Manual CL 500

SERVICE MANUAL
LAMINATOR FOR CARD PRINTER
CL-500
Importer and distributor : GRUPO COSMOCOLOR,S.A.DE C.V.

Prol. Paseo de la Reforma 5295
Col. Santa Fe, Deleg. Cuajimalpa C. P.
Phone : 55-50-81-64-40
Facsimile : 55-52-92-1416
SPECIFICATIONS
Item Content
Transfer method Halogen lamp built-in heat roller method
Transfer time Approx. 20 seconds
The time varies according to settings.
Usage environment Temperature 15°C - 30°C
Humidity 30 % - 70% (without condensation)
Storage environment Temperature –15°C - 55°C
Humidity 20 % - 80%
Power supply AC 100 V - 120 V (tolerance ±10%)
Power consumption Approx. 200 W
Unit mass Approx. 8 kg
Compatible specification VCCI-B
Accessories Power cord x 1 (for Europe or US market)
Instructions
Unit joining plate
Cleaning card x 1
Option Cleaning card set x 1 [10p/set (CX210-CC1)]
Changes may be made to the specifications and external appearance of this machine for product improvement
without prior notice.
KAS-T082-004
December 2006
CONTENTS
IMPORTANT SAFETY PRECAUTIONS
MODEL NAME ................................................................................. 1 ASSEMBLY DIAGRAM AND PARTS TABLE ............................ 33

1. DETAILED SPECIFICATION ....................................................... 1 IMPORTANT ............................................................................. 33
MECH ASSY (PLATE R ASSY) ................................................ 34
SCHEMATIC DIAGRAM .......................................................... 2 MECH ASSY (CENTER FRAME ASSY) .................................. 35
MAIN COMPONENTS LAYOUT DIAGRAM ............................... 3 MECH ASSY ............................................................................ 36
CARD GUIDE IN ASSY ............................................................ 37
1. FRONT: HEAT ROLLER, TRANSPORT ROLLER AND
CARD GUIDE OUT ASSY ........................................................ 38
SENSORS ................................................................................... 3
MEDIA T UP MOTOR ASSY ..................................................... 39
2. REAR: MOTOR, FAN, SENSORS AND SWITCHES .................. 4
HEATER MOTOR ASSY ........................................................... 40
3. VARIOUS CIRCUIT BOARDS AND POWER SUPPLY ............... 5
HEATER ASSY ......................................................................... 41
REMOVING MAIN PARTS ............................................................ 6 HEATER UNIT .......................................................................... 42
1. REPLACING HEATER ................................................................ 6 FEED MOTOR ASSY ............................................................... 43
2. REMOVING EXTERNAL PARTS AND WIRING FEED ROLLER ASSY .............................................................. 44
REFERENCE DIAGRAM ............................................................ 6 AC BLOCK ASSY ..................................................................... 45
2.1 REMOVING COVER ............................................................. 6 BOTTOM ASSY ........................................................................ 46
2.2 REMOVING FRONT PANEL ................................................. 6 MECH FRAME ASSY ............................................................... 47
2.3 WIRING REFERENCE DIAGRAM ........................................ 7 FRONT PANEL ASSY (FRONT) ............................................... 50
3. REMOVING MAIN PARTS .......................................................... 9 FRONT PANEL ASSY (REAR) ................................................. 51
3.1 SEPARATING CHASSIS AND MECHANICAL UNIT ............. 9 FINAL ASSY (PANEL) .............................................................. 52
3.1.1 Removing Power Supply and Main Board ...................... 9 FINAL ASSY (REAR) ............................................................... 53
3.1.2 Separating Chassis and Mechanical Unit ....................... 9 ANNEX ASSY ........................................................................... 54
3.2. REMOVING MECHANICAL MAIN PARTS ......................... 10 FINAL (PACKING) ASSY .......................................................... 55
3.2.1 Removing Feed Motor .................................................. 10
3.2.2 Removing Heater Unit and Heater ASSY ..................... 10
3.2.3 Removing Heat Roller .................................................. 11
3.2.4 Removing Transport Roller ........................................... 11
USING SERVICE MODE ............................................................. 12

1. USER MODE ............................................................................ 12
2. SERVICE MODE ....................................................................... 13
3. FIRMWARE UPDATE ................................................................ 14
MECHANISM OPERATION ......................................................... 17

1. INITIAL OPERATION ................................................................ 17
2. LAMINATING OPERATION ....................................................... 17
TROUBLESHOOTING .................................................................. 19
1. HANDLING ERROR CODES .................................................... 19
2. HANDLING CARD JAM ............................................................. 22
3. HANDLING THE SITUATION WHERE POWER SUPPLY
IS CUT OFF WHEN THE HEAT ROLLER IS DOWN ................ 24
SET UP GUIDE ............................................................................. 25

1. SETTING OF LAMINATE CONDITION ..................................... 25
2. SETTING PROCESS ................................................................ 27
3. VARIOUS CONDITIONAL SETTINGS ...................................... 28
4. CARD ADHESIVENESS ........................................................... 30
MAINTENANCE ............................................................................. 31
1. CLEANING ................................................................................ 31
2. LIST OF PARTS TO BE REPLACED ......................................... 31
ADJUSTMENT ............................................................................... 32
1. ARRANGEMENT OF ADJUSTMENT VOLUME ....................... 32
2. HOW TO ADJUST THE VOLUME ............................................. 32
SAFETY PRECAUTION
Important Safety Precautions
Prior to shipment from the factory, JVC products are strictly inspected to conform with the recognized product safety and electrical codes of the
countries in which they are to be sold. However, in order to maintain such compliance, it is equally important to implement the following precautions
when a set is being serviced.
•Precautions during Servicing

1. Locations requiring special caution are denoted by labels and in- 12. Crimp type wire connector
scriptions on the cabinet, chassis and certain parts of the product. In such cases as when replacing the power transformer in sets
When performing service, be sure to read and comply with these where the connections between the power cord and power trans-
and other cautionary notices appearing in the operation and serv- former primary lead wires are performed using crimp type connec-
ice manuals. tors, if replacing the connectors is unavoidable, in order to prevent
safety hazards, perform carefully and precisely according to the
2. Parts identified by the ! symbol and shaded ( ) parts are following steps.
critical for safety.
Replace only with specified part numbers. 1) Connector part number : E03830-001
Note: Parts in this category also include those specified to comply 2) Required tool : Connector crimping tool of the proper type which
with X-ray emission standards for products using cathode ray will not damage insulated parts.
tubes and those specified for compliance with various regu- 3) Replacement procedure
lations regarding spurious radiation emission (1) Remove the old connector by cutting the wires at a point
. close to the connector.
Important : Do not reuse a connector (discard it).
3. Fuse replacement caution notice.
Caution for continued protection against fire hazard.
Replace only with same type and rated fuse(s) as specified.
4. Use specified internal wiring. Note especially:

