

Exit Track 2 Sensor SEN 3 MRB

Card Exit Sensor SEN 4 MRB

Barrel Home Sensor SEN 5 MRB

Carriage Home Sensor SEN 8 MRB

Head Open Home Sensor SEN 9 MRB

Ethernet Switch Power SEN 10 MRB

Card Entry Sensor SEN 12 MRB

Entry Track Sensor SEN 13 MRB

Barrel Encoder ENC 0 MRB

Carriage Encoder ENC 2 MRB

Barrel Expansion Board (LATCH) LATCH MCB

Barrel Expansion Board J7 MCB

(AGND TP5)(AC INLET)

Barrel Expansion Board (DC INLET) EXP 2 MRB

Barrel Swivel Cable (RFID SPECIAL) RFID 0 MRB

1-72
 Component Connector Board

Fan J7 MRB

Ethernet Switch (Port 1) SYS ENET MRB

The Barrel Smart Card module control board assembly includes a barrel
expansion board and power supply to power and control special functions
within the mechanism. The expansion board/power supply and its connections
are shown below.

Buffer Flipper Module Service Manual 1-73

Emboss/Indent/Secure Indent

Component Connector Board

Card Transport (Tabbed Belt) Motor MOTOR 1 MRB

(Motor A)

Wheel Motor (Motor B) MOTOR 2 MRB

Card Entry Motor (Motor C) MOTOR 3 MRB

Vertical Lift Motor (Motor D) MOTOR 4 MRB

Card Entry Sensor SEN 8 MRB

Card Return (Track) Sensor SEN 9 MRB

Card Exit Sensor SEN 10 MRB

Tabbed Belt Home Sensor SEN 11 MRB

Wheel Home Sensor SEN 12 MRB

Vertical Lift Home Sensor SEN 13 MRB

Punch Home Solenoid Sensor SEN 14 MRB

Die Home Solenoid Sensor SEN 15 MRB

Fans J7 MRB

Front Solenoid FRONT SOL Emboss

Exp Bd

Back Solenoid REAR SOL Emboss

Exp Bd

1-74
 The Emboss/Indent module expansion board is located within the module
control board enclosure beneath the XE control board. Its connections are
shown below.

Buffer Flipper Module Service Manual 1-75

 Route solenoid cable harnesses and extension cables as shown below.

1-76
Topping

Component Connector Board

Card Entry Motor MOTOR 1 MRB

Card Transport Motor MOTOR 2 MRB

Foil Advance Motor MOTOR 3 MRB

Platen Cam Drive Motor MOTOR 4 MRB

Card Entry Sensor SEN 8 MRB

Card Exit Sensor SEN 9 MRB

Tabbed Belt Home Sensor SEN 10 MRB

Foil Lift Arm Home Sensor SEN 11 MRB

Platen Home Sensor SEN 12 MRB

Supply Encoder ENC 0 MRB

Foil Motion (Take-Up) Encoder ENC 1 MRB

Cam Position (Platen) Encoder ENC 2 MRB

RFID Antenna RFID 0 MRB

Vacuum Sensor Board SPECIAL MRB

Topping Expansion Board (AC MRB

INPUT)

Topping Expansion Board LATCH/J9 MCB

QA Expansion Board (QA Option EXP1 MRB

Only)

LED Backlight Board J31(QA Option BACKLIGHT QA Exp Bd

Only)

Camera Power (QA Option Only) MODULE I/O QA Exp Bd

Buffer Flipper Module Service Manual 1-77

 The Topping module expansion board is located within the module control
board enclosure beneath the XE control board. Its connections are shown
below.

1-78
High Speed Topping

Component Connector Board

Card Entry Motor MOTOR 1 MRB

Card Transport Motor MOTOR 2 MRB

Foil Advance Motor MOTOR 3 MRB

Platen Cam Drive Motor MOTOR 4 MRB

Card Entry Sensor SEN 8 MRB

Card Exit Sensor SEN 9 MRB

Tabbed Belt Home Sensor SEN 10 MRB

Foil Lift Arm Home Sensor SEN 11 MRB

Platen Home Sensor SEN 12 MRB

Supply Encoder ENC 0 MRB

Foil Motion (Take-Up) Encoder ENC 1 MRB

Cam Position (Platen) Encoder ENC 2 MRB

RFID Antenna RFID 0 MRB

Servo Drive Motor Controller (J5) RFID 1 MRB

Vacuum Sensor Board SPECIAL MRB

QA Expansion Board (QA Option EXP1 MRB

Only)

Servo Interlock Expansion Board (DC EXP2 MRB

INLET)

Servo Interlock Expansion Board LATCH/J9 MCB

(LATCH)

Servo Interlock Expansion Board (AC J7 MCB

INLET)

Servo Controller Signal(J5) RFID 1 MRB

Buffer Flipper Module Service Manual 1-79

 Component Connector Board

LED Backlight Board J31(QA Option BACKLIGHT QA Exp Bd

Only)

Camera Power (QA Option Only) MODULE I/O QA Exp Bd

The High Speed Topping module control board assembly includes a servo
interlock board and a servo driver to control the servo motor. The expansion
board/servo driver and their connections are shown below.

