FLEXIBLE PLATFORM

FOR VOLUME
CARD ISSUANCE

OPERATOR MANUAL
Revision 1.3
 Copyright

Important: the technical information contained in this

manual is property of MATICA System S.r.l. and is secured
by copyright. The terms of the license define and specify
permitted uses and other limitations.

Reproduction of any part of this manual, in any form, is

forbidden without the explicit written permission of MATICA
System S.r.l.

Technical information contained in the present manual is

subject to change without notice. If not otherwise specified,
any reference to companies, names, dates and addresses is
purely incidental and is only intended to illustrate the use of
the MATICA System S.r.l. product.

Every care has been taken in the collection and verification

of the documentation inserted in this manual; nevertheless
MATICA System S.r.l. cannot assume any responsibility
deriving from its use.

Copyright © 2012 MATICA System S.r.l.

All rights reserved
Published by MATICA System S.r.l.

Printed in Italy
Issue: February 2012
Revision 1.3

MATICA System S.r.l.

via Guido Rossa, 4/6
20037 – Paderno Dugnano
MILAN - ITALY
Phone +39.02.92272501
Fax +39.02.91084372

E-mail: [email protected]
Web: http://www.maticasystem.com

System 7000 Operator Manual Rev. 1.3 Page 2/48

 Contents

Table of contents

Chapter 1 – Introduction .......................................................... 4

1.1 Specifications ............................................................................. 4

1.2 Warnings ................................................................................... 6
1.3 Choice of site.............................................................................. 6

Chapter 2 – Start up .................................................................. 7

2.1 Installation................................................................................. 7
2.2 Working cycle ............................................................................. 8

Chapter 3 – Consumables ......................................................... 19

3.1 Changing Flip Over cleaning tape .................................................. 19

3.2 Changing Thermal module printing ribbon....................................... 22
3.3 Changing Top Indent ribbon ......................................................... 27
3.4 Changing Rear Indent ribbon ........................................................ 30
3.5 Changing Tipper ribbon ................................................................ 33

Chapter 4 – Error List ................................................................ 37

Chapter 5 – Cleaning and maintenance ................................. 45

5.1 Thermal Printer cleaning .............................................................. 45

5.2 Preventive maintenance schedule .................................................. 47

System 7000 Operator Manual Rev. 1.3 Page 3/48

 Chapter 1 - Introduction

Chapter 1 – Introduction
1.1 Specifications
Cabinet Size
Single Feed/Unload Width: 15.6 cm (6.1”)
Double Feed/Unload Width: 28.3 cm (11.1”)
Standard Cabinet Width: 37.2 cm (14.6”)
Standard Cabinet Depth: 55 cm (21.7”)
Double Feed Depth: 61 cm (24”)
Height (Cabinet Support included): 150 cm (59.1”)
User PC Support Width: 56 cm (22”)
User PS Support Depth: 52 cm (20.5”)

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 Chapter 1 - Introduction

Productivity Speed depending on the system configuration

Printing Mode Thermal Transfer and Sublimation
300 DPI Edge-to-edge printing
Card Format ISO CR80 – ISO 7810
Hopper Capacity Input: 600 cards
Output: 500 embossed cards (approx.)
Comm. Interface LAN
The machine weight depends on the system configuration.

Requirements
Electrical 110V ÷ 120V, 60 Hz or 220V ÷ 240V, 50 Hz.
Room electrical circuit with safety and emergency
interlocks switch.
AC voltage must be stable and constant.
Environment Room temperature: 13 ÷ 35°C (55/95°F).
Humidity: 20% to 80% non-condensing.
Room no subject to dust, smog and filing.
Place The machine must be disposed in closed place.
At least 60 cm as free space around the machine
must be guarantied.
Pavement surface must be flat.
If pavement is raised by floor like platform, be
sure that it able to support the machine weight.
Avoid that the machine is disposed near to:
- heating sources
- cooling sources
- electromagnetic sources
- water sources

Power consuming
Elements Power
Machine state
Standby Pick Working
Current Current Current Voltage Power Power
Modules A A A V W BTUh

Feeder & Stacker 0.1 0.1 0.1 220 22 75

Encoder 0.1 0.2 0.2 220 44 150
Multichip 5 Stations 0.1 0.2 0.2 220 44 150
Thermo 0.1 0.4 0.4 220 88 300
Embosser 0.1 1.0 1.0 220 220 750
Tipper (1 Module) 0.4 0.9 0.4 220 198 675
Laser 4 4 4 220 900 3,070

System 7000 Operator Manual Rev. 1.3 Page 5/48

 Chapter 1 - Introduction

1.2 Warnings
Respect these warnings and follow the indications labeled on the system.
Power the system through the electrical power supply indicated on the
related label.
Connect the system to plugs-in provided with a grounding device. Avoid
using plugs-in placed on the same circuit in connection with machines
starting up and stopping periodically. Take care of the power supply cable,
in order to avoid damaging or wearing out.
The system has never to be installed near heat or cooling sources.
When the cover is open the system automatically stops all the motors;
this kind of safety is useful when cleanings and changing of consumables
have to be performed.
Only perform the adjustments reported in this manual: a wrong
adjustment may cause serious damages.