1) Wires covered with PVC tubing
2) Double insulated wires cut close to connector
3) High voltage leads
Fig.3
5. Use specified insulating materials for hazardous live parts. Note
especially: (2) Strip about 15 mm of the insulation from the ends of the
1) Insulation Tape 3) Spacers 5) Barrier wires. If the wires are stranded, twist the strands to avoid
2) PVC tubing 4) Insulation sheets for transistors frayed conductors.
15 mm
6. When replacing AC primary side components (transformers, power
cords, noise blocking capacitors, etc.) wrap ends of wires securely
about the terminals before soldering.
Fig.4
(3) Align the lengths of the wires to be connected. Insert the

wires fully into the connector.
Fig.1 Metal sleeve
7. Observe that wires do not contact heat producing parts (heatsinks,

oxide metal film resistors, fusible resistors, etc.)
8. Check that replaced wires do not contact sharp edged or pointed Connector
parts.
Fig.5
9. When a power cord has been replaced, check that 10-15 kg of
force in any direction will not loosen it. (4) As shown in Fig.6, use the crimping tool to crimp the metal
sleeve at the center position. Be sure to crimp fully to the
complete closure of the tool.
Power cord
1.2
2.0
5 Crimping tool
5.5
Fig.2 Fig.6
10. Also check areas surrounding repaired locations. (5) Check the four points noted in Fig.7.
11. Products using cathode ray tubes (CRTs) Not easily pulled free Crimped at approx. center
of metal sleeve
In regard to such products, the cathode ray tubes themselves, the
high voltage circuits, and related circuits are specified for compli-
ance with recognized codes pertaining to X-ray emission.
Consequently, when servicing these products, replace the cath- Conductors extended
ode ray tubes and other parts with only the specified parts. Under
Wire insulation recessed
no circumstances attempt to modify these circuits. more than 4 mm
Unauthorized modification can increase the high voltage value and
cause X-ray emission from the cathode ray tube. Fig.7
I
SAFETY PRECAUTION
• Safety Check after Servicing

Examine the area surrounding the repaired location for damage or deterioration. Observe that screws, parts and wires have been returned
to original positions, Afterwards, perform the following tests and confirm the specified values in order to verify compliance with safety
standards.
1. Insulation resistance test

Confirm the specified insulation resistance or greater between power cord plug prongs and exter-
nally exposed parts of the set (RF terminals, antenna terminals, video and audio input and output
terminals, microphone jacks, earphone jacks, etc.). See table 1 below.
2. Dielectric strength test

Confirm specified dielectric strength or greater between power cord plug prongs and exposed acces-
sible parts of the set (RF terminals, antenna terminals, video and audio input and output terminals,
microphone jacks, earphone jacks, etc.). See table 1 below.
3. Clearance distance
When replacing primary circuit components, confirm specified clearance distance (d), (d’) be-
tween soldered terminals, and between terminals and surrounding metallic parts. See table 1
below.
Fig. 8
4. Leakage current test

Confirm specified or lower leakage current between earth ground/power cord plug prongs and
externally exposed accessible parts (RF terminals, antenna terminals, video and audio input and
output terminals, microphone jacks, earphone jacks, etc.). a b
Measuring Method : (Power ON) Z A c
Insert load Z between earth ground/power cord plug prongs and externally exposed accessible Externally
exposed V
parts. Use an AC voltmeter to measure across both terminals of load Z. See figure 9 and following
accessible part
table 2.
Fig. 9
5. Grounding (Class 1 model only)

Confirm specified or lower grounding impedance between earth pin in AC inlet and externally exposed accessible parts (Video in, Video out,
Audio in, Audio out or Fixing screw etc.).
Measuring Method:
Connect milli ohm meter between earth pin in AC inlet and exposed accessible parts. See figure 10 and grounding specifications.
Fig. 10
Table 1 Specifications for each region
Table 2 Leakage current specifications for each region

Note: These tables are unofficial and for reference only. Be sure to confirm the precise values for your particular country and locality.
II
MODEL NAME
MODEL NAME
Alphabets and numbers after the model name indicate the different destinations and specifications.
ID label display: CL-500*1-CO
1. DETAILED SPECIFICATION
*1 : Destination
U : For North America (100 V – 120 V specification)
E : For Europe (100 V – 120 V specification) (220 V – 240 V specification)
1
SCHEMATIC DIAGRAM
SCHEMATIC DIAGRAM
AC 100 V/200 V switching model
Card insert detection

sensor (Board)
Laminate position External machine

CN11 Interlock switch
sensor (Board) IF connector
When the interlock switch is turned off
Card ejecting sensor (cassette is removed), the 24 V power
(Board) supply for the motor is switched off, all
CN10 Printer IF connector motor stops and the heater is turned off.
Film (Black)
Mark sensor end CN5
Mark sensor
Thermistor (Board) °C
Film FG sensor *1 Not available for AC 100 V model

(Board) *2 Not available for AC 100 V model
Interlock switch *3 Not available for AC 100 V model
Heat roller pressure CN13
(Cassette switch)
position sensor (HR2)
Heat roller standby
position sensor (HR1) KEP3160-A *2
MAIN PWB
100 V/200 V
Card transport AC selector switch (Board)
motor CN1
Transformer
AC inlet
Film reeling *1
motor CN601
Relay connector CN3
Heater *3
cam motor
CN3 CN7 CN4 KEP4101-F
PROTECT PWB
CN12 Power
supply CN2
CN2 CN8 CN501
KEP4101-A
Back fan motor AC PWB
CN9 CN502
CN8 CN6
CN4 CN5 CN1
Card cooling
fan motor
Halogen heater
Front panel Relay connector
KEP3160-B CN9 CN6 °C Thermostat
FRONT PWB
Power switch
2
MAIN COMPONENTS LAYOUT DIAGRAM

1. FRONT : HEAT ROLLER, TRANSPORT ROLLER AND SENSORS
Thermostat Film mark sensor and

end mark sensor
Heat roller
Thermistor
Card ejecting sensor
Halogen heater
Laminate position sensor
Card insert detection sensor
3
2. REAR : MOTOR, FAN, SENSORS AND SWITCHES
Film reeling motor
Cassette interlock SW
Heater cam motor
Film FG sensor
Heat roller
pressure position sensor
Card cooling fan
Heat roller
standby position sensor
Card transport motor
AC select switch
Back fan
4
3. VARIOUS CIRCUIT BOARDS AND POWER SUPPLY
Power unit
Front board
Transformer
Protective board
AC board Main board AC select SW board
5
REMOVING MAIN PARTS
REMOVING MAIN PARTS

