Evolis BadgePass NXT5000 User manual

280 Trace Colony Park • Ridgeland, MS 39157

601.499.2131

www.badgepass.com

September 2012.

Ref. KU-034-ENG Rev A1

Service Manual

Page 2

BadgePass Service Manual 1

Table of Contents 2

Introduction 3

Liability Statement 3

Proprietary Notice 3

Trademark Acknowledgments 3

Environmental information – recycling of end-of-life products 3

Operator 4

Mechanical Maintenance Personnel 4

Electrical Maintenance Personnel 4

Symbols 5

Safety 6

Safe Environment 6

Safe Human Interface 6

General Safety Regulations 7

Picture List 8

Description 10

Explode View 11

Spare Parts List 18

Available Tools 19

Step 1 - Reject Box - CI010222 20

Step 2 - Enclosure Side - CI010214 21

Step 3 - LCD Control Panel (With Cable) - S10086 22

Step 4 - Upper and Hopper Feeder - S10123 to S10126 23

Step 5 - Feeder Belts Kit - S10092 25

Step 6 - Tighting Belts Kit - S10094 26

Step 7 - Common Motor - S10097 ( Feeder) 27

Step 8 - Enclosure Base - CI011190 29

Step 9 - Flip Over Sensor - S10121 30

Step 10 - Ribbon Braking Kit - S10093 31

Step 11 - Transport Belts Kit - S10091 33

Step 12 - Ribbon Detection Kit - S10087 35

Step 13 - Stepper/Feeder Motor - S10098 36

Step 14 - Flip Over Module - S10128 37

Step 15 - Cleaning Roller - S10122 39

Step 16 - I/O Shield - CI010322 40

Step 17 - Enclosure Bottom Plate - SE010079 41

Step 18 - Main Board USB ETH - S10114 42

Step 19 - Common Motor - S10097 (Up and Down) 43

Step 20 - Common Motor - S10097 (Ribbon) 44

Step 21 - Stepper Motor - S10096 45

Step 22 - Head Roller Kit - S10099 47

Step 23 - Flex Sensor Kit - S10088 51

Step 24 - Print Head (KPE) - S10084 53

Step 25 - Ribbon Sensor - S10089 54

Step 26 - Enclosure Cover - CI010205 55

Step 27 - Enclosure Buttom - CI010206 56

Step 28 - Fan Kit - S10100 57

Step 29 - Print Head Cable - S10085 59

Step 30 - Head Bracket - S10138 60

BadgePass Contact 61

Table of Contents Service Manual

Page 3

Introduction Service Manual

The BadgePass printer is designed to

Liability Statement

This product has been built to the high standards of BadgePass. 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.

BadgePass 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 BadgePass without notice.

Proprietary Notice

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

Trademark Acknowledgments

Microsoft Windows, Windows Embedded, are registered or trademarks of Microsoft Corporation In the United States

or other countries.

Atom ® is a registered trademark of Intel Inc.

TrueType is a registered trademark of Apple Inc.

The information contained in this present document is subject to change without prior notice. All product or program

names mentioned in this document are registered trademarks owned by the respective companies. They are only

used in this document for editorial purposes.

Environmental information – recycling of end-of-life products

The manufacture of the equipment that you have purchased required the extraction and use of natural

resources. It may contain materials that are hazardous to health and the environment. To prevent the dispersal

of such materials into our environment and reduce the pressure on our natural resources, we recommend that

you use existing collection systems.

Note:

The crossed-out dustbin symbol on your device is a reminder to use these systems.

If you need further information on collection, re-use and recycling systems, contact your local or regional waste

management body.

Page 4

Introduction Service Manual

This manual describes the disassembly operation and trouble shooting of BadgePass NXT5000 printer. The manual

has been prepared in conformance with subsequent modifications and integrations and is composed of:

• Safety regulations for use and maintenance

• General machine specifications

• Machine installation

• Operating modes

• Repairs and adjustments

• Electrical diagrams

Personnel assigned to operating the machine, in addition to being professionally trained for their specific job must

read the manuals, pay careful attention to safety regulations and the sections pertinent to their job.

Individuals assigned to operating the machine are broken down as follows:

Operator:

Assigned to loading the elements to process, visual inspection of the work cycle, unloading of finished product and

cleaning of the machine.

Mechanical Maintenance Personnel:

Assigned to mechanical maintenance of the machine.

Electrical Maintenance Personnel:

Assigned to electrical maintenance of the machine.

Note:

BadgePass shall not be held responsible for any non-conforming use of equipment of its manufacture.

If you need further information on collection, re-use and recycling systems, contact your local or regional waste

management body.

Page 5

Generic Warning:

This symbol indicates the need to read the manual carefully or the necessity of an important maneuver or

maintenance operation.

Symbols Service Manual

The symbols used in this manual along with their meaning are shown below. The symbols are repeated within the

chapters and/or sections and have the following meaning:

Electricity Warning:

This symbol indicates dangerous voltage associated with the powerful enough to constitute an electrical

risk. This symbol may also appear on the machine at the risk area.

Temperature Warning:

This symbol indicates high temperature associated to some components. Wait the module to cool down

completely before removing some component. This symbol may also appear on the machine at the risk area.