1-80
Buffer Flipper Module Service Manual 1-81
Quality Assurance

Component Connector Board

Vision Card Entry Motor MOTOR 1 MRB

Transport Arm Motor MOTOR 2 MRB

Rotator Motor MOTOR 3 MRB

Z-Axis Motor MOTOR 4 MRB

Mag Stripe Entry Motor MOTOR 5 MRB

Tabbed Belt Motor MOTOR 6 MRB

Vision Card Entry Sensor SEN 0 MRB

Transport Arm Home Sensor SEN 1 MRB

Rotator Home Sensor SEN 2 MRB

Z-Axis Home Sensor SEN 3 MRB

Mag Stripe Entry Sensor SEN 4 MRB

Mag Stripe Roller Entry Sensor SEN 5 MRB

Tabbed Belt Home Sensor SEN 6 MRB

Track Closed Sensor SEN 7 MRB

Mag Stripe Card Exit Sensor SEN 8 MRB

Mag Stripe Card Track Right Sensor SEN 9 MRB

Mag Stripe Card Track Left Sensor SEN 10 MRB

Rotator Card Entry Sensor SEN 11 MRB

Vision Card Exit Sensor SEN 12 MRB

Interface Board EXP 1 MRB

Rear Camera Ethernet CONSOLE MRB

1-82
Magnetic Stripe

Component Connector Board

Card Input Motor MOTOR 1 MRB

Transport Motor MOTOR 2 MRB

Card Entry Sensor SEN 8 MRB

Tab Belt Home Sensor SEN 9 MRB

Eject Door Sensor SEN 10 MRB

Card Exit Sensor SEN 11 MRB

Expansion Board (J14) EXP 1 MRB

Buffer Flipper Module Service Manual 1-83

Dual Head Magnetic Stripe
The two magnetic stripe mechanisms of the Dual Head Magnetic
Stripe module are connected to one common module control board
assembly.

Component Connector Board

Verify Card Input Motor MOTOR 1 MRB

Verify Transport Motor MOTOR 2 MRB

Encode Card Input Motor MOTOR 3 MRB

Encode Transport Motor MOTOR 4 MRB

Encode Card Entry Sensor SEN 0 MRB

Encode Tab Belt Home Sensor SEN 1 MRB

Encode Eject Door Sensor SEN 2 MRB

Encode Card Exit Sensor SEN 3 MRB

Verify Card Entry Sensor SEN 8 MRB

Verify Tab Belt Home Sensor SEN 9 MRB

Verify Eject Door Sensor SEN 10 MRB

Verify Card Exit Sensor SEN 11 MRB

Verify Expansion Board (J14) EXP 1 MRB

Encode Expansion Board (J14) EXP 2 MRB

Module Interlock INTLK/ATTN MRB

LIGHT

Ethernet to System Controller SYS ENET MRB

1-84
Label

Component Connector Board

Supply Motor MOTOR 1 MRB

Take-Up Motor MOTOR 2 MRB

Card Entry Motor MOTOR 3 MRB

Card Transport Motor MOTOR 4 MRB

Tabbed Belt Home Sensor SEN 9 MRB

Label Peel Shoe Home Sensor SEN 10 MRB

Card Entry Sensor SEN 11 MRB

Card Exit Sensor SEN 12 MRB

Take Up Roll Full Sensor SEN 13 MRB

Label Peel Shoe Encoder ENC 0 MRB

Label Registration Sensor SPECIAL MRB

Buffer Flipper Module Service Manual 1-85

High Speed Label

Component Connector Board

Nip (Pinch) Motor MOTOR 1 MRB

Carriage Elevation (Vertical Travel) MOTOR 2 MRB

Motor

Card Entry (Rollers) Motor MOTOR 3 MRB

Tabbed Belt (Transport) Motor MOTOR 4 MRB

Affixer Shoe Solenoid MOTOR 5 MRB

Pinch Roller (Nip Arm) Down Sensor SEN 6 MRB

Liner Tension (Broken Liner) Sensor SEN 7 MRB

Tabbed Belt Home Sensor SEN 8 MRB

Affixer Shoe Home Sensor SEN 9 MRB

Affixer Shoe Bottom Sensor SEN 11 MRB

Affixer Shoe Apply Sensor SEN 12 MRB

Card Entry Sensor SEN 13 MRB

Card Exit Sensor SEN 14 MRB

Take-Up Full Sensor SEN 15 MRB

Label Registration Sensor SPECIAL MRB

Servo Controller Signal(J5) RFID 0 MRB

ENC 0

Servo Interlock Expansion Board (DC EXP2 MRB

INLET)