1. REPLACING HEATER 2. REMOVING EXTERNAL PARTS
1) Remove two screws Å and remove the protective AND WIRING REFERENCE
sheet. DIAGRAM
2) Remove one screw ı, shift the connect base a little
and remove the hook on the inner right hand side to 2.1 REMOVING COVER
remove the halogen lamp.
1) Remove six screws Å and remove the top cover !.
Important : Do not remove screw Ç as this will break
2) Pull the fan cable from the main board and remove
the contact point of the heater.
screw ı and the rear panel.
3) Pull the halogen heater out to the front, replace it
with a new halogen heater and attach the screws in
the reverse order.
Important : Do not touch the glass section of the halo-
gen heater. Oil secretion from your hand Fan cable
may reduce the lamp life.
C Screw
QYSDSP4008N
Protective sheet (Do not remove) x6
CN2 A
Rear panel
B
11
QYSDSP
4008N
Connect
base
Screw A
2.2 REMOVING FRONT PANEL
Screw B 1) Remove cassette 5 and remove four screws Å.
A Screw 2) Remove the front panel 4 slightly and pull the con-
nector on the front board.
CN02
Inset Diagram 2
Insert the claws on both sides of the
front panel to the plate and fasten
Insert to FRONT with screws.
board CN02
Inset Diagram 1
(TFS0125) 4
Inset Diagram 1
QYSDSP3006Nx4
A
Connector
(TFS0126)
5
Insert to shaft
Important
Inset Diagram 2 • Screws should be tightened.
• Do not wedge the wire into sharp edges.
6
REMOVING MAIN PARTS
2.3 WIRING REFERENCE DIAGRAM

1) Refer to this photograph and each assembly diagram to organize the wiring.
7
REMOVING MAIN PARTS
8
REMOVING MAIN PARTS
3. REMOVING MAIN PARTS 3.1.2 Separating Chassis and Mechanical Unit

1) To separate mechanical ASSY ⁄ , ¤ and bottom
3.1 SEPARATING CHASSIS AND ME- chassis 1, check that all connectors are removed,
CHANICAL UNIT then remove eight screws Å and pull up the ASSY.
3.1.1 Removing Power Supply and Main Board
Align the claws on the
1) Demount the connector, remove four screws Å and rear first and then align
the front and side.
pull out the power supply 8.

(TSA0135)
22 G.NO.002
21 G.NO.001
• Ensure that the faston

is tightly and securely
inserted.
Motor wires should not
CN6 touch the gears KJJ46271-003 x2
Clamp
W K A
Bk A
Inset Diagram 1 Inset Diagram 2 KJJ46271-003 x3
Thread CN6 wire through
the outside of other wires as Inset Diagram 3
it is to be kept away from
heat generating parts. K
Clamp
KJJ46271
-003 x3 Clamp
Clamp FILMM A
Tighten the
screws without
Clamp hiding the
earth mark 1
CAMM
Yellow
Inset Diagram 1 CN6 CN13
Yellow
CN6 Inset Diagram 1
CN1 Inset Diagram 1
CN8
CN3
CN201
Clamp
O Important
8 A Br
Connector black • Screws should be tightened.
KJJ46271 • Ensure that the faston • Do not wedge the wire into sharp edges.
is tightly and securely Y
-003 x4 R
Clamp inserted. Inset Diagram 3
Inset Diagram 2
CN202
2) Remove each connector on the cable, remove three

screws ı and pull up the main board 1 while drag-
ging it horizontally.
3) After pulling out each connector, remove two screws
Ç on each side and pull out the AC block 2, 3.
Only available in G.No.002
CN501
CN502
C KJJ46271-003
Push in the remaining P.SW.
wire under the AC PWB BLK plate.
Orange Take care not to twist the wire or Thread wire from CN7 through the rear
CN8 let it touch the sharp edges of the plate side rather than other wires as shown
CN9 in the diagram.
front plate.
(From P.SW)
Clamp
5
CN1
For G.No.002, (From CN7)
thread CN2 under the CN7 wire. CN9
(From INLET) (Front)
CN5
KJJ46271
CN2 -003x3
CN4
CN4 (FAN)
(TSA0136)
B
Clamp
G.NO.002 3
Do not clamp the wires
CN7 such as CDI as they
G.NO.001 2 (From heater) are taut.
Yellow CN5
Clamp
Thread CN4 wire
through the interior of
CN9 (orange) or CN6 (yellow).
C (From CN2) 1
For G.NO.001,
KJJ46271-003 CN7 and CN9 are (TSA0137)
short plug CN8 is open
Do not allow wires to come near

the transistor as far as possible
9
REMOVING MAIN PARTS
3.2 REMOVING MECHANICAL MAIN 3.2.2 Removing Heater Unit and Heater ASSY
PARTS 1) Referring to 3.2.1, remove the feed motor ASSY 4,
3.2.1 Removing Feed Motor remove two screws Å and take out the photo sen-
sor bracket.
1) Refer to the assembly diagram to unravel the wir-
2) Remove E ring & , take out heater cam sensor 0
ing, remove two screws Å and remove the feed
and press gear 9 , remove one screw ı and pull
motor ASSY 4.
out the platen pulley 5.
Trail the wire so that it does not touch
the tip of the screws.
Ensure that the heat resistance binder
Thread under
CASSETTE SW SA.
3) Pull out the heater unit 3 wiring in advance from
is not caught and hinders the movement
of the heater. Clamp each board and wire clamp, then remove two screws
Wind the wire
tightly with
Ç on the front side and three screws Î on the rear
cord clip and side.
fasten.
4) While paying attention to the wires from the heater

unit 3, slowly pull out the heater unit from the front
Ensure the wirings
do not touch sharp
side to remove it.
edges.
5) Remove screw ´ and protective sheet 8 in the same
way as replacing the halogen lamp.
Clamp 6) Remove two screws Ï to remove the heater front
plate.
7) Remove one E ring ˝ and shift the heater bracket
shaft 9 to remove the heater ASSY #.
4 A
(TSS0229) QYSPSPH
4008Nx2
Trail the wire so that it does not
touch the tip of the screws. Thread under
Ensure that the heat resistance CASSETTE SW SA.
Install it after installing Check that the heater rises naturally when you binder is not caught and hinders
the HEATER. release your hand after pressing down the the movement of the heater.
heater on the front side. Clamp
Rearrange the wires at the rear side
when they are taut, or are caught Wind the wire
on and cause constrained movements. tightly with cord
QYSDSP
3006N x2
clip and fasten.
Inset Diagram 1
HEATER ASY wiring
E Ensure the wirings
KJJ46271 8 do not touch
-003 x2 sharp edges.
Photo sensor
(TSS0227) 3 Bracket
Clamp
Install after installing Inset Diagram 1
the GUIDE IN ASY
GUIDE OUT ASY. A KJJ46271-003
9
Tighten the fix screws x 3
on the rear side first, then
tighten the front side. 10
Photo sensor
Bracket
17 QYREE4000X
D
KJJ46271
-003x3 Apply thread lock cream
on the thread of the screw and tighten.
A
KJJ46271-003 QYSDSP
B 4008N
Put this right

at the end
Tighten screws at the flat and tighten 5
surface of the platen the screws.
roller shaft.
4
(TSS0229)
10
REMOVING MAIN PARTS
3.2.4 Removing Transport Roller

