Datacard 150i Desktop Card Personalization System: Owner's Manual

Datacard® 150i Desktop
Card Personalization System
Owner’s Manual
February 2008
Part No. 539782-001, Rev A

Liability Statement
This product has been built to the high standards of Datacard Group. Please do
not attempt to operate or repair this equipment without adequate training. Any
use, operation, or repair in contravention of this document is at your own risk.
By acceptance of this system you hereby assume all liability consequent to your
use or misuse of this equipment. Datacard assumes no liability for incidental,
special, or consequential damage of any kind. Equipment specifications,
applications, and options are subject to change at the sole discretion of Datacard
without notice.
Proprietary Notice
All drawings and information herein are the property of DataCard Corporation.
All unauthorized use and reproduction is prohibited.
Trademark Acknowledgments
Datacard is a registered trademark and service mark of DataCard Corporation in
the US and other countries.
Windows is a registered trademark of Microsoft Corporation.

All other product names are the property of their respective owners.
Datacard Group
11111 Bren Road West
Minnetonka, MN 55343-9015
952.933.1223
Fax: 952.933.7971
www.datacard.com
© 2008 DataCard Corporation. All rights reserved.

Printed in the United States of America.
ii
Contents
Chapter 1: Introduction ____________________________________________________________ 1

Overview of the 150i System ___________________________________________________________1
Internal Components of the 150i System________________________________________________2
Rear Components of the 150i System __________________________________________________3
Financial Card Access ________________________________________________________________4
Supplies/Options _____________________________________________________________________4
Chapter 2: Procedures _____________________________________________________________ 5
Powering On the 150i System __________________________________________________________5
Changing the Password_______________________________________________________________6
Opening the Top Cover _______________________________________________________________7
Loading Blank Cards in the Input Hopper_______________________________________________8
Loading a Single Card ________________________________________________________________9
Loading a Pre-Embossed Card ______________________________________________________ 10
Unloading Completed Cards ________________________________________________________ 11
Unloading Reject Cards_____________________________________________________________ 12
Removing or Inserting the Topper Cassette ___________________________________________ 13
Replacing the Topping Foil __________________________________________________________ 14
Replacing the Front Indent Ribbon___________________________________________________ 15
Replacing the Rear Indent Ribbon ___________________________________________________ 16
Chapter 3: Troubleshooting________________________________________________________ 19
Identifying Errors Using Indicators_____________________________________________________ 19
Identifying Errors Using Error Codes ___________________________________________________ 20
General System Errors _______________________________________________________________ 21
Magnetic Stripe Errors _______________________________________________________________ 25
Communication Errors ______________________________________________________________ 26
Troubleshooting Tips ________________________________________________________________ 27
Service Required Errors ______________________________________________________________ 28
Obtaining Service __________________________________________________________________ 28
iii
Revision Log
150i Desktop Card Personalization System Owner’s Manual
Revision Date Description of Changes

A February 2008 Replaces Administrator’s Guide, Part No. 526638-001.
Regulatory Compliance
Notice for USA (FCC Notice)

This equipment generates, uses, and can radiate radio frequency energy. If it is
not installed and used in accordance with this instruction manual, it may
interfere with radio communications. This equipment has been tested and found
to be within the limits for Class A computing devices, pursuant to Title 47 CFR
Part 15 Subpart B of FCC rules, designed to provide reasonable protection
against radio interference in a commercial environment. Operation of this
equipment in a residential environment may possibly cause interference. In the
event of interference, the users, at their own expense, will be required to take
whatever measures are necessary to correct the problem.
Any changes or modifications to this device not expressly approved by the party
responsible for compliance could void the user's authority to operate the
equipment.
Notice for Canada

This digital apparatus does not exceed the Class A limits for radio noise for
digital apparatus set out in the Radio Interference Regulations of the Canadian
Department of Communications.
Le présent appareil numérique n’émet pas de bruits radioélectriques dépassant

les limites applicables aux appareils numériques de la classe A prescrites dans le
Règlement sur le brouillage radioélectrique édicté par le ministère des
Communications du Canada.
iv
Safety
All Datacard products are built to strict safety and reliability specifications in
accordance with UL60950-1 and CUL requirements; therefore, safety issues
pertaining to operation and repair of Datacard equipment are primarily
environmental and human interface.
The following basic safety tips are given to ensure safe installation, operation and
maintenance of Datacard equipment and are not to be considered as
comprehensive on all matters of safety.
Safe Environment
• Connect equipment to a grounded facility power source. Do not defeat or
bypass the ground lead.
• Place the equipment on a stable surface (table), and ensure floors in work area
are dry and non-slip. Insulated rubber floor mats are preferred.
• Know the location of equipment branch circuit interrupters or circuit breakers
and how to turn them on and off in case of emergency.
• Know the location of fire extinguishers and how to use them. Use only ABC
type extinguishers on electrical fires.
• Know local procedures for first aid and emergency assistance at the customer
facility.
• Use adequate lighting at the equipment.
• Maintain recommended range of temperature and humidity in equipment area.
Safe Human Interface

