The Datacard MX6000 System

Common
Architecture
 Lesson Purpose: To introduce the architecture of the Datacard MX6000
System from a module level, highlighting commonality
where it exists. Information discussed will not be
re-covered in later module or system lessons.

• sizes
• cascade hardware
• casters
“module frame” • covers
architecture

Module module mechanical • motors

• sensors
Interface commonality
• card guides
Designs….. • rollers

module electrical
commonality
• ac/dc power distribution
• power supplies
• interlock interface
• common logic boards
Hardware: -- Module Frames
Modules Sizes…
10” MX6000 module frames are available in only
one standard size: 10 inch widths. An MX6000
module design can use any multiple of this
particular width.

Card Input Module: 10”

Smart Card Module: 10”
Magnetic Stripe Module: 10”
Card Cleaning Module: 10”
Graphics Module: 10”
Color (D2T2) Module: 10” (requires 3 modules)
Color Artista VHD Module: 30”
Overlay (DuraGard) Module: 20”
Emboss Module: 10”
Topper Module: 10”
Label Affixer Module: 10”
Card Output Module: 10”
Laser Engraving Module: 10”
 Hardware: -- Module Frames
Modules are easily cascaded in an in-line fashion. The right side of each
module incorporates a pair of locator pins within the design (assemblies are
actually welded to the frame), that interface with a corresponding pair of
rectangular receptacles on the left side of each module.

locator pin
receptacle

Cascade
locator pin assemblies
Hardware…
 Hardware: -- Module Frames

Cascading Modules…

Adjacent modules are secured to each

other using a total of (5) screws. The
mounting locations (pointed out with red
arrows) utilize screws just like the Maxsys
System, with the adjacent downstream
frame supplying the pem nuts.

Three circular opening are located on the

airflow
main
front of the frame in order to allow cooling
channel air to escape from the air-flow main
channel. This airflow is used to provide
cooling for the module logic board that
mounts on the face of the module frame.
Hardware: -- Module Supports
module support brackets

support tier

locator pins Each module utilizes a 2-tier module

support on the entrance side of the
frame. This tiered bracket approach
allows module designs of varying
heights to be implemented while
maintaining a fixed distance above
the frame surface for the card track.

The module supports contain four

attached brackets used for mounting
purposes. A pair of locator pins on
the support tier mate with holes in
the module frame.
Hardware: -- Module Supports
Each tier area contains a pair of mounting holes. Since
each tiered module support is used to support the
resident module mechanical assembly and the upstream
module mechanical assembly, it is possible that both
modules are designed to mount on the same pair of tiers.

Mounting holes nearest the module centerline are for the

resident module mechanical assembly.

Mounting holes farthest from the module centerline are

module
for the upstream module mechanical assembly.
centerline

resident module upstream module

hole possibilities hole possibilities
Hardware: -- Module Shipping Posts
1

1 remove screw
on each post
2 springs apply
upward pressure
3 module base is
lifted slightly One or two shipping posts are also incorporated into the
4 slide module base module design to ensure stability of the module mechanical
over downstream assembly during shipment. When installing a module into
tier an in-line MX6000 System, following the 5-step procedure
5 use removed to the left will result in a slight lift of the module base so it
screw to secure
will more easily interface with the downstream tiered
mechanism to
downstream tier module support.
Hardware: -- Module Shipping Posts
Other shipping post spring designs……
Cleaning Module

DuraGard Module

Card Input Module

Smart Card Module
 Hardware: -- Module Frames
Power Supply Opening…
An opening exists on the rear of all module frames but a power supply is only required in this
location on graphics modules and (d2t2) color modules. All modules will have a cover located
over this opening even if a power supply is not needed. Eight screws
secure this cover to the frame.

power supply
mount screws

opening for opening

mounting cover
power supply
Hardware: -- Module Frames
Module Casters…

Casters on the MX6000 are 1

common to the ones now used
on the Maxsys System.

Each wheel contains a brake

pad that can be lowered by
rotating the slotted wheel by
hand (no tools required).