Servo Interlock Expansion Board LATCH/J9 MCB

(LATCH)

Servo Interlock Expansion Board (AC J7 MCB

INLET)

1-86
 The High Speed Label module control board assembly includes a servo
interlock board and a servo driver to control the servo motor. The expansion
board/servo driver and their connections are shown in the figure below.

Buffer Flipper Module Service Manual 1-87

Multi-Card Buffer

Component Connector Board

Transport Arm Motor MOTOR 1 MRB

Card Entry Motor MOTOR 2 MRB

Rack Motor MOTOR 3 MRB

Card Exit Motor MOTOR 4 MRB

Card Entry Sensor SEN 8 MRB

Transport Arm Home Sensor SEN 9 MRB

Rack Home Sensor SEN 10 MRB

Card Exit Sensor SEN 11 MRB

Rack Position Encoder ENC 0 MRB

Expansion Board EXP 1 MRB

1-88
Vision Verification

Component Connector Board

Card Entry Motor MOTOR 1 MRB

Placement Arm Motor MOTOR 2 MRB

Horizontal Rack Motor MOTOR 3 MRB

Card Rotation Motor MOTOR 4 MRB

Card Exit Motor MOTOR 5 MRB

Rotator Out Sensor SEN 0 MRB

Card Entry Sensor SEN 9 MRB

Placement Arm Home Sensor SEN 10 MRB

Rack Home Sensor SEN 11 MRB

Rack Back Sensor SEN 12 MRB

Card Exit Sensor SEN 13 MRB

Card In Frame Sensor SEN 14 MRB

Rotator Home Sensor SEN 15 MRB

Expansion Board EXP 1 MRB

Buffer Flipper Module Service Manual 1-89

Standard Output

Component Connector Board

Card Transport Motor MOTOR 1 MRB

Tray 2 Paddle Motor MOTOR 2 MRB

Tray 1 Paddle Motor MOTOR 3 MRB

Card Exit Sensor SEN 8 MRB

Right Full Sensor SEN 9 MRB

Left Full Sensor SEN 10 MRB

Card Entry Sensor SEN 11 MRB

Right Flipper Sensor SEN 12 MRB

Left Flipper Sensor SEN 13 MRB

Cover Sensor SEN 14 MRB

1-90
MX6100/MX8100 High Capacity Card Output

Component Connector Board

Card Entry Motor MOTOR 1 MRB

Tab Belt Motor MOTOR 2 MRB

Card Pusher Motor 1 MOTOR 3 MRB

Card Pusher Motor 2 MOTOR 4 MRB

Card Pusher Motor 3 MOTOR 5 MRB

Card Entry Sensor SEN 0 MRB

Card Exit Sensor SEN 1 MRB

Tab Belt Home Sensor SEN 2 MRB

Card Track Sensor SEN 3 MRB

Card Pusher Home Sensor 1 SEN 4 MRB

Card Picker Home Sensor 2 SEN 5 MRB

Card Pusher Home Sensor 3 SEN 6 MRB

Card Pusher Home Sensor 1 SEN 7 MRB

Card Picker Home Sensor 2 SEN 8 MRB

Card Pusher Home Sensor 3 SEN 9 MRB

Tray Full 1 SEN 10 MRB

Tray Full 2 SEN 11 MRB

Tray Full 3 SEN 12 MRB

Tray Present 1 SEN 13 MRB

Tray Present 2 SEN 14 MRB

Tray Present 3 SEN 15 MRB

Module Interlock J7 MRB

Pause Resume Board (J1) Pause/ MRB

Resume

Buffer Flipper Module Service Manual 1-91

Replace the XE Module Control Board Assembly

Replace the XE module control board when troubleshooting indicates it is

defective. The module control board is located behind the front panel of the
module.

The module power supply is part of the control board. Therefore,

when the control board is removed, the power supply is also removed
and VPD information is lost.

Removal Procedure
Follow standard ESD procedures whenever you touch a
ESD! circuit board.

1. Export the VPD information as described in “Exporting VPD Information” in

Chapter 2 of the System and Controller Service Manual.

2. Power off the system and unplug the power cord.

3. Remove the front panel from the module as described in the System and
Controller Service Manual.
Warning: High voltage is present in the control board. Even with
power off, the caps are charged and dangerous. Leave node
board covers on and do not touch anything under them, unless
necessary.