1.3 Choice of site

Follow the instructions reported below to choose the site where you want
to place the 7000 System and to remove the package.

Before starting the installation, choose a wide and functional area with the
following requirements:
- A level and rigid surface. Yielding surfaces, like pre-manufactured
platforms or floors covered with a fitted carpet, don’t guarantee the
right alignment of the modules making up the 7000 System.
- A good accessibility. Leave free spaces all around the machinery, in
order to allow access to inspection and maintenance areas, and a
right ventilation of the system. Also leave at least one meter in front
of the machine, so that the operator using the front panel has got a
proper working area.
- Favorable environment conditions. Install the 7000 System in a cool
and dry place; avoid too cold or too warm temperatures; keep the
machinery far from humidity, dust and smoke. Don’t directly expose
to heat or sunlight. No electromagnetic interferences.
- Proper electrical power supply. Connect the system and its devices
with cables fit to your electrical power supply net. When using
extensions or multiple plugs-in, be sure that the total absorption
doesn’t exceed the maximum allowed value.

System 7000 Operator Manual Rev. 1.3 Page 6/48

 Chapter 2 – Start up

Chapter 2 – Start up
2.1 Installation
The system specifications are written on the machine label; verify that the
voltage marked on the label corresponds with your country voltage
supply. Connect the power cord on the machine support to the wall
socket, then connect the LAN interface cable on the back panel of the
system.

The service key on the machine back panel enable or disable the cover
open safety. If the key can be removed, the cover open safety is enable
so the machine stops if a cover is opened. Otherwise if the key can’t be
removed, the cover open safety is disabled and the machine doesn’t stop
even if a cover is opened.
The emergency button on the machine front side bypass the service key;
when this button is pushed the machine stops even if the service key is in
the position that disables the cover open safety.

Power on the machine turning the main switch clockwise.

Now the system is ready to work.

Sevice
LAN key
System fuses

Power cord

Main switch

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 Chapter 2 – Start up

2.2 Working Cycle

To perform a working cycle you must introduce the plastic cards to be

personalized into the automatic Input Hopper, with the magnetic stripe on
the bottom right side of the card. Then you had to run the desired job
with the Maticard Pro software.

If the machine is equipped with a Double Input Hopper, insert the card in
the desired one and it will be pushed into the Rotator module. This module
simply pass the card to the next module if it comes from the Hopper on X-
axis or rotate the card 90° if it comes from the Hopper on the Y-axis.

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 Chapter 2 – Start up

If the card it’s moved towards a Smart Station, this module can be
equipped with a Chip contact, a Chip contactless, a Barcode reader and a
OCR reader to personalize the card.

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 Chapter 2 – Start up

If the card it’s moved towards a Transport, this module just passes the
card to the next module.

If the card it’s moved towards an Encoder, this module encodes (write &
read) the magnetic stripe present on the card, with a capacity of reading
and writing 3 tracks at high or low coercivity.

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 Chapter 2 – Start up

If the card it’s moved towards a Multiple Smart Card personalization

module, this one can manage the personalization of the chip present up to
five cards in the same time. The mechanism works as an “elevator” by
which the 5-station Smart Card module raises itself one station at the
time until all 5 stations have been loaded, upon which the module
descends to its initial position. At this point the first card, now fully
personalized, is transferred to the next module and replaced by a new
card, and the process described above is repeated.
If there isn’t any chip personalization, the Multiple Smart Card module just
passes the card to the next module.

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 Chapter 2 – Start up

If the card it’s moved towards a Small Transport, this module just passes
the card to the next module.

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 Chapter 2 – Start up

If the card it’s moved towards a Flip Over, this module can pass the card
to the Thermal Printer module, if the card has to be printed on the same
side, or rotate it 180° if the card has to be printed on the other side.
The Flip Over can be equipped with an AdvanceClean® system to ensure
that cards will be free from dust and debris.

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 Chapter 2 – Start up

The Thermal Printer module performs an edge to edge graphic printing of

the card in the desired position; the printing could be black, black with
overlay protection, scratch off or full color with overlay protection,
depending on the ribbon type. Refer to Chapter 5 for the Printer cleaning.

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 Chapter 2 – Start up

If the card it’s moved towards a Laser, this module engraves the card in
the desired position. The Laser Module needs a vacuum system to avoid
the dispersion of harmful dust (please refer to the related documentation).

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 Chapter 2 – Start up

If the card it’s moved towards an Embosser, this module emboss the
characters present into its drum in the desired position on the card. This
module can be equipped with two indent module, front and rear, to
perform the indenting personalization of both sides of the card in a single
pass.

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 Chapter 2 – Start up

If the card it’s moved towards a Tipper, this module colors the embossed
characters; the color depends on the kind of ribbon mounted.

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 Chapter 2 – Start up

At the end of the cycle, the card is stored in the Output module; if the
card is well personalized will be in the upper Output Hopper, while if the
card is rejected or defective will be in the lower Reject Box.