• Use proper lifting techniques when moving or installing the equipment.
• Use standard electrostatic discharge (ESD) precautions when working on or
near electrical circuits.
• Do not defeat or disconnect safety interlocks on covers.
v
vi
Chapter 1: Introduction
The Datacard® 150i Desktop Card Personalization System delivers high quality,
ready-to-use cards in a fast, secure, single pass operation.
This manual describes the components of the 150i System and the basic operating
procedures. Information on troubleshooting, obtaining service and ordering
supplies is also included.
Overview of the 150i System

The 150i system includes the following components.
• Output Hopper Door

• Single Card Access Door
• Keyhole
• Keypad
• Display
• Indicators
• Top Cover
• Power Switch
150i Desktop Card Personalization System 1

Internal Components of the 150i System
The assemblies inside the 150i system include the following Modules.
• Card Transport Module • Input Hopper

• Embossing Module • Magnetic Stripe Encoding Module
• Rear Indent Printing Module • Reject Tray
• Front Indent Printing Module • Smart Card Personalization Module
(Optional) (Optional)
• Output Tray • Topper Module
2 Owner’s Manual
Rear Components of the 150i System
The following components are located on the back of the 150i system.
• On/Off Switch
• Communication Ports
• Host
• Service
• Smart Card 1 (Option)
• Power Receptacle
• Fan

Financial Card Access
The 150i system contains security features to restrict the generation of financial
cards during shipment. If the security requirements are not met, the system will
display an error. Your Datacard Authorized Service provider will assist in
ensuring that the security requirements are correctly enabled for your
application.
Supplies/Options
The following table lists supplies that may be ordered.
Description Part Number

Cassette, Reusable 596666-002
Topping Foils*
Dark Blue 597950-001
Black 597950-002
Gold 597950-003
White 597950-004
Red 597950-006
Silver 597950-015
Indent Module Ribbons*

Black 596805-001,
case of 10, 715227
White 596805-002,
case of 10, 715228
*With average use, a ribbon equals approximately 1,800 cards.
4 Owner’s Manual
Chapter 2: Procedures
Use the following procedures to operate the 150i System.
Powering On the 150i System

Connect the power cord from the wall outlet socket to the 150i system. To power
ON the 150i system, switch the on/off switch to ON.
• 1 = ON
• 0 = OFF
The 150i system will display a “Ready” message on Line 1 after power up.
Line 2 will display the current version of the internal software, followed by
the current total number of good cards produced. If an error occurs, an error
code is displayed.

Changing the Password
The command for unlocking the cover is *0. The default password for the system
as shipped from the factory is 000. The cover can be unlocked by keying the
following sequence *0 0000.
To change the password, do the following:
Change Password Code
*1[0000][5555]
Old Password New Password

Enter *1 (change password code) followed by the current password and then the
new password. For example, to change the default password 0000 to 5555, enter
*100005555. In this example, the keystrokes to open the Top Cover again using
the new password would be *05555.
If you do not remember your current password, use the key or contact your
Datacard Service Representative to reset it.
6 Owner’s Manual
Opening the Top Cover
The Top Cover can be opened with either a four-digit password or a key. The
default password shipped from the factory for the 150i system is *00000. This
password should be changed upon receipt of the machine.
• To open the Top Cover using a password, using the keypad, enter *0 (unlock
code) followed by your 4-digit password (XXXX). The solenoid to open the
Top Cover will be energized for 5 seconds.
• The message “OPEN COVER!” is displayed. If the password is entered
incorrectly, “ACCESS DENIED!” is displayed. To reenter the correct
password, press *0 followed by the correct password.
• To open the Top Cover using a key, insert the key in the keyhole and turn it
clockwise a quarter turn.