4. Some versions of the module control board assembly contain a full-length

cover that must be removed prior to accessing cable connections. If
necessary, loosen the retaining screws as shown to remove the housing
cover.

1-92
 The module control board assembly housing may have a different
appearance than the figure shown above. The possible full-length
cover types may differ as shown:

5. Remove the module registration board (1 in the following figure) from the
front of the module control board (4). Refer to “Replace the Module
Registration Board” on page 1-55.

Do not disconnect the sensor and motor cables from the front of
the module registration board. The connector locations are
mapped within the System Diagnostics and must be redefined if
cables are not returned to their original positions.

Buffer Flipper Module Service Manual 1-93

 Caution: Make sure that all sensor and motor cable connections to
the module registration board match the mapping that is defined
in System Diagnostics. If cables are not connected properly as
defined, there is the potential for damage to components within
the module.
6. Disconnect all connectors and cables from the face of the control board.

Note how the cables are routed so you can route them properly
during replacement.

1-94
 7. Loosen the two screws (5 in the following figure) at the bottom of the
control board mounting bracket (2).

8. Slide the control board housing up through the slotted holes and place it on
an anti-static mat.

The module control board assembly housing may have a different

appearance than the figures shown in this section. Some versions
of the assembly contain a full-length cover that must be removed
prior to accessing cable connections.

9. Remove the four screws that secure the front cover (3 in the previous figure)
of the control board housing. Remove the cover.

Buffer Flipper Module Service Manual 1-95

 10. Remove the mounting screws that secure the module control board to the
housing. Remove the board.

The Barrel Smart Card module control board assembly also

contains a power supply board assembly. Remove the mounting
screws that secure the power supply (6 in the following figure),
bracket (7), and expansion board (8) to the module control board
mounting bracket.

1-96
 The Embossing/Indent and Topping module control board
assemblies also contain an expansion board. Remove the
mounting screws that secure the solenoid board (9 in the
following figure) to the standoffs inside the module control board
mounting bracket.

Replacement Notes
 Align the tabs of the control board housing with the slots in the module
frame.
 Carefully insert and lower the mounting bracket tabs into the frame while
making sure that the slots at the bottom line up with the two mounting
screws. Make sure to keep the board straight. If the board is tilted, it will jam.
 Press firmly against the front of the faceplate to make sure that it is fully
seated.
 Tighten the two screws at the bottom of the control board.
 Reinstall the connectors as shown in “Node XE Control Board” on page 1-47.
 Reload Vital Product Data (VPD) information from the backup. For detailed
steps, refer to “Reloading VPD” in Chapter 2 of the System and Controller
Service Manual.

Buffer Flipper Module Service Manual 1-97

External Expansion Boards
Some modules require special expansion and sensor boards outside of the
module control board assembly to power and control special functions within
the mechanism. The following images show the modules with externally
mounted expansion boards.
Card Input

The location of the standard Card Input module vacuum sensor board and its
connections are shown in the figures below.

1-98
Magnetic Stripe

The location of the Magnetic Stripe module expansion board and its
connections are shown in the following figures.

Buffer Flipper Module Service Manual 1-99

 Connector Purpose

MS1 Upper NTT

MS2 IA/IAT

MS3 Lower NTT

ENC Encoder

EXP to NODE Power and Data

1-100
Multi-Card Buffer

The location of the Multi-Card Buffer module expansion board and its
connections are shown in the following figures.

Buffer Flipper Module Service Manual 1-101

Topping

The location of the Topping module vacuum sensor board and its connections
are shown in the following figures.

1-102
Vision Verification

The location of the Vision Verification module expansion board and its
connections are shown in the following figures.

Buffer Flipper Module Service Manual 1-103

Node XE2
The Node XE2 module control board assembly processes all module activity
and system-level communication and powers all module functions with an
integrated power supply. The Node XE2 board powers the attached registration
board and receives registration board output. Some modules also require a
special expansion board that is mounted below the Node XE2 board.

A Node XE module control board assembly is used on the following modules:

 Multi-Point Laser Module
 Drop on Demand Printing Module
 Color Label Printing Module

Node XE2 Control Board

The Node XE2 module control board is contained within the module control
board enclosure in the front of the module frame. It serves as a motherboard
for the module registration board.

1-104
Multi-Point Laser

Refer to the following table for the names of the motors and sensors of the
Multi-Point Laser module and their connections.