6
KJJ46271-003
F x2
1) Referring to 3.2.1, remove the feed motor and other
peripheral parts.
Inset Diagram 1
2) After removing two guides 7 , remove four screws
Apply lots of heat
resistance grease. Å and take out the card guide IN ASSY 1 and card
13
QYREE3000X guide OUT ASSY 2. At this time, pull out connec-
G
Install after installing
the cover and main
tors for CDI, LAM and CDO in advance.
machine
3) Remove two roller drive gears $.
Inset Diagram 2
Wiring
Long
4) Loosen four set screws ı that stop the pulley @
13
Apply a thin coat of grease
Short
and remove them together with the belt * from the
on the outside of the BKT
shaft hole, thread through
the shaft and move it about
9
Hitch the spring shaft of each roller.
to blend it. Inset Diagram 3 in advance.
Thread through
Inset Diagram 3
the tip of the spring 5) Remove E ring Ç on the opposite side. Once the
Stepped side
Press the thermostat wire
against the plate and
Press the thermostat wire
against the plate and
flatten it such that the head
Join
dry bearing 0 on both sides of the shaft is removed,
the transport rollers 4, 5 will be removed.
ensure that it does not does not protrude out.
9 bob too much.
Pull over the cable Join

(12mm)
Long portion covering to the terminal
Apply lots of and join it.
(10mm)
Short portion heat resistance (Distance between the KJJ46271-003 x2
grease on the terminal and the KJJ46271-003 x2
press cam. covering is approx. 0mm) 7 A A
About center
Join
Arrange the wires and join (TSS0225)
them such that they do not 7
protrude or float out of the 2
Approx. 5mm plate. (TSS0224)
1
Inset Diagram 1 Approx. 50 mm from Inset Diagram 2 Wiring
the edge of the contact base
CDO
LAM
CDI
3.2.3 Removing Heat Roller e

5 x2
QYREE d
1) Remove two screws Å on both sides of the heater 5000X x4 c
C b
ASSY. Detach the connect base claw from the heater x4

10
a
bracket 6 to remove the connect base. The halo- 4 x2

gen heater & will be removed.
2) Loosen four set screws ı of the heater ring 4 to
remove the heater ring from the heat roller. The
heater bushing 3 is detached from the heater
e
Apply thread lock cream
c
d Coat with grease after tightening the screws.
bracket 6 and the heat roller 1 is removed. a
b
QYREE6000X
The screws will be further
tightened
10 x4 (torque 1.96 - 2.35Nm).
x2 B QYYASPW4004F x4
18
Batch bonding x 2
Press down the terminal 12 x4

wire so that it does not float up.
14 x2 QYREE
Solder the wire CDI LAM 4000X x2
horizontally as shown
in the diagram.
Contact Coat with grease
base Thermostat SA
Inset Diagram 4 Thread the wire
A back and forth
QYSPSP Inset Diagram 4 the roller as
L2606N QYREE
shown in the diagram. 3000X x2
Press down the terminal wire

Hook the claw section, so that it does not float up.
press it against the 4
plate and tighten
the screws. Inset Diagram 3
B 3 6 QYSPSPL
QYYASPW A 2606N
2003Fx2
Inset Diagram 1 Pull the hook
Inset Diagram 3 Connect base section, press it against the
QYYASPW plate and tighten the screws.
2003Fx2
Inset Diagram 2 B Inset Diagram 3 Align the protruding section of
1 3 the contact plate with the contact
(Clamp ring) 2 point of the heater.
Inset Diagram 3 Clean the glass surface
with alcohol and thread
4 inside the heat roller.
Do not touch the glass
Always use a jig to press surface with bare hands.
down the plate and spring
and tighten the screws.
Inset Diagram 3 Installing heater ring 17
(Clamp ring)
Fix the heater ring and check for any backlash 2 Inset Diagram 2
(the state where the heat roller is rotated by
hand and there is no load).
When the rotation is heavy, pull the heater ring towards the outer
edge and retighten. At this time, take care not to let the heater ring drop.
The spring Inset Diagram 2 Installing the clamp ring
side is Uniform surface
convex Align with uniform surface
surface
6 Insert one screw out of Tighten the two screws Stick the clamp ring to the heat roller when
two into the rift of the evenly such that the heater the clamp ring is twisted flat and there is a
Inset Diagram 1 clamp ring and tighten. ring does not tilt to one side. space between them as shown in the diagram.
Important : Once the spring section (Inset Diagram 1) that acts as a suppress strength on the heater is removed, the
heat roller can only be reassembled with a jig. Do not remove it.
To reassemble the heat roller, refer to Inset Diagrams 2-3, allow only a little backlash for the heater bracket
and assemble the heat roller where it does not have any brushing load.
11
USING SERVICE MODE
USING SERVICE MODE

“User Mode” is used for operating settings. “Service Mode” is used for service and maintenance purposes.
Setting modes
MENU ENTER
Normal User Mode setting Setting value
operation state item selectable state selectable state
EXIT EXIT
Use to select item. Use to select item.
Use ENTER to confirm a setting value.
1. USER MODE
Entry method: When the machine is in preheat, ready or error state, press the MENU button to go into User Mode.
Setting Items Setting value