System 7000 Operator Manual Rev. 1.3 Page 18/48

 Chapter 3 – Consumables

Chapter 3 – Consumables

3.1 Changing Flip Over cleaning tape

When the Thermal Printer cleaning tape is finished it must be replaced, in
order to avoiding plastic cards from dust before printing.
First of all remove the used tape from its rolls.

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 Chapter 3 – Consumables

Now insert partially the spools of the new tape in the two rolls with the full
spool in the right roll and the empty spool in the left one; the tape must
unwind counterclockwise.
Be sure to put the tape outside the lower shaft and inside the upper shaft.

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 Chapter 3 – Consumables

Push completely the tape spools in the two rolls and finally turn clockwise
the left roll to tension the tape.

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 Chapter 3 – Consumables

3.2 Changing Thermal module printing ribbon

When the Thermal printing ribbon is finished, it must be replaced.
First of all unhook the print head by pulling leftward the related handle, in
this way the head lifts up horizontally.

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 Chapter 3 – Consumables

Then remove the used ribbon from its rolls.

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 Chapter 3 – Consumables

Now insert the full spool of the new ribbon in the right roll; the tape must
unwind counterclockwise.
Then pass the ribbon under the related shaft and under the print head.

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 Chapter 3 – Consumables

Now insert the empty spool of the new ribbon in the left roll.
Then push down the print head until it will be hooked to the related pin on the
printer module.

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 Chapter 3 – Consumables

Finally turn counterclockwise the left roll to tension the ribbon.

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 Chapter 3 – Consumables

3.3 Changing Top Indent ribbon

To change the Top Indent ribbon, first of all you must unscrew the two
cover disk knobs and remove the two disks (fig. 1).

Cover disk

Knob Knob

Cover
disk

fig. 1

Now you can remove the used ribbon (fig. 2).

fig. 2

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 Chapter 3 – Consumables

Then you can insert the empty spool on the left disk matching one of the
spool hole with the related disk pin and full spool on the right disk
matching one of the spool hole with the related disk pin; be sure that the
ribbon unwinds on the left side of the full spool (fig. 3).

Full spool

Pin

Pin

Empty spool

fig. 3

Be sure that the ribbon will pass trough this path: over the first roll, under
the second and third rolls, between the rubber red roll and its pin, over
the empty spool (fig. 4).

Empty spool

Rubber
Roll

Pin

1st Roll

3rd Roll 2nd Roll

fig. 4

System 7000 Operator Manual Rev. 1.3 Page 28/48

 Chapter 3 – Consumables

Fasten the ribbon on the empty spool with a stick tape (fig. 5).

Stick tape

fig. 5

Match the hole on each of the two cover disks with the related ones on the
ribbon disks and tighten the disks knobs into the aforesaid holes (fig. 6).

Cover disk

Knob
Knob

fig. 6

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 Chapter 3 – Consumables

3.4 Changing Rear Indent ribbon

To change the Rear Indent ribbon, first of all you must unhook the desired
Indent cartridge by pulling the related lever on the right side (fig. 1).

Lever

fig. 1

Now you can pull out the lower cartridge (fig. 2).

fig. 2

Then you have to put the lower cartridge on a plain surface (fig. 3) and
pull the spring that releases the ribbon cover (fig. 4).

Spring

fig. 3 fig. 4

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 Chapter 3 – Consumables

At this point you need to lift up the ribbon cover (fig. 5) and remove the
used ribbon from the cartridge (fig. 6).

fig. 5 fig. 6

Now you can insert the new ribbon in the related pins with the full spool
on the left pin and the empty spool on the two right pins (fig. 7), from the
ribbon rolls point of view.

fig. 7

You must be absolutely sure that the ribbon runs with the ink side
opposite to the pin spools, trough this path: outside the two rolls near
the full spool (fig. 8), outside the first roll and inside the second roll near
the empty spool and finally outside the big red roll (fig. 9).

fig. 8 fig. 9

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 Chapter 3 – Consumables

Now you have to put the side projections of the lower cartridge in the
related left (fig. 10) and right (fig. 11) inserts on the module

Insert

fig. 10

Insert

fig. 11

Finally you must push the cartridge in order to hook it, paying attention to
pass the ribbon over the lower punches (fig. 12).

fig. 12

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 Chapter 3 – Consumables

3.5 Changing Tipper ribbon

When the Tipper ribbon is finished (fig. 1) you have to unhook the ribbon
cartridge, by pulling the black knob on the left of the module, in order to
extract the cartridge itself (fig. 2).