MCB
Component Connection

Card Input Motor J13

Card Indexer Motor J12

Card Output Motor J11

Turret Rotation Motor J16

(Y-Axis)

Carriage Motor J10

(Z-Axis)

Horizontal Tilt Motor J19

(X-Axis)

Card Entry Sensor J9

Card Indexer Home Sensor J8

Turret (Vertical) Rotation Home J7

Sensor

Horizontal Tilt Home Sensor J15

Turret Z-Axis Home Sensor J13

Air Filter Present Sensor J14

Chamber Interlock Sensor J4

Chamber Cover Switch Sensor J7

(Control Board)

Card Exit Sensor J11

Buffer Flipper Module Service Manual 1-105

Drop on Demand Printing Module

Refer to the following tables for the names of the motors, sensors, pumps, and
valves of the Drop on Demand Printing module and their connections.
Pre-Treat Station Motors and Sensors

MCB
Component Connection

Entry Roller Motor Slot 3 Motor 1

Grit 1 Roller Motor Slot 1 Motor 1

Grit 2 Roller Motor Slot 1 Motor 2

Plasma Nozzle Vertical Lift Motor Slot 3 Motor 2

Card Entry Sensor Exp B Sens 1

Intermediate 1A Sensor Exp B Sens 2

Intermediate 1B Sensor Exp B Sens 3

Intermediate 2A Sensor Exp B Sens 4

Intermediate 2B Sensor Exp B Sens 5

Card Exit Sensor Exp B Sens 6

Nozzle Home Sensor Exp B Sens 7

Nozzle Lift Position Encoder Exp B Encoder

Nozzle Enclosure Sensor Exp B Sens 8

Exhaust Sensor Exp C Sens 1

Print Station Motors and Sensors

MCB
Component Connection

Flopper Exit 1 Sensor Slot 3 Sens 1

Flopper Rotate Home 1 Slot 3 Sens 2

Flopper Rotate Down 1 Slot 3 Sens 3

1-106
 MCB
Component Connection

Flopper Translate Home 1 Slot 3 Sens 4

Grit Entry 1 Slot 3 Sens 5

Grit Clear 1 Slot 3 Sens 6

Slide 1 Pressure Sensor Slot 1 Sens 7C

Slide 2 Pressure Sensor Slot 1 Sens 8C

Slide 1 Encoder Slot 1 Enc B

Slide 2 Encoder Slot 1 Enc C

Slide 1 Home Sensor Slot 1 Sens 1B

Lift 1 Down Sensor Slot 1 Sens 2B

Lift 1 Lower Mid Sensor Slot 1 Sens 3B

Lift 1 Upper Mid Sensor Slot 1 Sens 4B

Lift 1 Up Sensor Slot 1 Sens 5B

Platen 1 Left Sensor Slot 1 Sens 6B

Platen 1 Right Sensor Slot 1 Sens 7B

Slide 1 End Slot 2 Sens 1B

Slide 2 Home Sensor Exp Sens 1

Lift 2 Down Sensor Exp Sens 2

Lift 2 Lower Mid Sensor Exp Sens 3

Lift 2 Upper Mid Sensor Exp Sens 4

Lift 2 Up Sensor Exp Sens 5

Platen 2 Left Sensor Exp Sens 6

Platen 2 Right Sensor Exp Sens 7

Slide 2 End Slot 2 Sens 2B

Buffer Flipper Module Service Manual 1-107

 MCB
Component Connection

Grit 1 Roller Motor Slot 5 Channel

7

Flopper Translate 1 Motor Slot 1 Channel 2

Flopper Rotate 1 Motor Slot 1 Channel 3

Slide 1 Horizontal Motor Slot 5 Channel

3

Slide 2 Horizontal Motor Slot 5 Channel

4

Slide 1 Vertical Motor Slot 5 Channel

5

Slide 2 Vertical Motor Slot 5 Channel

6

Cap Vertical Motor Slot 3 MTR6

Cap Horizontal Motor Slot 3 MTR5

LED UV Curing Station Motors and Sensors

MCB
Component Connection

Print Done Sensor Exp Sens 8

Kick Arm Encoder Slot 3 Encoder 1

Grit Entry 3 Sensor Exp Sens 9

Grit Exit 3 Sensor Exp Sens 10

Grit Entry 4 Sensor Exp Sens 11

Grit Exit 4 Sensor Slot 1 Sens 6C

Cure Entry Sensor (Zone 5) Slot 1 Sens 8B

Cure Exit Sensor Slot 1 Sens 1C

(Zone 5)

1-108
 MCB
Component Connection

Belt Entry Sensor (Zone 5) Exp Sens 13

Belt Exit Sensor (Zone 5) Exp Sens 14

Belt Home Sensor (Zone 5) Exp Sens 15

Flopper Rotate Home 2 Sensor Slot 1 Sens 2C

Flopper Rotate Down 2 Sensor Slot 1 Sens 3C

(Zone 6)