Loading Blank Cards in the Input Hopper
To load the Input Hopper, perform the following steps:
1. Unlock and lift up the Top Cover.
2. Remove the Input Hopper Card Weight.
3. Insert up to 100 blank cards in the Input Hopper, with the front of the card
up and the top edge of the card toward the rear of the 150i system.
If you are encoding Magnetic Stripe cards, place the Magnetic Stripe face
down and oriented toward the rear of the 150i system. If the optional front
Smart Card module is being used, insert the Smart Card so the chip is facing
up and to the left as shown. If the optional rear Smart Card Module is being
used, insert the Smart Card so the chip is facing down and to the right.
Contactless cards can be encoded with the card positioned either way.
4. Replace the Input Hopper Card Weight oriented as shown.
5. Close the Top Cover.
8 Owner’s Manual
Loading a Single Card
A single card loaded in the Single Card Track will be personalized by the 150i
system before any cards loaded in the Input Hopper. To manually load a single
card, perform the following steps:
The 150i system must be in the Ready Mode before loading a single card. Do
not insert a card while the 150i system is processing cards. Do not place more
than one card in the Single Card Track. The Input Hopper Card Weight must
be present for the reliable feeding of cards.
1. Open the Single Card Access Door.
2. Place a single card on the Single Card Track, with the front of the card up and
the top edge of the card toward the back of the 150i system.
If you are encoding Magnetic Stripe cards, place the Magnetic Stripe face
down and toward the rear of the 150i system. If the optional front Smart Card
Module is being used, insert the Smart Card so the chip is facing up and to
the left as shown. If the optional rear Smart Card Module is being used, insert
the Smart Card so the chip is facing down and to the right. Contactless cards
can be encoded with the card positioned either way.
3. Close the Single Card Access Door. The single card is the next card in the
stack to be personalized.

Loading a Pre-Embossed Card
A pre-embossed card loaded in the Single Card Track will be personalized by the
150i system before any cards loaded in the Input Hopper. To manually load a
pre-embossed card, perform the following steps:
The 150i system must be in the Ready Mode before loading a pre-embossed
card. Do not insert a pre-embossed card while the 150i system is processing
cards. Do not place more than one pre-embossed card in the Single Card
Track. Pre-embossed cards must not be loaded in the Input Hopper. The
Input Hopper Card Weight must be present for the reliable feeding of cards.
1. Open the Single Card Access Door.
2. Place a pre-embossed card on the Single Card Track, with the front of the
card up and the top edge of the card toward the back of the 150i system.
3. Close the Single Card Access Door. The pre-embossed card is the next card in
the stack to be personalized.
10 Owner’s Manual
Unloading Completed Cards
Remove completed cards from the 150i system by opening the Output Door and
removing the card(s). The Output Tray can hold up to 15 cards.
The 150i system will not process cards when the Output Door is open. Do not
open the Output Door while a card is being processed.

Unloading Reject Cards
The Reject Tray holds up to 10 rejected cards. To remove rejected cards from the
150i system, perform the following steps:
2. Remove all rejected cards from the Reject Tray.
Keep loose objects, such as jewelry or clothing, away from parts inside the
150i system; they may become caught.
The Topper Platen may be very hot.
12 Owner’s Manual
Removing or Inserting the Topper Cassette
To replace the Topper Cassette, perform the following steps:
The Topper Platen may be very hot.
2. Lift the Topper Cassette Release Ring and pull the Topper Cassette out of the
Topper Module (toward the front of the 150i System).
3. Lift the Topper Cassette Release Ring and insert the new Topper Cassette in
the Topper Module until it is firmly in place.

Replacing the Topping Foil
To replace the Topping Foil, perform the following steps:
1. Unlock and lift the Top Cover.
2. Lift the Topper Cassette Release Ring and pull the Topper Cassette out of the
Topper Module (toward the front of the 150i system).
3. Pull the Take-up Pin out of the Topper Cassette and remove any used
Topping Foil from the Take-up Spool.
4. Pull the Feed Spool from the Topper Cassette and remove the core and any
unused foil from the Topper Cassette Feed Spool.
5. Insert the Topper Cassette Feed Spool into the core of the new topping foil.
6. Insert the Feed Spool with the new Topping Foil so it feeds from the top with
the shiny side up and snap into place in the cassette.
7. Wrap the Topping Foil with the shiny side toward the Topping Foil Roller.
8. Wrap the end of the Topping Foil, shiny side out, around the Take-up Spool
and replace the Take-up Pin so it holds the topping foil securely in place.
Remove slack in the Topping Foil either by winding either the Take-up Spool
gear or the Supply Spool.
9. Replace the Topper Cassette by lifting the Topper Cassette Release Ring and
inserting the Topper Cassette in the Topper Module until it is firmly in place.
14 Owner’s Manual
Replacing the Front Indent Ribbon
The Front Indent Printing Module is located behind the Embossing Wheel.
This procedure is necessary only if the optional Front Indent Printing Module
has been ordered.
To replace the Front Indent Ribbon, perform the following steps:
1. Unlock and lift the Top Cover
2. Slide the Take-up Retainer off the Take-up Spool and set it aside.
3. Wrap the indent ribbon, from the Supply Spool, the Foil Motion Wheel, and
around the Ribbon Guide Rollers.
4. Tape the edge of the ribbon, dull side out, to the core (innermost part of the
ribbon).
5. Place the core on the Take-up Spool, as shown below and slide the Take-up
Retainer on the Take-up Spool until it clicks in place.