Knob
Knob

fig. 1 fig. 2

While you are holding the cartridge, you must remove the used ribbon
from its spool (fig. 3) and pull the disk spring that holds the old carton
core (fig. 4).

fig. 3 fig. 4

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 Chapter 3 – Consumables

Then you can extract the old carton core (fig. 5) and insert in the same
position the new ribbon by pulling the related disk spring (fig. 6). Be
careful that the ribbon unwinds over the core.

fig. 5 fig. 6

Now you must be absolutely sure that the ribbon follows this path: under
the nearest shaft, over the first little roller, under the black shaft (fig. 7),
between the third shaft and the second little roller and finally under the
farer little roller (fig. 8).

fig. 7 fig. 8

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 Chapter 3 – Consumables

At this point you have to pull up the ribbon, pass it over the upper shaft,
and put the cartridge in its beginning position on the module (fig. 9);
then you can hook the cartridge by pushing it until the black knob clicks
(fig. 10).

fig. 9 fig. 10

Now you must insert the new carton core in the top spool (fig. 11) and
fasten the ribbon on it with a stick tape (fig. 12).

fig. 11 fig. 12

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 Chapter 3 – Consumables

Finally you have to push the black button on the module (fig. 13) in order
to tighten the ribbon and wind it on the top spool (fig. 14).

fig. 13 fig. 14

System 7000 Operator Manual Rev. 1.3 Page 36/48

 Chapter 4 – Error List

Chapter 4 – Error List

When an error occurred the PC will show the messages listed below; apply
the proper procedure to remove the error condition and read carefully the
error comments. If there are more modules of the same kind, in order to
distinguish which module generated the error, the related module name is
followed by a number that represents the order, in the working cycle, of
one module compared to the other ones of that kind.
ERROR CODE POSSIBLE CAUSES

0001 FEEDER x
Communication error with the Feeder board.
NOT CONNECTED
0002 FEEDER x
System error; please contact the technical support.
NACK ANSWERED
0003 FEEDER x
System error; please contact the technical support
RESET (NACK-3!!)
The card can’t be loaded; check if:
3012 FEEDER x a) Card jam;
START LOAD ERROR b) Card in sensor damaged;
c) Loading motor damaged.
The card can’t be loaded; check if:
3013 FEEDER x a) Card jam;
END LOAD ERROR b) Card out sensor damaged;
c) Loading motor damaged.
If the hopper is empty add cards; while if the hopper isn't
empty, check if:
3014 FEEDER x a) Cards are stuck together or bowed;
EMPTY b) Mechanical impediments;
c) Alignment between modules;
d) The Loading motor moves correctly.
3015 FEEDER x
Card Jam. Remove the card
JAM ERROR
0001 FLIP OVER x
Communication error with the Flip Over board.
NOT CONNECTED
0002 FLIP OVER x
System error; please contact the technical support.
NACK ANSWERED
0003 FLIP OVER x
System error; please contact the technical support
RESET (NACK-3!!)
3004 FLIP OVER x
Card already present inside the module while expected free.
CARD ALREADY INSIDE
3005 FLIP OVER x
Card jam. Remove the card.
2 SENSORS ARE BUSY
3006 FLIP OVER x
Movement error when searching the 180° sensor.
ROTATE ERROR
Error on module card input. Check if:
3007 FLIP OVER x a) Card jam;
CARD-IN ERROR b) Card-in sensor damaged;
c) Motor damaged.
Error on module card output. Check if:
3008 FLIP OVER x a) Card jam;
CARD-OUT ERROR b) Card-out sensor damaged;
c) Motor damaged.
The Flip Over can’t rotate because of a card not positioned
3009 FLIP OVER x
in the middle of the module (but under the card in or the
UNABLE TO ROTATE
card out sensor).
3010 FLIP OVER x
The Flip Over is in a incorrect position. Check the motor.
UNABLE TO MOVE
3125 FLIP OVER
Ribbon finished or not present or cleaning cycle error
CLEANING RIBBON ERROR

System 7000 Operator Manual Rev. 1.3 Page 37/48

 Chapter 4 – Error List

ERROR CODE POSSIBLE CAUSES

0001 ENCODER x
Communication error with the Encoder board.
NOT CONNECTED
0002 ENCODER x
System error; please contact the technical support.
NACK ANSWERED
0003 ENCODER x
System error; please contact the technical support
RESET (NACK-3!!)
3004 ENCODER x
Card already present inside the module while expected free.
CARD ALREADY INSIDE
3005 ENCODER x
Card Jam. Remove the card.
2 SENSORS ARE BUSY
If there is one card in the Encoder check if:
a) The card is slipping on rollers, if so clean them;
b) Check if pulleys are fixed correctly on their shaft;
3016 ENCODER x c) Check if the Encoder motor is damaged;
CARD JAM
If there isn’t any card in the Encoder check if:
a) Check if one of the three card movement sensors is
damaged or dirty.
Error on module card input. Check if:
3007 ENCODER x a) Card jam;
CARD-IN ERROR b) Card-in sensor damaged;
c) Motor damaged.
Error on module card output. Check if:
3008 ENCODER x a) Card jam;
CARD-OUT ERROR b) Card-out sensor damaged;
c) Motor damaged.
3018 ENCODER x
Invalid data.
DATA ERROR
5019 ENCODER x a) Check if the cards are up side down;
TRACK 1 EMPTY b) Check if the encoder head is connected correctly.
5020 ENCODER x a) Check if the cards are up side down;
TRACK 2 EMPTY b) Check if the encoder head is connected correctly.
5021 ENCODER x a) Check if the cards are up side down;
TRACK 3 EMPTY b) Check if the encoder head is connected correctly.
a) Check if the magstripe is scratched or dirty on track 1;
5022 ENCODER x
b) Check if the Encoder head is dirty;
TRACK 1 ERROR
c) Check for timing belt tension.
a) Check if the magstripe is scratched or dirty on track 2;
5023 ENCODER x
b) Check if the Encoder head is dirty;
TRACK 2 ERROR
c) Check for timing belt tension.
a) Check if the magstripe is scratched or dirty on track 3;
5024 ENCODER x
b) Check if the Encoder head is dirty;
TRACK 3 ERROR
c) Check for timing belt tension.
5025 ENCODER x
Error on the track 1 Start Sentinel.
TRACK 1 STX ERROR
5026 ENCODER x
Error on the track 2 Start Sentinel.
TRACK 2 STX ERROR
5027 ENCODER x
Error on the track 3 Start Sentinel.
TRACK 3 STX ERROR
5028 ENCODER x
Smart card reading / writing error
CHIP ERROR
5059 ENCODER x
Error during the track 1 verification.
VERIFY ERROR TRACK 1
5060 ENCODER x
Error during the track 2 verification.
VERIFY ERROR TRACK 2
5061 ENCODER x
Error during the track 3 verification.
VERIFY ERROR TRACK 3