Single Single side laminate
Mode Both Duplex laminate(Indicate when printer setting on CX-120)
Pass No laminate (Card transport)
1mil
Film 0.6mil
Overlay
-7 The patch position of the card is towards the left
-6
-5
-4
-3
-2
-1 Shifting to the next setting moves the patch position by approx. 0.17mm.
Film Position 0 Important:
1 The setting range is determined by the settings in Card offset in Service Mode.
2
3
4
5
6
7 The patch position of the card is towards the right
120 120
125 125
130 130
135 135
140 140
Temp 145 145
150 150
155 155
160 160
165 165
170 170
175 175
180 180
4 4mm/s
4.5 4.5mm/s
5 5mm/s
5.5 5.5mm/s
6 6mm/s
Speed 6.5 6.5mm/s
7 7mm/s
7.5 7.5mm/s
8 8mm/s
8.5 8.5mm/s
9 9mm/s
9.5 9.5mm/s
10 10mm/s
12
USING SERVICE MODE
Off The card cooling fan does not rotate when laminating
Low The card cooling fan rotates when laminating(Air flow:Low)
Card Fan Half The card cooling fan rotates when laminating(Air flow:Half)
High The card cooling fan rotates when laminating(Air flow:High)
Full The card cooling fan rotates when laminating(Air flow:Full)
0sec
5sec
Cool Time
7sec
10sec
Off Does not enter Power Save mode
10 Enters Power Save mode after the machine is in Ready state for 10 minutes
Power Save 20 Enters Power Save mode after the machine is in Ready state for 20 minutes
1 LCD contrast is deepest
2
LCD Contrast 3
4
5 LCD contrast is palest
Without HR Cleaning of transport roller (heat roller is not pressed)
Cleaning
With HR Cleaning of heat roller (heat roller is pressed)
2. SERVICE MODE
Entry method:
When the machine is in preheat, ready or error state, press the EXIT, MENU, then release the MENU button first to go
into Service Mode.
Setting Items Setting value
-7 The patch position of the card is towards the left
-6
-5
-4
-3
-2
-1
Card Offset 0 Shifting to the next setting moves the patch position by approx. 0.17mm.
1
2
3
4
5
6
7 The patch position of the card is towards the right
Sensor Not used, HR2, HR1, Black mark, End mark, Card exit, Laminate position, Card entrance
Card Motor Card transport motor rotates
Motor Film Motor Film reeling motor rotates
Cam Motor Press the heat roller and return to standby position
Temp Heat roller thermistor output (hex decimal number)
Ver Firmware Version
Total Laminated panels
1
Mk.SensLvl 2 Film (Black) mark sensor sensitivity setting
3 Standard setting : 1
0
0.5
Temp+Gain 1 + Adjustment gain of the set interior temperature adjustment for heat roller temperature
1.5 Standard setting : 2
2
0
0.5
Temp-Gain 1 - Adjustment gain of the set interior temperature adjustment for heat roller temperature
1.5 Standard setting : 1.5
2
CX210 Connect CX210, CX-320 and CX-3** series This setting value will be neglect
Printer and give priority to the setting of
CX-120 Connect CX-120 and CX-1** series
Number of Number of rotations of film reeling motor the connecting printer.
Motor-N rotations
(rpm)
H.Time ∗∗∗ Heated hours
H.Time Init Initializing heated hours
13
USING SERVICE MODE
3. FIRMWARE UPDATE
Check the original setting parameter of laminator before downloading, because they may be changed after download.
<CAUTION> Turn of the power of printers and laminators, before connecting or disconnecting the cable between the
printers and laminators otherwise some malfunction may be caused.
3.1 Connecting with CX210

(1) Connect the laminator and printer with the Laminator communication cable.
[The connect position of printer is different from usually. Before operating update, connect the cable between
OPTION1(printer) and PRINTER(laminator) as drawing below; ]
CX210
CL-500
PC
SCSI
OPTION1 PRINTER
(DSUB15) (DSUB9)
(Back view)
Fig. 1
(2) Turn on the power of laminator.

(3) Turn on the power of printer.
(4) Communication Error will be occurred on printer.
(5) Set printer to ‘download’ mode included in maintenance mode, and update the firmware (Lami***.icf) with printer
downloading tool.
While handling update, laminator can’t display it’s status on the front panel, and printer shows “Downloading Keep
Power On” on the LCD display.
<CAUTION>
It takes about 1 ~ 2 minutes to finish the procedure of download. Don’t turn off the power of laminator and printer.
(6) After complete the download correctly, the laminator start the initialize by itself and LCD display of printer change to
“Download Ready” .
(7) Turn off the power of laminator and printer, and connect the communication cable between laminator and printer.
14
USING SERVICE MODE
3.2 Connecting with CX-120 and CX-1** series

(1) Connect the laminator and printer with the Laminator communication cable same as usual.
CX-120
(CX-1** series) CL-500
PC
USB
LAMINATOR PRINTER
(DSUB9) (DSUB9)
(Back view)
Fig. 2

(4) Wait the situation of the printer turned to READY and laminator turned to PREHEAT or READY.
(5) Update the firmware (Lami***.icf) with printer status monitor.
While handling update, laminator can’t display it’s status on the front panel.
<CAUTION>
(7) Turn off and on the power of printer to replace the version information saved in the printer.
15
USING SERVICE MODE
3.3 Connecting with CX-320 and CX-3** series

(1) Connect the laminator and printer with the Laminator communication cable same as usual.
CX-320
(CX-3** series) CL-500
PC
USB
OPTION2 PRINTER
(DSUB9) (DSUB9)
(Back view)
Fig. 3

(4) Wait the situation of the printer and laminator turned to PREHEAT or READY.
(5) Set printer to ‘download’ mode included in maintenance mode, and update the firmware (Lami***.lmf) with printer
status monitor.
While handling update, laminator can’t display it’s status on the front panel, and printer shows “Downloading Keep
Power On” on the LCD display.
<CAUTION>
(7) Turn off and on the power of printer to replace the version information saved in the printer.
16
MECHANISM OPERATION
MECHANISM OPERATION
1. INITIAL OPERATION 4 Stage: Heat roller pressing operation
Initial Operation when Power On The heater cam motor is rotated and stops when a
1. Stop every motor and turn off the heater. slit arrives at the heat roller pressure position sen-
2. Return the heat roller to the initial position. sor.
3. Check the status when the power is turned off. 5 Stage: Laminating operation
4. Check the film is installed. The card transport motor sends out the length of
5. Check the number of rotations of the film reeling film to be laminated and rotates in a laminating
motor. speed in the exit direction.
6. Turn on the heater. At the same time, the film reeling motor rotates in
Stop at this point when an error has occurred. the reeling direction according to the laminating
speed.
2. LAMINATING OPERATION 6 Stage: Heat roller separation, film peeling opera-
1 Stage: Card feeding operation tion
When a card arrives at the card insert detection The heater cam motor rotates and stops when the
sensor, the card transport motor is rotated in the heat roller standby position sensor detects a slit.
exit direction. When the card exits the card insert At the same time, it transports the card in a fixed
detection sensor, a fixed length card is transported length and stops.
and stopped. At the same time, when the end mark sensor de-
2 Stage: Film position setting operation (when tects a film (black) mark, the film reeling motor stops.
patch film is installed) (when patch film is installed)
The film reeling motor is rotated in the reeling di- The film reeling motor stops accordingly when the
rection and stops when the film (black) mark sen- card transport motor stops. (when overlay film is
sor detects the film (black) mark. installed)
3 Stage: Card laminate position setting operation 7 Stage: Card ejecting operation
The card transport motor is rotated in the exit di- The card transport motor rotates in the exit direc-
rection and stops when the card exits the laminate tion and stops after the card exits the card eject
position sensor and after moving the offset card. sensor.
Fwd
Off
Rvs
Film reeling motor
Off
Down
Heater cam motor
Off
Up
Hi
Card insert detection sensor
Lo
Hi
Laminate position sensor
Lo
Hi
Lo
Hi
Film (Black) mark sensor
Lo
Hi
End mark sensor
Lo
Hi
Heat roller pressure position sensor
Lo
Hi
Heat roller standby position sensor
Lo
17
MECHANISM OPERATION
2.1 When Cool Time is set 2 Using 0.6mil, Overlay