Replacing the Rear Indent Ribbon
The Rear Indent Module is located behind the Embossing Wheel.
This procedure is necessary only if the Rear Indent Module has been purchased.
To replace the Rear Indent Ribbon, perform the following steps:
1. Unlock and lift the Top Cover.
2. Remove the Take-up Retainer and full Take-up Spool.
3. Remove the Supply Retainer and Supply Spool. Unwind any remaining
Ribbon from the Supply Spool Core and move it to the Take-up Spool to be
the Take-up Core.
4. Install a full Indent Ribbon Supply Spool. Unwind a few inches of Ribbon
from the Supply Spool and reinstall the Supply Retainer. Be sure to maintain
tension on the Ribbon during the threading process.
5. Carefully thread the Indent Ribbon with the shiny side contacting the Ribbon
Guide rollers and the Ribbon Foil Motion as shown below.
When threading the Indent Ribbon, make sure the ribbon is between the
Card Guide and the Lower Emboss Wheel as shown.
6. Tape the edge of the Ribbon, dull side out, to the Take-up Core.
7. Slide the Take-up Retainer onto the Take-up Core until it clicks in place.
16 Owner’s Manual
18 Owner’s Manual
Chapter 3: Troubleshooting
The system administrator for the 150i system performs the following
troubleshooting procedures.
Identifying Errors Using Indicators

Use the indicators above the display on the front of the 150i system to identify its
current condition.
Power Indicator
When the 150i system is ON, the power indicator is illuminated.
Ready Indicator
When the Ready Indicator is illuminated, the 150i system is ready to accept data.
When the Ready Indicator is not illuminated, the 150i system cannot receive data.
When the Ready Indicator is blinking, the 150i system is processing data. When the
Ready Indicator stops blinking, the card is completed.
Error Indicator
When the Error Indicator is illuminated, an error has occurred, and an Error Code is
displayed. Refer to Error Codes to identify the correct action to remedy the error (see
error information on the following pages).
When the Error indicator is not illuminated, the 150i system is functioning correctly.
Service Indicator
When the Service Indicator is illuminated, an error requiring service has occurred.
Note the Error Code and message from the 150i system display and contact your
Datacard Service Representative to perform the repair. Do not attempt to correct the
problem on your own.
Optional Indicator
The Optional Indicator is used by the application to communicate applications
messages. When the Optional Indicator is illuminated or blinking, see your
Application Administrator or the display for further information. If you have a
problem, contact your Application Administrator.

Identifying Errors Using Error Codes
When the Error indicator is illuminated, an Administrator Recoverable Error has
occurred. An Error Code is displayed on the display located to the left of the
keypad on the front of the 150i system.
The error codes are structured to tell the operator not only what the failure is, but
also where the failure occurred in the system. There are three types of errors,
general, magnetic stripe and communication.
General error codes are displayed on the system LCD in a 6-character format
XXYYZZ (such as PK023B). For general system errors only the last 2 characters
(ZZ) are significant. Magnetic stripe error codes (starting with MS) and
communication errors (starting with AP) are listed in separate tables.
The 150i system continually returns codes to the host application indicating the
status of card processing. The messages displayed by the host application are not
as specific as the error codes displayed on the LCD. Recording of the error code
displayed on the LCD of the 150i system by the operator provides the most
accurate representation of system malfunction when it occurs.
Errors are displayed information only. The system generally remains online and
able to receive data. Generally, sending another data record will cause the system
to move any card detected in the system to the internal reject hopper. If a
mechanical failure has occurred or a card is lost inside the system, operator
intervention inside the system may be required.
If the directed corrective action does not resolve the problem, contact the
Datacard Service Provider.
Use the following tables to identify and correct errors.
20 Owner’s Manual
General System Errors
When a general system error occurs, a status code is sent to the application based
on what type of error is happening. Call for service if the specified corrective
action does not resolve the problem.
Error Error Status Code Card