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 Chapter 4 – Error List

ERROR CODE POSSIBLE CAUSES

0001 TRANSPORT x
Communication error with the Transport board.
NOT CONNECTED
0002 TRANSPORT x
System error; please contact the technical support.
NACK ANSWERED
0003 TRANSPORT x
System error; please contact the technical support
RESET (NACK-3!!)
3004 TRANSPORT x
Card already present inside the module while expected free.
CARD ALREADY INSIDE
3005 TRANSPORT x
Card jam. Remove the card.
2 SENSORS ARE BUSY
Error on module card input. Check if:
3007 TRANSPORT x a) Card jam;
CARD-IN ERROR b) Card-in sensor damaged;
c) Motor damaged.
Error on module card output. Check if:
3008 TRANSPORT x a) Card jam;
CARD-OUT ERROR b) Card-out sensor damaged;
c) Motor damaged.
0001 MCHIP x
Communication error with the Multichip board.
NOT CONNECTED
0002 MCHIP x
System error; please contact the technical support.
NACK ANSWERED
0003 MCHIP x
System error; please contact the technical support
RESET (NACK-3!!)
3004 MCHIP x
Card already present inside the module while expected free.
CARD ALREADY INSIDE
3005 MCHIP x
Card Jam. Remove the card.
2 SENSORS ARE BUSY
Error on module card input. Check if:
3007 MCHIP x a) Card jam;
CARD-IN ERROR b) Card-in sensor damaged;
c) Motor damaged.
Error on module card output. Check if:
3008 MCHIP x a) Card jam;
CARD-OUT ERROR b) Card-out sensor damaged;
c) Motor damaged.
Lift module error; check if:
a) Card jam;
3030 MCHIP x
b) Home sensor damaged;
RESTORE ERROR
c) Castle motor damaged;
d) Castle belt broken.
Card transport input error.; check if:
a) Card jam;
3031 MCHIP x
b) Castle-in sensor damaged;
CASTLE-IN ERROR
c) Castle motor damaged;
d) Castle belt broken.
Card transport output error.; check if:
a) Card jam;
3032 MCHIP x
b) Castle-out sensor damaged;
CASTLE-OUT ERROR
c) Castle motor damaged;
d) Castle belt broken.
3033 MCHIP x The chip contacts remain opened/closed.
CONTACTS MOVEMENT ERROR Check the contacts motor.
5025 MCHIP x
Smart card reading / writing error
CHIP ERROR !