Flopper Translate Home 2 Sensor Slot 1 Sens 4C

(Zone 6)

Flopper Exit 2 Sensor (Zone 6) Slot 1 Sens 5C

Flopper Entry 2 Sensor (Zone 6) Exp Sens 16

Kick-arm Motor Slot 1 Channel 4

Grit 3 Roller Motor Slot 5 Channel 1

Grit 4 Roller Motor Slot 5 Channel

2

Grit 5 Roller Motor Slot 5 Channel

8

UV Exit Roller Motor Slot 1 Channel 7

UV Belt Exit Motor Slot 1 Channel 8

Flopper Rotate 2 motor Slot 3 Channel

2

Flopper Translate 2 motor Slot 3 Channel 1

Four Card Buffer Station Motors and Sensors

MCB
Component Connection

Roller Entry 7 Sensor Exp Sens 17

Roller Exit 7 Sensor Exp Sens 18

Buffer Flipper Module Service Manual 1-109

 MCB
Component Connection

Roller Entry 8 Sensor Exp Sens 19

Roller Exit 8 Sensor Exp Sens 20

Roller Entry 9 Sensor Exp Sens 21

Roller Exit 9 Sensor Exp Sens 22

Roller Entry 10 Sensor Exp Sens 23

Roller Exit 10 Sensor Exp Sens 24

Exit Rollers 1 Motor Slot 3 Channel

3

Exit Rollers 2 Motor Slot 3 Channel

4

Exit Rollers 3 Motor Slot 3 Channel

5

Exit Rollers 4 Motor Slot 3 Channel

6

Ink Delivery System Motors, Sensors, and Pumps

MCB
Component Connection

Cyan RFID Slot 3 RFID 2

Magenta RFID Slot 3 RFID 3

Yellow RFID Slot 3 RFID 4

Black RFID Slot 3 RFID 5

White RFID Slot 3 RFID 1

Cyan Overflow Sensor Exp Sens 9

Magenta Overflow Sensor Exp Sens 10

Yellow Overflow Sensor Exp Sens 11

1-110
 MCB
Component Connection

Black Overflow Sensor Exp Sens 12

White Header 1 Overflow Sensor Exp Sens 13

White Header 2 Overflow Sensor Exp Sens 14

Cyan Header Pressure Slot 1 Sens 6B

Magenta Header Pressure Slot 1 Sens 5B

Yellow Header Pressure Slot 1 Sens 4B

Black Header Pressure Slot 1 Sens 3B

White Header Pressure Slot 1 Sens 7C

White Vacuum Pressure Slot 1 Sens 8C

CMYK Vacuum Pressure Slot 1 Sens 7B

Cyan Supply Empty Slot 3 Sens 1B

Magenta Supply Empty Slot 3 Sens 2B

Yellow Supply Empty Slot 3 Sens 3B

Black Supply Empty Slot 3 Sens 4B

White Supply Empty Slot 3 Sens 5B

Waste Bottle Present Exp Sens 16

Waste Bottle Full Exp Sens 15

Cyan Header Tank Float Exp Sens 2

Magenta Header Tank Float Exp Sens 3

Yellow Header Tank Float Exp Sens 4

Black Header Tank Float Exp Sens 5

White Header Tank 1 (Rear) Float Exp Sens 6

White Header Tank 2 (Front) Float Exp Sens 7

Buffer Flipper Module Service Manual 1-111

 MCB
Component Connection

Waste Header Tank Float Exp Sens 8

Main Overflow Bottle Full Slot 1 Sens 2C

Fan Control Sensor Slot 1 Sens 1C

White Bulk Tank Circ Encoder Slot 1 Enc B

White Bulk Tank Float Slot 1 Sens 1B

Cap Home Horizontal Exp Sens 17

Cap Home Vertical Slot 3 Sens 6B

Cap Encoder Horizontal Slot 3 Enc B

Cap Encoder Vertical Slot 3 Enc C

White Tank Recirculation Motor Slot 3 MTR7

White Bulk Tank Fill Pump Slot 1 MTR1B

Cyan Header Tank Supply Pump Slot 2 MTR1A

Magenta Header Tank Supply Pump Slot 2 MTR1B

Yellow Header Tank Supply Pump Slot 2 MTR2A

Black Header Tank Supply Pump Slot 2 MTR2B

White Header Tank Supply Pump Slot 2 Sens 2B

White Recirculation Pump Slot 2 Sens 1B

Waste Pump Slot 2 Sens 4B

White Vacuum Pump Slot 2 MTR2B

CMYK Vacuum Pump Slot 2 MTR4B

1-112
Ink Delivery System Valves

MCB
Component Connection

Cyan Outlet Valve 1 (large) Slot 2 MTR6A

Cyan Outlet Valve 2 (small) Slot 2 MTR6B

Magenta Outlet Valve 1 (large) Slot 2 MTR7A

Magenta Outlet Valve 2 (small) Slot 2 MTR7B

Yellow Outlet Valve 1 (large) Slot 2 MTR8A

Yellow Outlet Valve 2 (small) Slot 2 MTR8B