Possible Corrective Action
Message Code Meaning Sent to Processing
Cause (Operator)
(LCD) (LCD) Application Status
Transport XXYY01 The card Loose card in Open the top cover and verify no B = X and Y Card moved to
Error carriage could system obstructions (such as cards) Stepper Error reject tray if
XXYY02 not verify its prevent the card carriage transport possible
left-to-right from moving to the right or left.
XXYY03 position. Remove any cards that have fallen
inside the system. Try sending the
XXYY04 card again.
Transport XXYY05 The card Loose card in Open the top cover and verify that
Error carriage could system there are no obstructions to prevent
XXYY06 not verify its the card carriage transport from
forward and moving forward or back. Remove all
XXYY07 back position. cards from the input hopper. Check
the input hopper to determine if any
XXYY08 cards are jammed or protruding
from the back. Try sending the card
again.
Transport XXYY09 The input The input Remove the weight and all cards
Error hopper hopper is from the input hopper.
XXYY0A mechanism jammed –
could not find gears out of Open the output door to gain
home position. synch access to the input hopper O-ring
belt. Lift up slightly on the bracket
that holds the throat gap motor
(brass colored, at the back of the
input hopper), pull down on the O-
ring belt to move the hopper to
home position. Release the motor
bracket. Reinitialize the system. Try
sending the card data again.
Too many Remove all cards from the input

single cards hopper and remove any jammed or
inserted protruding cards. Reinitialize the
system. Try sending the card data
again.
Feed error – Remove all cards from the input

cards stuck hopper and remove any jammed or
together protruding cards. Reinitialize the
system. Fan the cards before
loading them to remove the static.
Try sending the card data again.
Emboss XXYY0B The emboss The Try sending the card data again. If D = Wheel Card moved to
Wheel Error wheel could not embossing the error repeats, confirm that the Stepper Error reject tray
XXYY0C find home wheel could embossing wheel is not jammed
position. not verify and can spin by turning it manually.
home position
before
embossing a
card

Cause (Operator)
Embossing XXYY0D The upper or Two cards in Remove cards from carriage or any D = Wheel Card moved to
Error lower emboss card carriage loose cards in system. Try sending Stepper Error reject tray
XXYY0E mechanism did the card data again.
not find home
XXYY0F as expected.
XXYY10 Excessive Remove cards from carriage or any
variation in the loose cards in system. Reinitialize
XXYY12 card stiffness the system. Try sending the card
or thickness data again.
XXYY13
XXYY14
Coordinate XXYY15 Data exceeds Too many Send the same card data again. Try R = Embossing No card
Out Of Range physical limits emboss sending a different customer record. limits exceeded processed
of the card characters on
the card or
invalid
embossing
location
specified.
Command out XXYY16 Sensors in the Interlock Ensure that the cover is closed M = Interlock Card processing
of sequence system did not circuit opened properly and that the interlock open stops
transition in the while picking switch bracket is not bent.
expected card.
sequence.
Card Supply XXYY17 Card supply No cards Load cards Z = Input hopper No card
Empty sensor did not loaded empty processed
transition as
expected. Card weight Install weight.
not installed
Card Feed XXYY18 Card Picked No cards in Remove and reload cards. Install G = Card Feed Card in input
Error sensor did not input hopper, card weight correctly. Error hopper or
become card weight magnetic stripe
blocked as installed module
expected. backwards.
Cards stuck Fan cards before loading to remove

together static. Reload cards.
Card weight Remove and reload cards. Install

not installed weight.
Card Feed XXYY19 Card Picked Too many Remove all cards from the input G = Card Feed Card in Input
Error Sensor single cards hopper and remove any jammed or Error hopper or
remained inserted. protruding cards. Reinitialize the magnetic stripe
blocked after system. module
transport
attempted to Card weight Install weight.
pick card. not installed
None XXYY1A Requested None None

motor is on.
None XXYY1B User requested None None
motor stop.
None XXYY1C Illegal wheel Flash memory Reinitialize system P = System Error No card
position failure processed
requested.
22 Owner’s Manual
Cause (Operator)
None XXYY1D Illegal device Flash memory Reinitialize system P = System Error No card
command failure processed
Card XXYY1E System did not The card Remove cards from carriage or any
Registration register the moved while loose cards in system. Reinitialize
Error XXYY1F position of the in the carriage the system. Send card data again.
card in the
XXYY20 carriage.
XXYY21
XXYY22
XXYY23
XXYY24
XXYY25
Interlock Seen XXYY26 The interlock The top cover Close the Top Cover. M = Interlock Card processing
switch opened was opened open stops
XXYY27 unexpectedly. during card
processing.
Check Output XXYY28 Output stacker Output door Close the output door. K = Output No card
Tray sensor blocked open Stacker Full processed
Stacker full Remove all cards from the stacker.
Topping XXYY29 Topper platen The topper Open the top cover and verify no N = Topper Jam Card jammed in
Platen Error sensor did not platen did not obstructions around or in topper or topper module.
transition as move down. platen sensor. Check topping foil for Operator
expected. correct routing. intervention
required.
Topping XXYY2A Topper platen The topper Open the top cover and verify no
Platen Error sensor did not platen did not obstructions around or in Topper or
transition as return to home platen sensor. Check Topping foil
expected. position for correct routing. Reinitialize the
system.
Card Not XXYY2B Registration The card did Remove cards from carriage or any O = Stacker Error Card position
Stacked sensor not stack loose cards in system. Reinitialize unknown.
transitioned properly the system. Send card data again. Operator
unexpectedly. intervention
required.
Foil Advance XXYY2C Topper foil The system Confirm that the foil is loaded E = Topper Foil No card
Error motion not did not detect correctly. Break processed
detected. topper foil
motion. Ensure that the supply spool moves
freely and is not binding.
Reject Tray XXYY2D The Reject tray Reject tray Empty the reject tray. J = Reject Stacker No card
Full sensor is has multiple Full processed
blocked. cards
Top XXYY2E The topper Pending Shut down 150i system and allow it N = Topper Jam Card jammed in
Temperature temperature is electrical to cool at least 5 minutes. Then topper module.
Error too high. failure. send card data again. Call for Operator
service. intervention
required.
Top XXYY2F The system Pending Shut down 150i system and allow it
Temperature detected the electrical to cool at least 5 minutes. Then
Error topper failure. send card data again. Call for
temperature is service.
not hot enough.