1 Using 1mil After the film position search is finish, the card is
After the film position search is finish, the card is moved to the position that is detected by the card
returned to the position that is detected by the card eject sensor. The card cooling fan rotates to cool
insert detection sensor and the operation stops in the card in the Cool Mode setting time. After the
the configured Waiting Time. card is cooled, it is returned to the position that is
After operation is stopped in the set time, the next detected by the card insert detection sensor and
operation is performed after the card laminating the next operation is performed after the card
position setting operation. laminating position setting operation.
Mechanism Operation 1
Film reeling motor
Film FG disc & sensor Heat roller pressure
position sensor
Film end mark sensor
Heater
cam motor
Heat roller standby

position sensor
Film (black)
mark sensor
Card ejecting sensor Laminate position Card insert

detection sensor detection sensor
Mechanism Operation 2
Film reeling motor
Heat roller standby
position sensor
Heat roller pressure position sensor
Heater cam motor

Card transport
motor
Film end mark

sensor (Top)
Film (Black) mark

sensor (Bottom)
Laminate position
detection sensor
Card insert
detection sensor
18
TROUBLESHOOTING
TROUBLESHOOTING
1. HANDLING ERROR CODES
No. Error Content/Text Displayed Error Detection Action Parts to be replaced

1 Card Jam (near the card When feeding card from the en- Check the setup condition. During sensor operation error
entrance) trance, the card does not arrive Check the operation of the card During card entrance sensor
Card Jam (In) at the card entrance sensor within entrance sensor using the sen- board ASSY, or main board, or
a certain amount of time. sors in Service Mode. sensor connection cable motor
When ejecting card from the en- Check the operation of the card operation error.
trance, the card does not exit from transport motor using the motors Card transport motor, or main
the card entrance sensor within a in Service Mode. board, or motor connection cable.
certain amount of time.
2 Card Jam (near the When transporting card, the card Check the operation of the card During sensor operation error
center of the laminator) does not arrive at the card detec- detection sensors (card entrance Each sensor board ASSY, or main
Card Jam (Middle) tion sensors (card entrance sen- sensor, laminate position sensor, board, or sensor connection ca-
sor, laminate position sensor, card card exit sensor) using the sen- ble.
exit sensor) within a certain sors in Service Mode. During motor operation error
amount of time. Check the operation of the card Card transport motor, or main
The card does not exit from the transport motor using the motors board, or motor connection cable.
laminate position sensor within a in Service Mode.
certain amount of time.
3 Card Jam (near the card When feeding card from the exit, Check the operation of the card During sensor operation error
exit) the card does not arrive at the exit sensor using the sensors in During card exit sensor board
Card Jam (Out) card exit sensor within a certain Service Mode. ASSY, or main board, or sensor
amount of time. Check the operation of the card connection cable motor operation
When ejecting card from the exit, transport motor using the motors error.
the card does not exit from the in Service Mode. Card transport motor, or main
card exit sensor within a certain board, or motor connection cable.
amount of time.
4 The laminate film is not When the film setting is patch film, Check that the film is properly During sensor operation error
found the black mark does not arrive at winded. Mark sensor board ASSY, or main
Film Search the black mark sensor within a Check the operation of the black board, or sensor connection ca-
certain amount of time during mark sensor and end mark sen- ble.
laminating or resetting operation. sor using the sensors in Service During motor operation error
When reeling film after laminating Mode. Film reeling motor, or main board,
in a laminate operation, the black Check the operation of the film or motor.
mark does not arrive at the end reeling motor using the motors in When a R.ENC error has occurred
mark sensor within a certain Service Mode. during a normal operation of the
amount of time. connection cable or motor, re-
When the film setting is overlay place the rotary encoder board, or
film, the encoder pulse output for main board, or connection cable.
film reeling detection during the
resetting operation is the output
when the film is not installed.
5 No cassette Cassette switch is detected. Check whether the cassette de- Cassette switch board, or main
No Cassette tection switch is pressed normally board, or connection cable.
when the cassette is installed.
6 Out of film When the film setting is patch film, Check whether the black mark During motor operation error
Film Run Out the mark senor and end mark sen- sensor and end mark sensor de- Mark sensor board ASSY, or main
sor detected marks at the same tect marks normally using the sen- board, or sensor connection ca-
time. sors in Service Mode. ble.
When the film setting is overlay
film, the end mark sensor de-
tected marks.
7 Heat roller cam operation When HR pressing, the slit does Check whether the cam motor During sensor operation error
error not arrive at the heat roller pres- operates normally using the mo- Each sensor, or main board, or
HR Cam sure position sensor within a cer- tors in Service Mode. sensor connection cable.
tain amount of time. Check whether the heat roller During motor operation error
When HR separation, the slit does pressure position sensor and heat Cam motor, or main board, or
not arrive at the heat roller roller standby position sensor de- motor connection cable.
standby position sensor within a tect slits normally using the sen-
certain amount of time. sors in Service Mode.
19
TROUBLESHOOTING

8 Heat roller over Heat roller temperature is de- If the error occurs during a heat Main board, or AC board, thermo-
heat tected with the heat roller thermo- roller temperature control circuit stat, or main board.
HR Overheat stat. failure or when the heat roller tem-
When the heat roller temperature perature is not hot, it may be a
exceeds 220˚C, a heat roller over- thermostat error.
heat error occurs.
9 Overheating inside the The set interior temperature is Heat roller temperature control Main board, or AC board.
laminator detected with the interior tempera- circuit failure.
Overheat ture thermostat.
When the set interior temperature
exceeds 70˚C, a laminator interior
overheat error occurs.
10 Heat roller thermostat Heat roller temperature is de- Measure the resistance value of Heat roller thermostat, or main
failure tected with the heat roller thermo- the heat roller thermostat. If the board, or thermostat connection
Temp Sensor stat. error occurs when the thermostat cable.
The heat roller thermostat output resistance value is normal, it may
is 0˚C and below. be a main board or connection
cable error.
11 Overcooling inside the The set interior temperature is If the error occurs when the set Main board, or thermostat board,
laminator detected with the interior tempera- interior temperature is higher than or connection cable.
Overcool ture thermostat. 5˚C, it may be a main board, ther-
When the set interior temperature mostat board or connection cable
is lower than 5˚C, a laminator in- error.
terior overcool error occurs.
12 O p e r a t i o n e r r o r i n EEPROM data cannot be read Replace the main board. Main board.
memory for saving set- normally.
ting values
Memory Err
13 Heat roller setting tem- The setting value of the heat roller Replace the main board. Main board.
perature error temperature is more than 210˚C.
Set Temp Err
14 Rotary encoder error for Rotary encoder is not output dur- Check whether the film reeling During motor operation error
film reeling detection ing laminating and laminate film motor operates normally using the Film reeling motor, or main board,
R.Encoder Err initialization. motors in Service Mode. or motor connection cable.
When a R.ENC error has occurred
during a normal motor operation,
replace the rotary encoder board,
or main board, or connection cable.
15 Operation error related Heat roller temperature is detected Check the AC select switch set- When the halogen heater is dis-
to heater with the heat roller thermostat. ting for AC voltage switching connected.
Heater Err When the heat roller temperature model. When there is an error in the halo-
is lower than the set temperature Check the status of the halogen gen heater thermostat.
at the start of preheat, the heat roller heater. Thermostat, main board, or AC
temperature does not rise about 30 Check the thermostat conduction. board.
seconds later after preheat begins. When the thermostat is not con-
The heat roller temperature is ducted, the heat roller may be-
about 30˚C lower than the set tem- come overheat abnormally and
perature in preheat or ready state. this may be a control circuit error.
16 Printer connection cable Connection status with printer is Check whether the printer con- Printer connection cable, or main
is pulled out detected. nection cable is plugged in prop- board, or printer.
PRT.Communicate The connection with the printer erly.
during operation is cut off.
20
TROUBLESHOOTING