System 7000 Operator Manual Rev. 1.3 Page 39/48

 Chapter 4 – Error List

ERROR CODE POSSIBLE CAUSES

0001 ROTATOR x
Communication error with the Rotator board.
NOT CONNECTED
0002 ROTATOR x
System error; please contact the technical support.
NACK ANSWERED
0003 ROTATOR x
System error; please contact the technical support
RESET (NACK-3!!)
3004 ROTATOR x
Card already present inside the module while expected free.
CARD ALREADY INSIDE
3005 ROTATOR x
Card jam. Remove the card.
2 SENSORS ARE BUSY
3006 ROTATOR x
Movement error; check the motor.
ROTATE ERROR
Error on module card input. Check if:
3007 ROTATOR x a) Card jam;
CARD-IN ERROR b) Card-in sensor damaged;
c) Motor damaged.
Error on module card output. Check if:
3008 ROTATOR x a) Card jam;
CARD-OUT ERROR b) Card-out sensor damaged;
c) Motor damaged.
The Rotator can’t rotate because of a card not positioned in
3009 ROTATOR x
the middle of the module (but under the card in or the card
UNABLE TO ROTATE
out sensor).
3010 ROTATOR x
The Rotator is in a incorrect position. Check the motor.
UNABLE TO MOVE
0001 UNLOAD x
Communication error with the Unloader board.
NOT CONNECTED
0002 UNLOAD x
System error; please contact the technical support.
NACK ANSWERED
0003 UNLOAD x
System error; please contact the technical support
RESET (NACK-3!!)
Error on module card input. Check if:
3007 UNLOAD x a) Card jam;
CARD-IN ERROR b) Card-in sensor damaged;
c) Motor damaged.
3010 UNLOAD x
The module can’t move. Check the motor.
UNABLE TO MOVE
During a reset operation or if the card has been ejected:
a) Check if the motor is damaged;
3035 UNLOAD x b) Check if the home sensor is damaged or dirty;
HOME POSITION ERROR
If the card hasn’t been ejected:
a) Check for mechanical impediments.
3036 UNLOAD x
Card Jam. Remove the card.
UP POSITION ERROR
3037 UNLOAD x If the stacker is full unload it.
STACKER FULL If the stacker isn’t full check if the full sensor is damaged.
The card can’t be loaded; check if:
3038 UNLOAD x a) Card jam;
UNABLE TO LOAD b) Loading sensor damaged;
c) Loading motor damaged.

System 7000 Operator Manual Rev. 1.3 Page 40/48

 Chapter 4 – Error List

ERROR CODE POSSIBLE CAUSES

0001 TIPPER x
Communication error with the Tipper board.
NOT CONNECTED
0002 TIPPER x
System error; please contact the technical support.
NACK ANSWERED
0003 TIPPER x
System error; please contact the technical support
RESET (NACK-3!!)
3004 TIPPER x
Card already present inside the module while expected free.
CARD ALREADY INSIDE
3005 TIPPER x
Card jam. Remove the card.
2 SENSORS ARE BUSY
Error on module card input. Check if:
3007 TIPPER x a) Card jam;
CARD-IN ERROR b) Card-in sensor damaged;
c) Transport Motor damaged.
Error on module card output. Check if:
3008 TIPPER x a) Card jam;
CARD-OUT ERROR b) Card-out sensor damaged;
c) Transport Motor damaged.
3050 TIPPER x
Tipper ribbon finished or broken.
RIBBON ERROR
3057 TIPPER x
Tipper temperature too low
TIPPER TEMPERATURE LOW
3058 TIPPER x
Tipper temperature too high
TIPPER TEMPERATURE HIGH
The Tipper can’t reach or leave its home position; check if:
5051 TIPPER x
a) Home sensor damaged;
TIPPER ERROR
b) Pad motor damaged.
5055 TIPPER x The Tipper pad has not enough pressure.
TIPPER PRESSURE ERROR Check the pad motor.
5056 TIPPER x
Tipper temperature out of range
TIPPER TEMPERATURE ERROR

System 7000 Operator Manual Rev. 1.3 Page 41/48

 Chapter 4 – Error List

ERROR CODE POSSIBLE CAUSES

0001 THERMO x
Communication error with the Thermo board.
NOT CONNECTED
0002 THERMO x
System error; please contact the technical support.
NACK ANSWERED
0003 THERMO x
System error; please contact the technical support
RESET (NACK-3!!)
5100 THERMO x
Unknown error.
UNKNOWN ERROR
5101 THERMO x
Wrong command sent.
COMMAND ERROR
5102 THERMO x
Wrong parameter value.
PARAMETER ERROR
5103 THERMO x
Wrong coordinates values.
COORDINATES ERROR
5104 THERMO x
Wrong parameters values.
NUMBER OF PARAMETERS ERR
3105 THERMO x
Hardware error.
FLASH MEMORY ERROR
5106 THERMO x Mismatch between Thermal printer ID card in buffer and ID
SECURITY ID ERROR card present under the printing head.
5107 THERMO x
Error on one of the printer sensors.
SENSOR ERROR
5108 THERMO x
Ribbon finished.
END OF RIBBON
5109 THERMO x
Wrong ribbon type or ribbon parameter.
RIBBON DETECT ERROR
5110 THERMO x Error during the card navigation; check the transport
CARD TRANSPORT ERROR motors, belts and rollers.
5111 THERMO x Card stopped in the module input; check the input motor,
INPUT ERROR IN PRINT MOD belts and rollers
3112 THERMO x Card stopped in the module output; check the output
OUTPUT ERROR IN PRINT MOD motors, belts and rollers.
5113 THERMO x The card doesn’t enter into the printer; check the modules
EDGE INPUT CARD IN PRINT M alignment.
5114 THERMO x Error during the card backward navigation; check the
MOVING BACK ERROR transport motors, belts and rollers.
5115 THERMO x
The print head is up.
PRINT HEAD COVER OPEN
5116 THERMO x
Low print head temperature.
HEAD TEMPERATURE ERROR
5117 THERMO x
Print head movement error; check the print head motor.
HEAD TRANSPORTATION ERROR
5118 THERMO x
Communication error between the PC and the printer.
COMMUNICATION ERROR