Cause (Operator)
Top XXYY30 The topper Pending Shut down system and allow it to N = Topper Jam Card jammed in
Temperature temperature is electrical cool at least 5 minutes. Then send topper module.
Error not in control. failure card data again. Call for service. Operator
intervention
required.
Indent Ribbon XXYY31 Indent ribbon End of indent Install indent ribbon.
Error motion not ribbon
detected
Ribbon not Install indent ribbon correctly.
installed Ensure that the ribbon is under the
correctly emboss card guide.
Ribbon broken Thread broken indent ribbon onto

take-up spool.
None XXYY32 Indent solenoid Electrical Call for service.

failure failure
XXYY33
Smart Card XXYY34 Smart Card Wrong cable Ensure that a straight through serial
Comm Error application is between cable is connected between the
not responding. system Host host port and the SC port.
port and SC
port
Coupler Configuration menu Smart Card

configuration HW=GemPlus
incorrect
Card Feed XXYY35 Throat Gap Electrical or Reinitialize the system. Send card G = Card Feed Card in input
Error motor not mechanical data again. Call for service. Error hopper or
homing failure magnetic stripe
module.
Operator
intervention
required.
Topping Limits XXYY36 Illegal Topping Host data Try sending a different customer
Error position attempting to record.
XXYY37 requested. position
embossing
above 0.0950
inch from
bottom of card
with Topper
option
enabled
24 Owner’s Manual
Magnetic Stripe Errors
When a Magnetic Stripe error occurs, a status code of H is sent to the Card
Wizard Application and the card is moved to the Reject Tray. Call for service if
the specified corrective action does not resolve the problem.
Error
Error Message Corrective Action
Code Meaning Possible Cause
(LCD) (Operator)
(LCD)
TRACK_TABLE_NOT_F MS 0902 The magnetic stripe The password requirements Reinitialize the system. Try
OUND configuration files cannot be for the system have not been sending card data again. Contact
accessed. met. the MIS department or your
application provider for
assistance.
The flash memory files are Reinitialize the system. Send card
corrupt. data again.
HARDWARE_CONFIG_E MS 0903 Invalid magnetic stripe The flash memory files are Reinitialize the system. Send card
RROR configuration corrupt. data again.
INVALID_START_CODE MS 0910 Incorrect character in Encoding data incorrect Send card data again. Try a
customer record different customer record.
INVALID_START_SENTI MS 0911 Incorrect character in Encoding data incorrect Send card data again. Try a
NEL customer record different customer record.
INVALID_END_SENTINE MS 0912 Incorrect character in Encoding data incorrect Send card data again. Try a
L customer record different customer record.
INVALID_CHARACTER MS 0913 Incorrect character in Encoding data incorrect Send card data again. Try a
customer record different customer record.
INVALID_DATA_LENGT MS 0914 Too many characters in Encoding data incorrect Send card data again. Try a
H customer record different customer record.
READ_OVERRUN_ERR MS 0915 Data written to magnetic Incorrect coercivity setting in Send card data again. Confirm
OR stripe could not be configuration menu that the coercivity configuration
confirmed setting is correct for the cards
used.
Cards with wrong coercivity Load correct card type.

setting used.
NO_TRANSITIONS_FOU MS 0916 System unable to read Cards loaded upside down or Load cards correctly.
ND transitions on magnetic backwards.
stripe after writing
NO_START_FOUND MS 0917 System unable to compare Cards loaded upside down or Load cards correctly.
magnetic stripe data written backwards.
to magnetic stripe data read
START_POSITIION_ERR MS 0918 System unable to compare Cards loaded upside down or Load cards correctly.
OR magnetic stripe data written backwards.
to magnetic stripe data read
LTJ_ERROR MS 0919 System unable to compare Faulty magnetic stripe on Inspect card magnetic stripes for
magnetic stripe data written card visible flaws. Replace bad card
to magnetic stripe data read stock.
BBJ_ERROR MS 091A System unable to compare Faulty magnetic stripe on Inspect card magnetic stripes for
to magnetic stripe data read stock.