Four screws secure the caster

assembly to the module frame 2
< frame bottom view > (from above).
Hardware: -- Module Mechanical Commonality
Miscellaneous
Fixed Card Guides
• guide entrance must reside 0.060” from module Card Transport
boundary Rollers
• card guides at exit must end 0.4” to 0.56” from • set screws have been replaced by a design
the module boundary utilizing a cross pin that secures the roller to
• card guides must not allow (2) 0.030” cards from the roller shaft (whenever possible)
passing through the module, side by side
hub

mounting screw
cross pin

• card entry
sheet metal front rollers
track incorporate a
spring-loaded
spring bearing design
cavity
Hardware: -- Module Mechanical Commonality
Card Sensing Vane or Belt Tab Sensing

• transmissive (pass-through)
• optical beam centerline located between • transmissive (pass-through)
• slot width of 0.38”
0.298” and 0.406” down from the top of
• when used for belt tab sensing, mount the
the card
• access must be provided for operator cleaning sensor so emitter is on the bottom for best
• card edge sensed at centerline +/- 0.005” dust resistance
• 3 foot cable length • 3 foot cable length
Hardware: -- Module Mechanical Commonality
Sensors
Alternate to Transmissive Card Sensor

amber (on) mounted orthogonal to card

sensor covered at a distance of 0.33”

amber (off)
sensor uncovered
green (on)
power usually mounted to sense the
green rear of the card
(flickering) reflective -type
marginal sense infrared sensor Why?
beam
-- easier to clean
-- easier to see the sensor LEDs
• sees clear cards -- more favorable on bowed cards
• easy to clean -- not a factor with cards of varying
• has good gain thickness
• has fairly small beam with good sensing accuracy (front spring-loaded drive roller)
• contains external feedback indicators (LEDs)
• doesn’t require adjustment
• compact / yet robust
Hardware: -- Module Mechanical Commonality
Sensors
Mechanical Sensing
• capable of sensing both steel and aluminum
inductive proximity sensors
• recommended sense distance
-- steel 0.098” +/- 15%
-- aluminum 0.048” +/- 15%
• since they are non-optical, they are not affected by dirt
• are fairly precise
• don’t require adjustment
• are compact / yet robust
• have external operational indicators (LEDs)

End Face
Sensing

area illuminates amber

when sensor covered
Front Face
Sensing
 Electrical: -- Node Boards
Types:
Purpose:
Each module within the MX6000 System contains a node board which provides the • Node 1 Board Uses
primary control for the module. Node boards perform the following functions: 558079-004
--manages all module functions --Card Input
--distributes module power (except when power supply is separate) --Card Output
--is responsible for inter-module connectivity --Cleaning
--contains motor drive circuits used to drive dc motors, steppers, or solenoids --Magnetic Stripe
--provides non-volatile storage for information identifying the module --Smart Card
--also provides non-volatile storage for serial number, and module
--Label
setup parameters
--Flipper
Location: • Node 2 Board Uses
This board ( either a node 1, node 2, node 3, or node 4/4A board ), dependent 559903-003
on module type, is mounted down the front of the module frame. --Artista VHD
--CardGard
--Overlay/DuraGard
--PB6500
• Node 3 Board Uses
564068-001
--Graphics
--D2T2 Color
• Node 4/A
568442-001
--Emboss
--Topping
Node 1 Type Node 2 Type Node 3 Type Node 4 Type --Laser Engraving
 Electrical: -- Node Boards
Mounting: The front face of the module frame contains a pair of mounting slots, high along the outer edges.
The node board is mounted within a chassis assembly that in turn uses a pair of hangers to attach
the assembly to the front face of the module frame. The chassis is also held in place by a pair of
screws (red arrows) along the bottom of the assembly.

mounting hanger
slots

node board assembly

mounted
chassis

node board
assembly
 Electrical: -- Node Boards
Protective Covers: cooling fan
The node 1 node 2 and node 4 boards have the module’s necessary
power supply requirements built into the logic board. Because of
this, a protective cover becomes necessary for obvious safety reasons