System 7000 Operator Manual Rev. 1.3 Page 42/48

 Chapter 4 – Error List

ERROR CODE AND DESCRIPTION SYMPTOM AND CORRECTIVE ACTION

0001 EMBOSSER x
Communication error with the Embosser board.
NOT CONNECTED
0002 EMBOSSER x
System error; please contact the technical support.
NACK ANSWERED
0003 EMBOSSER x
System error; please contact the technical support
RESET (NACK-3!!)
Check for X home sensor:
a) X home sensor is dirty: clean it with compressed air or
lint free cloth;
3039 EMBOSSER x b) X home sensor isn’t connected correctly on the board.
X HOME ERROR Check that all pulleys are fixed on the shaft.
Check X motor connection.
Check the belt’s state.
Card is picked by embossing clamp and is taken to the
embosser’s exit.
Check for X end sensor:
a) X end sensor is dirty: clean it with compressed air or lint
3040 EMBOSSER x free cloth;
X END ERROR b) X end sensor isn’t connected correctly on the board;
c) Remove any impediments along the X embossing travel;
d) Check that all pulleys are fixed on the shaft;
e) Check X motor connection;
f) Check the belt’s state.
3041 EMBOSSER x Card is embossed in a wrong way.
Y HOME ERROR Remove any impediments along the embossing Y travel.
The card can even be picked or not by the embosser’s clamp
and the embossing sequence isn’t completed correctly.
If the clamp picks the card but doesn’t start punching and
the drum keeps on moving:
a) Check drum motor home sensor;
b) Drum motor home sensor is dirty: clean it with
compressed air or lint free cloth;
c) Drum motor home sensor isn’t connected correctly on the
3042 EMBOSSER x board.
Z HOME ERROR
If the card is picked, but it is embossed in a wrong way
check:
a) Belt tension;
b) If pulleys are fixed on the shafts;
c) If the motor is moving correctly or it stalls.
If the card is picked by the clamp but the drum doesn’t
move check:
a) Drum motor connection on the board.
3046 EMBOSSER x
Machine cover open
COVER OPEN
3008 EMBOSSER x
Check the output sensor or card jam.
CARD-OUT ERROR
3053 EMBOSSER x Card correctly loaded and then lost by the Embosser card
CARD LOST guide.

System 7000 Operator Manual Rev. 1.3 Page 43/48

 Chapter 4 – Error List

ERROR CODE AND DESCRIPTION SYMPTOM AND CORRECTIVE ACTION

The clamp holds the card, but the embossing cycle doesn’t
start.
Check the entry sensor:
a) Entry sensor is dirty: clean it with compressed air or lint
free cloth;
b) Entry sensor isn’t connected correctly on the board.
The clamp moves straight to embossing area without a card
3054 EMBOSSER x
or after having made a bad noise:
CARD MISFEED
a) Check for Y home sensor;
b) Y home sensor is dirty: clean it with compressed air or
lint free cloth;
c) Y home sensor isn’t connected correctly on the board;
d) Check Y motor electrical connections;
e) Check if the pulley is fixed on Y motor shaft;
f) Check belt state.
5043 EMBOSSER x X-axis card movement error; reject the card.
X EMBOSS ERROR See ERROR 3039
5044 EMBOSSER x Y-axis card movement error; reject the card.
Y EMBOSS ERROR See ERROR 3041
5045 EMBOSSER x Z-axis card movement error; reject the card.
Z EMBOSS ERROR See ERROR 3042
The embossing clamp picks the card but the embossing
sequence isn’t completed correctly.
Check for any mechanical impediments along the embossing
leverage.
If the card is picked by the embosser’s clamp but just one
character is embossed:
a) Check punch motor home sensor;
b) Punch motor home sensor is dirty: clean it with
compressed air or lint free cloth;
5047 EMBOSSER x c) Punch motor home sensor isn’t connected correctly on the
PUNCH ERROR board.
If the card data aren’t embossed correctly check:
a) Belt status;
b) All pulleys are fixed on the shaft correctly.
The card is picked correctly by the embosser’s clamp and it
is placed correctly under the drum, but the embosser
mechanism doesn’t start, check:
a) If the embossing motor is connected correctly on the
board;
b) replace the motor.
Card not punched in infill way.
If ribbon is finished replace it.
5048 EMBOSSER x
INFILLER ERROR If ribbon isn’t finished:
a) Check if ribbon is installed correctly;
b) check if ribbon advance sensor is working correctly.
5049 EMBOSSER x
Infiller cartridge movement error.
CASSETTA ERROR
0001 SERVICE-BOARD
NOT CONNECTED Communication error with the Service board.
0002 SERVICE-BOARD
NACK ANSWERED System error; please contact the technical support.
0003 SERVICE-BOARD
RESET (NACK-3!!) System error; please contact the technical support

System 7000 Operator Manual Rev. 1.3 Page 44/48

 Chapter 5 – Cleaning and maintenance

Chapter 5 – Cleaning and maintenance

To ensure that the system operates correctly, it is necessary to carry out
periodic cleaning of some of the components that otherwise could cause
problems in cards production.