17 Cannot enter Cleaning Heat roller temperature is detected If the error occurs when the heat Thermostat, or main board, or
Mode with the heat roller thermostat. roller temperature is below 50˚C, connection cable.
HR is too hot! The heat roller temperature this may be a thermostat error.
exceeds 50˚C during Cleaning Measure the resistance value of the
Mode. thermostat. If the error occurs when
the thermostat resistance value is
normal, it may be a main board or
connection cable error.
18 Operation error in EEPROM sum data cannot be Update the firmware version to When the EEPROM SUM Err is still
EEPROM read normaly, when the power on. “017” or later. appear, replace the main board.
EEPROM SUM Err
Card jam at turn over unit After the CARD sensor in the Refer to the turn over unit manual. Refer to the turn over unit manual.
Card Jam(Flip) turning machine is detected as
card ON when transporting the
card, it does not become OFF
even after ** seconds.
After the CARD sensor in the
turning machine is detected as
card OFF when transporting the
card, it does not become ON even
after ** seconds.
19 Turn over unit error It does not return to the original Refer to the turn over unit manual. Refer to the turn over unit manual.
Mech Err(Flip) position even after ** seconds
during turning.
20 Maintenace door upon Inter lock switch is detected. Refer to the turn over unit manual. Refer to the turn over unit manual.
the tur n over unit is
onpen C h e c k t h e s c r e w o f t h e Inter lock switch board of the card
Door Open(Flip) maintenance door is tightened. turn over unit or main board of the
card turn over unit.
21 No response from the Unable to communicate with the Refer to the card turn over unit Refer to the turn over unit manual.
turn over unit turn over unit.(No response) manual.
EXT.Com(No Rsp)
C h e ck t h e c o n n e c t e d s t a t e Connection cable between the
between the laminator and turn laminator and turn over unit, or
over unit. main board of the laminator and
turn over unit.
22 Communication eroor Unable to communicate with the Refer to the card turn over unit Refer to the turn over unit manual.
with the turn over unit turn over unit. (Unusual dada) manual.
EXT.Com(Rsp Err)
Check the connected state between Connection cable between the
the laminator and turn over unit. laminator and turn over unit, or
main board of the laminator and
turn over unit.
23 Illegal command from Unable to communicate with the Refer to the card turn over unit Refer to the turn over unit manual.
upper laminator turn over unit. (Unusual dada or manual.
Com Err CE(Flip) the turn over unit is detected erorr)
between the laminator and turn laminator and turn over unit, or
over unit. main board of the laminator and
turn over unit.
24 Communication erorr Unable to communicate with the Refer to the card turn over unit Refer to the turn over unit manual.
with lower laminator turn over unit between the lower manual.
Com Err RE(Flip) laminator. (Unusual dada)
between the lower laminator and lower laminator and turn over unit,
turn over unit. or main board of the lower
laminator and turn over unit.
25 No response from lower Unable to communicate with the Refer to the card turn over unit Refer to the turn over unit manual.
laminator turn over unit between the lower manual.
Com Err NR(Flip) laminator. (No responce)
Check the lower laminator power on. Connection cable between the
C hbe
<NOTE> No.18 to No.25 is indicate when card turn over unit (will e ckrelease
t h e cin
o nfuture)
n e c t e dare
s tconnected.
a t e lower laminator and turn over unit,
between the lower laminator and or main board of the lower
turn over unit. laminator and turn over unit.
21
TROUBLESHOOTING
2. HANDLING CARD JAM

When a card not suitable for laminating is used in the laminator or when inappropriate laminating conditions are set,
the card may be warped or curled drastically by the laminating heat and cause a jam in the laminator.
Follow the steps below to remove the card.
1 Remove one Screw A and remove the maintenance cover on the left side of the top cover.
2 The guide is held by claws on the front panel. Push in the guide and lift up to remove.
Screw A
Maintenance cover
Guide
22
TROUBLESHOOTING
When the jam cannot be resolved in such state, follow the steps below to remove it.
1 Remove six screw B and remove the top cover.

2 The guide is held by claws on the front panel. Push in the guide and lift up to remove.
3 The protective sheet is inserted by claws in the card guide out ASSY. Remove this or remove 2 screw C and remove
the card guide out ASSY.
Screw B
Screw C
Screw B
Guide
Protective sheet
23
TROUBLESHOOTING
3. HANDLING THE SITUATION WHERE POWER SUPPLY IS CUT OFF WHEN THE HEAT ROLLER IS DOWN
When power supply is cut off in a power failure during laminating or when the front door is open and the cassette is
pulled out by mistake, the heat roller is lowered and the heat causes damage to the film and card.
In this case, turn off the power supply and follow the steps below to resolve the problem.
3.1 When a cassette is installed in the laminator

1 Check that the cassette is locked and the interlock switch is working. Then switch on the power supply and reset.
2 The heat roller returns to standby position and performs initialization. However, as the film and card is damaged by
the heat of the heat roller, initialization cannot complete and the machine stops by displaying some error.
3 Open the front door and pull out the cassette. (The film and card may be deformed due to the heat. Pull it out slowly
without damaging the cassette.)
4 After that, refer to the steps in section 2. Handling Card Jam, and remove the card and film.
5 Remove everything and check that the interior of the laminator is normal. Install the repaired film to the cassette and
perform initialization again.
3.2 When a cassette is not installed in the laminator