Page 6

Safety Service Manual

The following basic safety tips are given to ensure safe installation, operation, and maintenance of BadgePass

equipment and are not to be considered as comprehensive on matters of safety. The tests performed demonstrate

the safety and reliability of heating components when used correctly. It is necessary that the operator be informed of

precautionary regulations aimed at avoiding injury or damage to the equipment.

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, and ensure that the floors in the 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 the recommended range of temperature and humidity in equipment area.

• Do not use this product in an environment containing volatile or flammable compounds.

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.

Page 7

Safety Service Manual

General Safety Regulations

The User must comply with the regulations and work in the best possible safety conditions to prevent decreasing the

degree of machine safety. Therefore it is necessary to develop a Standard Operating Procedure (S.O.P.) related to

maneuvers to effect for turning on and off the equipment. This procedure, which shall be prepared around the time

of installation, shall serve as a reference for the Operator and shall be written in his/her language. Training is essential

and must include:

Familiarization with system operating procedures.

Understanding of the necessity for Individual Protection Devices (I.P.D.)

Note:

It is advisable not to change the intended use without previously contacting the Manufacturer.

Note:

Do not subject materials other than those the equipment was designed for.

Note:

Do not work on the electrical part if you are not trained to do so. Do not remove protection devices.

An additional risk may be represented by fire caused by processing materials other than those the equipment is

designed for.

The most serious collateral risk associated, which may be fatal, is electricity. This may occur when the manufacturer’s

warning and procedures are not followed. Unauthorized and untrained personnel must never do any work on the

electrical part. The safety devices must never be removed and their operation must be periodically checked.

Page 8

Picture List Service Manual

Drawing 1 11

Drawing 2 12

Drawing 3 12

Drawing 4 13

Drawing 5 14

Drawing 6 15

Drawing 7 16

Drawing 8 16

Drawing 9 17

Picture 1: BadgePass NXT5000 Printer 10

Picture 2: Tools 19

Picture 3: Reject Box 20

Picture 4: Top Cover 21

Picture 5: Side Bolt 21

Picture 6: Enclosure Side 21

Picture 7: Control Panel 22

Picture 8: Feeder inside Right Side 23

Picture 9: Feeder inside Left Side 23

Picture 10: Feeder Front Side 23

Picture 11: Feeder Right Side 24

Picture 12: Feeder Left Side 24

Picture 13: Feeder Belt 25

Picture 14: Feeder Tighting Belt 26

Picture 15: Feeder Tighting Belt-1 26

Picture 16: Feeder E-ring & pulley 27

Picture 17: Feeder Motor Cable 27

Picture 18: Feeder Motor-1 28

Picture 19: Feeder Motor-2 28

Picture 20: Enclosure Base side 29

Picture 21: Enclosure Base clip-1 29

Picture 22: Enclosure Base clip-2 29

Picture 23: Flip Sensor 30

Picture 24: Ribbon lock 31

Picture 25: Ribbon lock details 31

Picture 26: Ribbon lock gear 32

Picture 27: Transport Belt 33

Picture 28: Black Ribbon Belt 33

Picture 29: Tansport Belts 34

Picture 30: MLX Transport Belt 34

Picture 31: Ribbon Detection 35

Picture 32: Ribbon Detection Rivet 35

Picture 33: Motor Flip 36

Picture 34: Flip Sensor 37

Picture 35: Flip Motor 37

Picture 36: Flip Support 38

Picture 37: Flip Over 38

Picture 38: Cleaning Roller 39

Picture 39: I/O Shield 40

Picture 40: Bottom Plate 41

Picture 41: MainBoard Connections 42

Page 9

Picture List Service Manual

Picture 42: Fixing MainBoard 42

Picture 43: Gear Motor 43

Picture 44: Motor Clip 43

Picture 45: Common Motor Left Side 44

Picture 46: Common Motor clip 44

Picture 47: Stepper Motor 45

Picture 48: Transport Belt 45

Picture 49: Belt Idler screws 46

Picture 50: Stepper Motor 46

Picture 51: Black gears position 46

Picture 52: Left Side Components 47

Picture 53: Stepper Belt 47

Picture 54: Transport Belt 48

Picture 55: Disassembly Chassis screws 48

Picture 56: Separation of Chassis 49

Picture 57: Synchro Ribbon Support 49

Picture 58: Option roller & springs 50

Picture 59: Heat Roller -1 50

Picture 60: Heat Roller - 2 50

Picture 61: Flex connector 51

Picture 62: Flex Rivets 51

Picture 63: Flex Card Sensor 52

Picture 64: Print Head – 1 53

Picture 65: Print Head - 2 53

Picture 66: Print Head - 3 53

Picture 67: Ribbon Sensor - 1 54

Picture 68: Ribbon Sensor - 2 54

Picture 69: Ribbon Sensor - 3 54

Picture 70: Enclosure Cover - 1 55

Picture 71: Enclosure Cover - 2 55

Picture 72: Enclosure Button 56

Picture 73: Fan - 1 57

Picture 74: Fan Connector 57

Picture 75: Fan Cable Path 58

Picture 76: Fan - 2 58

Picture 77: Print Head Cable – Print Head Connector 59

Picture 78: Print Head Cable – Mainboard Connector 59

Picture 79: Print Head Cable Path 59

Picture 80: Head Bracket Connectors 60

Picture 81: Head Bracket Cables Path 60

Picture 82: Head Bracket Axis 60

Page 10

Description Service Manual

Picture 1: BadgePass NXT5000 Printer

Table of contents

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