The trough located at the bottom of the power supply cover is used
for routing of ethernet cables from the controller to each of
the modules for communication purposes..

power
supply
cover

with chip
chip cover
covers removed

NOTE:
Removing the protective cover,
even with power removed, can
expose you to capacitors that
have very long bleed times!! chip cover
cable
channel
 Electrical: -- Expansion Boards • Card Input Module
Purpose: 566395-001
• Magnetic Stripe Module
Each module within the MX6000 System contains an expansion board. Although
some expansion boards are unique, a generic version exists that supports the (9) 566377-001
modules that are listed below. The module expansion board performs the • Graphics Module
following functions: 568022-001
--serves as a standard interface for module sensors • D2T2 Color Module
--supports module specific electronics (i.e. magnetic encoding, 568022-001
graphics modules) • CardGard
568645-001
Location: • Generic Module (VI)
This board is mounted on / or very close to the module mechanical 566302-001
assembly, so as to dramatically reduce sensor cable lengths. --Smart Card
--Cleaning
--Overlay
--Card Output
• Generic Module (V2)
568627-001
--Topper
--Emboss
--Label
--Laser
--Flipper
• Color Artista VHD
Card Input Module Cleaning Module xxxxxx-xxx
 Electrical: -- Module Architecture
Module
MODULE Expansion Board
Module-specific
sensors
electronics

Intlk
Expansion I/F
Sw Cable
Connectivity
Block Diagram
A
I/O motor M
d
B
r
i C
M Caution: Check pin
attn. v
lite Proc Pwr e
r M orientation and
s D
M alignment when
Non-volatile storage connecting AC cable
Node Bd. from
to (backchannel) RS232 (backchannel) upstream
RS485
downstream module
module
Enet from controller

to ac ac from
out in
downstream upstream
module module
 Electrical: -- Backchannel Communication
Backchannel Characteristics: Purpose:
Used for configuration of system.
• serial
—assigns the node’s ethernet and/or IP address
• synchronous
• half-duplex
based on the physical position of the module
• point-to-point (RS485) within the system

Two Step Boot Process

Step 2 Step 1

Controller System
Initialization Initialization

Power
SW applied
activated
This routine configures the This routine configures
controller when the production the modules when power
software is activated by retrieving is applied.
VPD info from each node board..
 Electrical: -- Backchannel Communication
Step 1: System Initialization (triggered by power being applied to modules)

MX6000 System
I = connection to upstream module
O = connection to downstream module
NOTE: The backchannel communication lines co-exist in the same cables
as the ac wiring and interlock wiring to adjacent modules

Module Last Module 3 Module 2 Module 1 C

Node Bd. Node Bd. Node Bd. Node Bd. O
N
I O I O I O T
RS485 RS485 RS485 RS485 R
O
D45 D45 D45 D45 L
D46 D46 D46 D46 L
D47 D47 D47 D47 E
D48 D48 D48 D48 R
Terminating Intermediate Intermediate Initiating
Node Node Node Node
Each module node board can detect the presence of input connections to upstream modules and output connections to
downstream modules. A module with no input connection is defined as “initiating”, a module with no output connection
is defined as “terminating”, and all modules with both input and output connections are defined as “intermediate”.
During this step, communication between modules determines the total number of modules and module position within
the system.
***LEDs D45, 46, 47, and 48 on the module node boards are used for troubleshooting the module boot system.
 Electrical: -- Backchannel Communication
Fan J1
Step 1: System Initialization
(triggered by power-up) J2 Motor A
Example:Node 1 Board

J3 Motor B

LEDs Expansion
Console J4 Bd. Power
J6
Backchannel LEDs J5 Interlock \
Attention
Light