To clean all the transport rolls of the system and the Encoder module
head, you must absolutely use isopropyl alcohol; at this purpose you can
use an apposite cleaning card supplied by Matica System.

It is recommended to use the aforesaid products only for the indicated

components, in order to avoid damaging the system.
It is also useful to carry out a periodic general cleaning of the system, by
using a vacuum cleaner every week or 10,000 cards performed.

5.1 Thermal Printer cleaning

Classic cleaning of the printer

It is recommended to clean the print engine periodically every cycle of

5000 printed cards by means of a cleaning card.

Procedure:

• Remove the ribbon out of the Printer.

• Put the head-bracket down.
• Place a cleaning card at the input of the print engine.
• Use the command “Clean”.

The cleaning card will be taken, and will pass several times in the machine
to clean the transport rollers and the print head.

Note: If the cleaning sequence doesn’t run, check that the ribbon has
been removed from the printer.

System 7000 Operator Manual Rev. 1.3 Page 45/48

 Chapter 5 – Cleaning and maintenance

Print head cleaning

It is recommended to clean the print head periodically after each

replacement of the ribbon, using a swab.

Procedure:

First ensure that the system is powered off.

• Lift the print head bracket.

• Take a swab and press the tube to release the alcohol.
• Using the swab, rub the surface of the head softly.

The printer should not be used for 2 minutes after a cleaning as the print
head needs to be perfectly dry.

Advanced cleaning of the transport rollers

Sometimes it is necessary to make an advanced cleaning of the rollers

(about 50000 cards)

Procedure:

• Use the command “Roller 1” to rotate the module transport rollers.

• Use a swab to clean each of the rollers.
• Use the command “Roller 0” to stop the transport rollers.

System 7000 Operator Manual Rev. 1.3 Page 46/48

 Chapter 5 – Cleaning and maintenance

5.2 Preventive maintenance schedule

The S7000 Card Personalization Systems have been designed and
manufactured using high quality and high technologies materials
guaranteeing so, reliability, performance and long life.

Nevertheless to have always the best performances of the system it’s

advisable to make periodical inspections and preventive maintenances
taking under control the parts listed in the “Preventive Maintenance
Schedule”.

The “Preventive Maintenance Schedule” includes all the operations and

actions fundamental for the reliability of the system and must be
performed by qualified technical personnel.
The non correct or missing maintenance execution can carry out the decay
of the warranty in every form and type.

PREVENTIVE MAINTENANCE SCHEDULE

Time Cleaning and Lubrication Controls and inspections Replacement
- Cleanliness of all machine rubber rolls
Daily or
- Cleanliness of encoding head
5.000 cards
- Cleanliness of thermal print head
Weekly or - Cleanliness and removal of dust and dirty
- General Visual Inspection
25.000 cards from the machine
Monthly or - Cleanliness and removal of dust and dirty
- General Visual Inspection
100.000 cards from the machine
- Cleanliness and lubrication of all machine - Embossing X Axis Belt (tension and
moving axis. integrity)
Note: only PTFE oil must be used and few - Embossing Y Axis Belt (tension and
drops must be put integrity)
- Lubrication/greasing of Embossing Pins - Multichip Elevator belt (tension and
Striker integrity)
- Embossed character height
- Drum Home Position
Six months or
- Cleanliness of sensors - Tipper Pad (pressure and integrity) - Encoding head
500.000 cards
- Machine bearings
- All machine belts
- No play on mechanical axis
Yearly or - All machine
- Power Supply output voltages
1.000.000 cards springs
- Embossing punch cycle - All machine belts
- All machine offset - All machine rolls
- Drum wheel & Drum Motor Pulley for - Embossing Arm
joining Bearing
- Tipper Pad

The above schedule is referred to a working cycle of 8 hours having 500

cards per hour as throughput.

NOTE:
Belts, Rubber Rolls, Springs, Gears & Pulley, Encoding Heads and Thermal
Printer Heads (except the electrical part) are considered worn out parts
and not covered by machine warranty.

System 7000 Operator Manual Rev. 1.3 Page 47/48

 DECLARATION OF CONFORMITY

Declares that the product

System 7000
Has been designed and constructed to comply fully with the following EU Directives:

- Machinery Directive (2006/42/EEC)

- Low Voltage Directive (2006/95/EEC)
- Electromagnetic Compatibility Directive - EMC (2004/108/EEC)
- WEEE Directive (Waste Electrical and Electronic Equipment) (2002/96/EC)
- RoHS directive (waste electrical and electronic waste, substance
prohibitions) (2002/95/CE)

The declaration is based upon compliance of the product to the following standards:

EN 55022:2006+A1:2007
EN 55024:1998 + A1:2001 + A2:2003
EN 61000-3-2:2006 + A1 2009 + A2:2009
EN 61000-3-3:2008
EN 60950-1:2006+ A1:2009 + A11:2010
EN 6024-1:2006

Quality Manager
MATICA SYSTEM S.r.l.
Via Guido Rossa 4/6
20037 Paderno Dugnano (MI)
Italy