Error
Error Message Corrective Action
Code Meaning Possible Cause
(LCD) (Operator)
(LCD)
PARITY_ERROR MS 091B System unable to compare Faulty magnetic stripe on Inspect card magnetic stripes for
to magnetic stripe data read stock
LRC ERROR MS 091C System unable to compare Faulty magnetic stripe on Inspect card magnetic stripes for
COMPARE_ERROR MS 091D System unable to compare Faulty magnetic stripe on Inspect card magnetic stripes for
Communication Errors
When a data format error occurs, the code of U is sent to the Card Wizard
Application and no card is processed.
Error Message Error Code Cause Corrective Action

Data Format Error AP0B01 Error is displayed during initial communication None.
with some host Applications (e.g. Card Wizard)
and defaults to Ready after several seconds.
Send data again. Try sending a

different customer record.
Host data not in correct format.
Reinitialize system and try
sending data again.
Host data is encrypted but DES option is not Call for service.
installed or configured correctly.
None “Busy” or LCD display blanks System flash memory file may be corrupt or Reinitialize system. Call for
out when system is missing. service.
connected to host
26 Owner’s Manual
Troubleshooting Tips
Do not attempt any operation inside the system without first turning off the
power unless directed by service or support personnel.
When correcting errors, it is a good idea to perform the following:

• Load the Input Hopper if the card stock is low.
• Clear any rejected cards from the Reject Tray.
• Replace the foil in the Topper Module if it is getting low.
• Replace the Indent Ribbon if it is getting low.
• Make sure the Top Cover is closed and locked and the Output Hopper door
is fully closed.
• Resend data and/or reinitialize the system to attempt recovery.
If a card is loose in the 150i system:
• Check the inside of the 150i system for cards that may have fallen from the
Card Transport Module.
• Remove the cards and attempt to resume printing.
• Do not pull cards from the carriage. Remove cards in the transport Module
carriage by either by
o Reinitializing the system
OR
o Turning the Y (short) spiral leadscrew counterclockwise to move the
carriage to the rear and open the card grippers
OR
o Pushing on the gripper release lever under the card carriage
• Always move the Card Transport by turning either the X (long, left-to-right)
or Y (short, forward-to-rear) spiral leadscrew – never by only pushing on the
carriage.
If cards fall out of the Card Transport Module or jam frequently in the 150i
system, contact your Datacard Service Representative. When removing
jammed cards, take care not to damage components.
If a card is jammed in the Input Hopper:
• Remove any jammed cards from the Input Hopper by pulling cards from the
rear of the Input Hopper through the card throat.
• Attempt to resume printing.

If a card is jammed in the Embossing Module:
• Remove any jammed cards from the Embossing Module.
If a card is jammed in the Topper Module:
• Remove any jammed cards from the Topper Module.
If a card is jammed in the Front or Rear Indent Module:
• Remove any jammed cards from the front or rear Indent Module.
If a card is jammed in the Smart Card Module:
• Remove any jammed cards from the Smart Card Module.
Service Required Errors

When the Service indicator is illuminated, an error requiring service has
occurred. Note the Error Code and message from the 150i system LCD display
and contact your Datacard Service Representative to perform the repair. Do not
attempt to correct the problem on your own.
Obtaining Service
To obtain service, contact your Datacard Service Representative. Be prepared to
furnish error codes displayed on the 150i system.
28 Owner’s Manual
™
DATACARD®
CERTIFIED SUPPLIES
FOR THE DATACARD®