Black Outlet Valve 1 (large) Slot 2 MTR9A

Black Outlet Valve 2 (small) Slot 2 MTR9B

Magenta Vacuum Header Valve Slot 1 MTR3A

Yellow Vacuum Header Valve Slot 1 MTR3B

Black Vacuum Header Valve Slot 1 MTR4A

Cyan Vacuum Header Valve Slot 1 MTR4B

CMYK Vacuum Inlet Valve Slot 1 MTR5A

CMYK Vacuum Outlet Valve Slot 1 MTR5B

White Vacuum Header 1 Valve Slot 1 MTR7A

White Vacuum Header 2 Valve Slot 1 MTR7B

White Vacuum Outlet Valve Slot 1 MTR8B

White Vacuum Inlet Valve Slot 1 MTR8A

White Recirculate Valve Slot 1 MTR2A

Buffer Flipper Module Service Manual 1-113

Color Label Printing Module

Refer to the following tables for the names of the motors and sensors of the
Color Label Printing module and their connections.
Color Label Printing Module

MCB Jumper
Component Connection

Card Entry Buffer2 (Roller) Motor Slot 1 MTR4

Card Entry Buffer1 (Roller) Motor Slot 2 MTR5

Nip (Pinch) Roller Motor Slot 2 MTR2

Label Edge Detect Assembly Motor Slot 1 MTR6

Label Carriage Motor Slot 1 MTR2

Label Accumulator Motor Slot 1 MTR8

Label Articulated Shoe Motor Slot 1 MTR5

Label Entry Motor Slot 2 MTR4

Label Tabbed Belt Motor Slot 2 MTR2

Label Supply Roll Motor Slot 2 MTR8

Vision Entry (Roller) Motor Slot 2 MTR3

Vision Tabbed Belt Motor Slot 2 MTR6

Printhead Lift Motor Printhead Controller

Board

Maintenance Sled Motor J14 MJC4

Printhead Wiper Motor J15 MJC4

Circulation Pump Motor J7 MJC4

Waste Pump Motor Sensor J10 MJC4

Entry Buffer1 Entry Sensor Slot 1 B1

Entry Buffer1 Exit Sensor Slot 1 B2

Exit Buffer2 Entry Sensor Slot 1 C4

1-114
 MCB Jumper
Component Connection

Exit Buffer2 Exit Sensor Slot 1 C5

Label Entry Sensor Slot 1 B3

Label Exit Sensor Slot 1 B6

Drawer Slide Latch Sensor Slot 2 C3

Label Track 1 Sensor Slot 1 B4

Label Track 2 Sensor Slot 1 B5

Label Accumulator Home Sensor Slot 2 B1

Label Tabbed Belt Home Sensor Slot 1 C6

Label Carriage Home Sensor Slot 2 B2

Label Carriage Bottom Sensor Slot 2 B3

Label Shoe Home Sensor Slot 1 C8

Label Apply Registration Sensor Slot 2 B5

Label Top Sensor Slot 2 B6

Label Nip Down Sensor Slot 2 B7

Label Edge Detect Sensor Slot 2 C1

Label Edge Home Sensor Slot 2 C2

Vision Entry Sensor Slot 1 B7

Vision Track #1 Sensor Slot 1 B8

Vision Track #2 Sensor Slot 1 C1

Vision Track #3 Sensor Slot 1 C2

Vision Exit Sensor Slot 1 C3

Vision Belt Home Sensor Slot 1 C7

Humidity Sensor Slot 2 B8

Buffer Flipper Module Service Manual 1-115

LC Control Board
The LC module control board assembly processes all module activity and
system-level communication and powers all module functions with an
integrated power supply. The LC board powers the attached registration board
and receives registration board output. Some modules also require a special
expansion board that is mounted below the LC board.

The LC module control board assembly is used on the following modules:

 Cleaning Module
 Standard Capacity Input Module
 Standard Capacity High Speed Input Module
 Standard Capacity Output Module

 MX9100 Smart Card Barrel Module

 MX9100 Buffer/Flipper Module

 MX Gen 2 Vision Verification Module

 Standard Graphics Module
 High Speed High Capacity Input Module
 High Speed High Capacity Output Module

LC Control Board
The LC module control board is contained within the module control board
enclosure in the front of the module frame. It serves as a motherboard for the
module registration board.