J7 J8 Serial I/O
Ethernet

Ethernet LEDs J10 Motor C

power is sent to
downstream module AC Output J13 Motor D
J11
power arrives from AC Input J12
upstream module
 Electrical: -- Backchannel Communication
Step 1: System Initialization (triggered by power-up) Node Board
1
STAGE 2 STAGE 1 power-up reset
CPLD
assign power-up
addresses 2
to modules FPGA FPGA
configuration
op switch turned to “on” 1. Board reset issued by CPLD
boot-loader FPGA 4
which monitors the power supply 3 RAM
2. FPGA configures itself
3. Initial boot-loader gets loaded
4. Control transferred to boot-loader 5
(5 second delay looking for possible RS485 Interface
RS232 console keystroke)
5. (bcInit loaded from flash)
s reflect initiating, Node board statically examines AC J11 J12 AC
mediate or terminating RS485 for upstream and OUT IN
board downstream connections
s blink position 6. Module’s position within system
Note:
& total modules is determined (bcInit) When the node boards are manufactured,
7. VPD queried to determine module flash memory is populated with the latest
type so it knows what startup script versions of the following applications:
to request from the controller --vx Works (operating system)
8. Modules ethernet & IP addresses --bcInit (back channel initialization)
are set --bdTest (board test), and
9. Ethernet connection initialized --FPGA code
 Electrical: -- Backchannel Communication
Step 1: System Initialization (triggered by power-up)
Node Board
STAGE 2 STAGE 1 1
load & execute assign power-up power-up CPLD reset
vxWorks which addresses
establishes to modules 2
control with FPGA FPGA
Controller PC configuration
1. Board reset issued by CPLD FPGA
which monitors the power supply boot-loader 4
3 RAM
2. FPGA configures itself
10. vxWorks is loaded from 3. Initial boot-loader gets loaded
flash into memory 4. Control transferred to boot-loader 5
11. Control is passed to (5 second delay looking for possible RS485 Interface
vxWorks (establishing RS232 console keystroke)
communication with 5. (bcInit loaded from flash)
MX6000 controller PC) Node board statically examines AC J11 J12 AC
12. The node’s startup scriptRS485 for upstream and OUT IN
file is transferred to nodedownstream connections
board and executed 6. Module’s position within system
Note:
& total modules is determined (bcInit)
13. The script file directs the When the node boards are manufactured,
7. VPD queried to determine module
transferring and executing flash memory is populated with the latest
of the node’s firmware type so it knows what startup script versions of the following applications:
application to node boardto request from the controller --vx Works (operating system)
<initialization complete> 8. Modules ethernet & IP addresses --bcInit (back channel initialization)
are set --bdTest (board test), and
9. Ethernet connection initialized --FPGA code
 Electrical: -- Backchannel Communication
Node 1 Board
LED Power-on Sequence

D45—downstream back- Off = at start of boot

channel connected On = downstream backchannel serial
/ node ID indicator connection established
Blink = after connection the LED
will blink the board address
D46—serial Rx/Tx
character indicator
Off = at start of boot
D47—general purpose Blink = after FPGA loaded, will
programmable status blink to indicate backchannel
indicator initialization in progress and
continues until complete.
On = vxWorks has been loaded into D45 D46 D47 D48
the node board and control is
about to be relinquished to
vxWorks

D48—upstream back- Off = at start of boot

channel connected On = upstream backchannel serial
/ node ID indicator connection established
Blink = after connection the LED
will blink the board address
 Electrical: -- Backchannel Communication
Step 2: Controller Initialization (triggered by software activation) software
activation
MX6000 System

Module Last Module 3 Module 2 Module 1 C

O
N
I O I O I O T
RS485 RS485 RS485 RS485 R
O
D45 D45 D45 D45 L
D46 D46 D46 D46 L
D47 D47 D47 D47 E
D48 D48 D48 D48 R
Terminating Intermediate Intermediate Initiating
Node Node Node Node