150i DESKTOP CARD PERSONALIZATION SYSTEM
150i
SUPPLIES
Quality and savings through

the value of Datacard
Certified Supplies
Datacard® Certified Supplies are
specifically designed for high quality
card personalization and production Feature Key Benefits
results in the Datacard 150i desktop System-matched Assurance of Datacard engineering tested and proven
systems. Protect your investment by Supplies supplies performance with the 150i systems for maximum
using only Datacard Certifies Supplies. system uptime, reliability and optimal quality results.
We engineer superior performance Environmentally Supplies are free of hazardous materials, meeting RoHS and
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matched supply item we offer. For Supplies Guarantee Guarantee of supply quality and performance with the
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Page 1 of 2
DATACARD® CERTIFIED SUPPLIES
FOR THE DATACARD® 150i DESKTOP CARD PERSONALIZATION SYSTEM
Topping Foils
Item Number Description Yield/Roll* (approx.)
597950-001 Dark Blue 1,800
597950-002 Black 1,800
597950-003 Metallic Gold 1,800
597950-004 White 1,645
597950-006 Red 1,800
597950-015 Metallic Silver 1,800
597950-016 Premium Silver (best suited for varnish card stock) 1,800
*Topping foil yields are estimates based on common usage. Actual results may vary. Custom color topping
foil ribbon options are available upon request.
Indent Ribbons
Item Number Description Yield/Roll** (approx.)
596805-301 Black indent ribbon 1,800
(Recommended usage: Direct to PVC and security signature panels,
small to large character fonts for multi-application use.)
596805-203 White indent ribbon 1,550
(Recommended usage: Direct to PVC and security signature panels,
small to large character fonts for multi-application use.)
**Indent ribbon yields are estimated based on 1.0 in. (2.54 cm) of indenting per card. Yield results may vary
with various font size and number of characters per card.
***Indent ribbons available in 10 roll packs.
Accessories
Item Number Description Yield
596666-002 Reusable Topping Cassette N/A
Your best choice for supplies

Protect your investment in Datacard® solutions by only using Datacard® Certified Supplies. You can
11111 Bren Road West count on Datacard for all your supply needs. We engineer superior performance and reliability into
Minnetonka, MN 55343-9015 every system-matched supply item we offer. For you, that means high security and exceptional
+1 952 933 1223 performance. Worldwide representation creates a fast, direct connection with the supplies and support
+1 953-931-0418 FAX you need, when and where you need them.
www.datacard.com
Datacard, Datacard Certified Supplies and the

Datacard Certified Supplies icon are
trademarks, registered trademarks or service
marks of DataCard Corporation in the United
States and/or other countries.
© 2010 DataCard Corporation. All rights

reserved.
Specifications subject to change without

notice.
Page 2 of 2

Datacard 150i Desktop Card Personalization System: Owner's Manual

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Datacard® 150i Desktop

Card Personalization System

Part No. 539782-001, Rev A

Windows is a registered trademark of Microsoft Corporation.

© 2008 DataCard Corporation. All rights reserved.

Chapter 1: Introduction ____________________________________________________________ 1

Revision Date Description of Changes

Notice for USA (FCC Notice)

Notice for Canada

Le présent appareil numérique n’émet pas de bruits radioélectriques dépassant

Safe Human Interface

Overview of the 150i System

• Output Hopper Door

150i Desktop Card Personalization System 1

• Card Transport Module • Input Hopper

150i Desktop Card Personalization System 3

Description Part Number

Indent Module Ribbons*

Powering On the 150i System

150i Desktop Card Personalization System 5

To change the password, do the following:

Change Password Code

Old Password New Password

150i Desktop Card Personalization System 7

1. Unlock and lift up the Top Cover.

2. Remove the Input Hopper Card Weight.

5. Close the Top Cover.

150i Desktop Card Personalization System 9

150i Desktop Card Personalization System 11

1. Unlock and lift up the Top Cover.

2. Remove all rejected cards from the Reject Tray.

3. Close the Top Cover.

The Topper Platen may be very hot.

The Topper Platen may be very hot.

1. Unlock and lift up the Top Cover.

4. Close the Top Cover.

150i Desktop Card Personalization System 13

10. Close the Top Cover.

1. Unlock and lift the Top Cover

6. Close the Top Cover.

150i Desktop Card Personalization System 15

1. Unlock and lift the Top Cover.

2. Remove the Take-up Retainer and full Take-up Spool.

8. Close the Top Cover.

Identifying Errors Using Indicators

150i Desktop Card Personalization System 19

Use the following tables to identify and correct errors.

Error Error Status Code Card

Too many Remove all cards from the input

Feed error – Remove all cards from the input

150i Desktop Card Personalization System 21

Cards stuck Fan cards before loading to remove

Card weight Remove and reload cards. Install

None XXYY1A Requested None None

Stacker full Remove all cards from the stacker.

150i Desktop Card Personalization System 23

Ribbon broken Thread broken indent ribbon onto

None XXYY32 Indent solenoid Electrical Call for service.

Coupler Configuration menu Smart Card

Cards with wrong coercivity Load correct card type.

150i Desktop Card Personalization System 25

Error Message Error Code Cause Corrective Action

Send data again. Try sending a