1-116
Buffer Flipper Module Service Manual 1-117
Replace the LC Control Board Assembly
Replace the module control board when troubleshooting indicates it is defective. It is
located behind the front panel of the module.

Removal Procedure
Follow standard ESD procedures whenever you touch a
ESD! circuit board.

1. Back up (export) the Vital Product Data (VPD) information for the module
using the Diagnostics program. For detailed steps, refer to the System and
Controller Service Manual.

2. Power off the system and unplug the power cord.

3. Remove the front panel from the module. For detailed steps, refer to the
System and Controller Service Manual.
Warning: High voltage is present in the control board. Even with
power off the caps are charged and dangerous. Leave board covers
on and do not touch anything under them.

4. Disconnect all cables from the module control board assembly.

Note how the cables are routed so you can route them properly
during replacement.

5. Loosen, (but do not remove) the two mounting screws that attach the
control board mounting bracket to the module chassis.

6. Carefully lift and pull out the control board assembly. Place the control
board assembly on an anti-static mat.

1-118
Replacement Procedure
1. Align the tabs of the control board mounting bracket with the slots in the
module frame.

2. Carefully insert and lower the mounting bracket tabs into the frame while
making sure that the slots at the bottom line up with the two mounting
screws. Keep the board straight. If the board is tilted, it will jam.

3. Press firmly against the front of the faceplate to make sure that it is seated.

4. Tighten the mounting screws at the bottom of the control board mounting
bracket.

Buffer Flipper Module Service Manual 1-119

 5. Reinstall the connectors to their locations as described in “Replace the LC
Control Board Assembly” on page 1-118.

Reload the VPD information from the backup file. For detailed steps, refer to
the System and Controller Service Manual.

1-120
LC Control Board Connectors
The following figure shows connections to the LC module control board.

Buffer Flipper Module Service Manual 1-121

1-122
Cleaning Module

Module Control Board

Component Connector Assignment

Card Entry SEN1

Interm 1 SEN2

Interm 2 SEN3

Card Exit SEN4

Turret Home SEN5

Tape Break SEN6

Transport Motor MTR1

Turret Motor MTR2

Take-up Motor MTR3

Standard Capacity Input Module

Module Control Board

Component Connector Assignment

Card Entry SEN1

Card Exit SEN2

Picker 1 Home SEN3

Roller Motor MTR1

Picker 1 Motor MTR2

Buffer Flipper Module Service Manual 1-123

Standard Capacity Output Module

Module Control Board

Component Connector Assignment

Card Entry SEN1

Card Exit SEN2

Cover Closed SEN3

Pusher 1 Home US SEN4

Pusher 2 Home DS SEN5

Reject Tray Full US SEN6

Good Tray Full DS SEN7

Entry Motor MTR1

Pusher 1 Motor MTR2

Pusher 2 Motor MTR3

Standard Capacity High Speed Input Module

Module Control Board

Component Connector Assignment

Card Entry SEN1

Card Exit SEN2

Picker 1 Home SEN3

Roller Motor MTR1

Picker 1 Motor MTR2

1-124
High Capacity High Speed Input Module

Module Control Board

Component Connector Assignment

Card Entry SEN1

Tab Belt SEN2

Interim SEN3

Tab Belt SEN4

Picker 1 Home SEN5

Picker 2 Home SEN6

Pusher 1 Home SEN7

Pusher 2 Home SEN8

Tray 1 Present SEN9

Tray 2 Present SEN10

Tray 1 Empty SEN11

Tray 2 Empty SEN12

Lid Open SEN13

Entry Motor MTR1

Tab Belt Motor MTR2

Picker 1 Motor MTR3

Picker 2 Motor MTR4

Separator 1 MTR5

Separator 2 MTR6

Buffer Flipper Module Service Manual 1-125

High Capacity High Speed Output Module

Component Module Control Board Connector Assignment

Card Entry SEN1

Card Exit SEN2

Pusher 1 Home SEN3

Pusher 2 Home SEN4

Pusher 3 Home SEN5

Tab Belt SEN6

Lid Open SEN7

Station 1 SEN8

Station 2 SEN9

Station 3 SEN10

Tray 1 Full SEN11

Tray 2 Full SEN12

Tray 3 Full SEN13

Tray 1 in Place SEN14

Tray 2 in Place SEN15

Tray 3 in Place SEN16

Intermediate 1 SEN17

Intermediate 2 SEN18

Entry Motor MTR1

Tab Belt Motor MTR2

Pusher 1 Motor MTR3

Pusher 2 Motor MTR4

Pusher 3 Motor MTR5

1-126