When the operator activates the MX6000 controller software, the controller will be
required to query the MX6000 system (VPD files) in order to determine the total number of modules,
the module types, and the sequence of the modules in the system. It will also determine each node’s
version and serial number etc, as well as the module’s hardware offsets.
 Electrical: -- System Block Diagram
Module Module Module
Intlk Intlk Intlk
sensors sensors sensors
Sw Sw Sw
PC Controller
Module Module Module
Expansion Board Expansion Board Expansion Board
Expansion I/F Expansion I/F Expansion I/F

Node Bd. Node Bd. Node Bd.

motor motor motor
I/O I/O I/O
d d d fan 2 fan 1
r r r
i i i
Proc v M Proc v M Proc v M
e e e
r r r switched
s M s M s M
RS232 RS232 RS232 extra AC Dist.
RS485 pwr M RS485 pwr M RS485 pwr M
e-stop
ac ac M ac ac M ac ac M
Enet Enet Enet sw.
out in out in out in
filter
attn. attn. attn. J7
lite lite lite

to
switch
2
Cat 5 E-net
ac and
backchannel Ethernet Switch
cable
Hardware: -- Module Interlock
The interlock tower is mounted in the front right corner
Interlock Tower of each module except the Card Input and Card Output
Modules. The tower houses a small logic board that
contains a hall-effect switch along its top edge. This
switch interacts with a magnet attached to the module
cover to serve as the module’s interlock for removing
power to moving parts when a cover is opened.

magnet

hall-effect switch

interlock
tower interlock
adjustment
slots

I/O connection
to module node
board
Hardware: -- Module Covers
Each module (except for Card Operator Attention Light
Input and Card Output) will
have an operator attention light Off --running normal or power off
that is displayed through an
Amber Flashing --module error
opening in the module front
or failure
cover. The light originates
from 4 LED’s that are con- Amber Solid --module supply low
tained on the interlock &
operator attention light board.
A conveyor component is then
used to transmit the light out
through the front cover opening.

interlock & operator

attention light board

operator lite conveyor

attention lite 4 LED’s
 Electrical: -- Interlock Circuit Design Benefits
Primary Design Feature:
To disable only the module downstream upstream
with its’ hood open, and
also the immediate adjacent
modules.
module
module with module
+ open hood +
Note:
• If the hood ganging feature
is utilized and multiple covers Design Benefits:
are lifted as a group, then this •reduced production losses (fewer scrapped cards
group along with the immediate as a result)
upstream and downstream •minimize number of motors that get shut down
modules are affected. ( less error recovery as a result)
• Jumpers can be placed on the •simpler cabling, fewer boards, fewer electrical
node board to prevent motors connections, no system-wide cabling scheme
from shutting down in the event (greater reliability as a result)
of an interlock module shutdown
 Electrical: -- Interlock Block Diagram
Module
Downstream Interlock
Module Switch

Upstream
Module

Note:
Circuitry in center
is duplicated for
To Motor
upstream & Driver Circuit
downstream modules
 Electrical: -- No Interlocks Open
Downstream Module
Interlock Module
Module Interlock
Switch
Switch

CL CL
Upstream
Module

CL

Note:
Circuitry in center
is duplicated for
To Motor
upstream & Driver Circuit
downstream modules
 Electrical: -- Interlock Open

Downstream Module
Interlock Module
Module 1 (lose 3 current paths) Interlock
Switch
Switch
2 X
3 CL
Upstream
(current path 4 X Module
for motor
driver circuit (current path
of downstream for motor
module) 5 driver circuit
of downstream
module)

Note:
Circuitry in center
is duplicated for
To Motor
upstream & Driver Circuit
downstream modules
 Electrical: -- No Interlocks Open
If No Module
Module
Downstream Interlock
Switch Interlock
Module….. Switch

CL
Upstream
Module
Jumper

CL

Note:
Circuitry in center
is duplicated for
To Motor
upstream & Driver Circuit
downstream modules
 Electrical: -- No Interlocks Open
Downstream Module If No
Module Interlock
Switch
Upstream
Module…..

CL CL

J1
CL

Note:
Circuitry in center
is duplicated for
To Motor
upstream & Driver Circuit
downstream modules
End