1 When the cassette is not installed, the interlock switch is turned off. Initialization cannot be performed. Follow the
steps below to recover.
2 Open the front door and remove any film. However, if the film is entangled in the transport roller or stuck onto the
curled card, do not pull it out by force. Use a cutter to cut the film and remove the roll at the supply and reeling side.
3 Install an empty cassette without the film. Perform initialization in this state and recover the heat roller from its
lowered state. Follow the steps below.
4 When the film is entangled in the transport roller, it may be further entangled as the transport roller is rotated in the
initialization operation. Hence, once the transport roller starts to rotate during initialization, switch off the power
supply at this point.
5 After the power is switched off, open the front cover and remove the cassette. At this point, the heat roller has risen
to the normal position, so refer to section 2 and 3.1 and remove the film.
6 Remove everything and check that the interior of the laminator is normal. Install the repaired film to the cassette and
perform initialization again.
24
SET UP GUIDE
SET UP GUIDE
CL500 series Card Laminator is using heat press roller system to the surface of the card. It is important to do best setting
to securing sufficient adhesive strength and minimum warp of the card, by heating occurs at the time of lamination. This
guide explains the method of a set up in the case of laminating on the card which is printed by CX-320 (CX210 and CX-
3** series) or CX-120 (CX-1** series). The situation which the warp of the card is generated is different respectively
according to the card. Please have an evaluation enough for prior use referring to this guide when using the Laminator.
The setting value indicated to this guide is a reference value to the last, and does not guarantee a performance.
Please acknowledge not securing about the fault by the poor adhesion by the characteristic of the card and
trouble by the card warp.
1. SETTING OF LAMINATE CONDITION

(1) Default Values
Among items that can be set in User Mode and Service Mode, those related to the laminating performance and the
default values are indicated below. Regarding to the detail of items, refer to section 3. Various Conditional Settings.
*Service Mode is a set mode only for the dealer and serviceman.
Connect with CX-320 (CX210 and CX-3** series)

No Mode Item Default Values Remarks
1 User Mode Film 1mil 0.6mil Overlay Select film type.
2 Temp 170°C 155°C 130°C Default value of the heat roller surface
temperature is tide to Film selection.
3 Speed 5.5mm 8.5mm 8.5mm Default value of the speed of the card
/sec /sec /sec during laminating is tide to Film selection.
4 Card Fan Half Off Off Card cooling fan during laminating
5 Cooling Time 0sec Card cooling time before laminating
6 Service Temp + Gain 2 Temperature gain at low temperature.
7 Mode Temp - Gain 1.5 Temperature gain at high temperature.
Connect with CX-120 (CX-1** series)

No Mode Item Default Values Remarks
1 User Mode Film 1mil 0.6mil Overlay Select film type.
2 Temp 160°C 145°C 130°C Default value of the heat roller surface
temperature is tide to Film selection.
3 Speed 5.5mm 8.5mm 8.5mm Default value of the speed of the card
/sec /sec /sec during laminating is tide to Film selection.
4 Card Fan Half Off Off Card cooling fan during laminating
5 Cooling Time 0sec Card cooling time before laminating
6 Service Temp + Gain 2 Temperature gain at low temperature.
7 Mode Temp - Gain 1.5 Temperature gain at high temperature.
The values in the above list are decided as the fastest operation speed and getting minimized card warp. Each kinds of
cards shall have different condition in the best suited, please have an evaluation enough for prior use.
25
SET UP GUIDE
(2) Example of Settings

The recommendation setting values when connects with CX-320 (CX210 and CX3** series) and CX-120 (CX-1**
series), and performing single side printing of a PVC card is shown below. CX-320 (CX210 and CX3** series) and CX-
120 (CX-1** series) are changed in the service mode.
Notes : The PVC card has various kinds and optimal conditions differ, respectively. In order to pull out the
performance of the Laminator to its maximum, please set it up after finding the best setting values.
Connect with CX-320 (CX210 and CX-3** series)

In case of CX-320 (CX210 and CX-3** series), the cards are heated in the printer previous to lamination, so it is
important to adjust the setting of the printer in the optimum condition.
Film 1mil 0.6mil overlay
Surrounding temperature 15 – 25°C 26 – 30°C 15 – 30°C 15 – 30°C
CL-500 Temp 170°C 155°C 130°C
Speed 5.5mm/s 8.5mm/s 8.5mm/s
Card fan Half High Off Off
Cool Time 0sec 0sec 5sec
CX-320 Retransfer Temp +1
(CX210 and Speed +2
CX-3** Bend Temp OFF OFF -2 -2
series) Remedy Speed +2 +2 -2 0
Cool 0sec 0sec 0sec 0sec
Connect with CX-120 (CX-1** series)

There is no Bend Remedy function in CX-120 and CX-1** series. Therefore, the optimum conditions are set up in the
combination of the setting item of Laminator. The example of a setup where adhesiveness was thought as important is
shown in the following.
Film 1mil 0.6mil overlay
Surrounding temperature 15 – 25°C 26 – 30°C 15 – 30°C 15 – 30°C
CL-500 Temp 175°C 150°C 130°C
Speed 7.0mm/s 7.5mm/s 8.5mm/s
Card fan Half High Off Off
Cool Time 0sec 0sec 5sec
26
SET UP GUIDE
2. SETTING PROCESS
We will recommend the condition setting to be tested after about 20 minutes have passed since it started. [There is no
Bend Remedy function of the card in CX-120 (CX-1** series).]
<NOTE> CX-320 including CX210, CX-320 and CX-3** series.
CX-120 including CX-120 and CX-1** series.
Adhesive evaluation 4. Card Adhesiveness
No Raise the Heat roller temperature, or

Adhesive is enough?
lowered the laminate speed.
Yes 3. (2) User Mode settings
No Both sides print by CX-320, Bend Remedy set OFF.

Card is warp?
(After set OFF, leaves it about an hour.)
Yes
3. (4) Printer (CX-320) Settings
End If laminated surface is convex CONVEX
If laminated surface is concave CONCAVE
CONVEX
The items in the broad outline are CONCAVE
common tuning for CX-320 and
CX-120.
Using 1mil Patch, CX-320 Bend Remedy set OFF. Card Fan: Decrease the Card Fan wind.
(After set OFF, leaves it about an hour.) Full→High→Half→Low→Off
3. (4) Printer (CX-320) Settings 3. (2) User Mode settings
Card Fan: lncrease the Card Fan wind. Single side print by CX-320, Bend Remedy set
Off→Low→Half→High→Full On. (Only 0.6mil Patch and Overlay film)
3. (2) User Mode settings 3. (4) Printer (CX-320) Settings
In the case of single side print and CX-320 Bend The optimal value is set by combining the
Remedy set ON. Card Fan setting and Bend Remedy
(Only 0.6mil Patch and Overlay film) setting on the CX-320
3. (4) Printer (CX-320) Settings
Cooling Time: 5 to 10sec Cooling Time: 5 to 10sec
3. (2) User Mode settings 3. (2) User Mode settings
No
Card is warp?
Yes
Decrease the Heat roller temperature then
End Go to Adhesive evaluation
27
SET UP GUIDE
3. VARIOUS CONDITIONAL SETTINGS

(1) Card warping case
When the laminator is connected to a re-transfer printer, the card temperature is high during printer output. Hence,
cards with a low heat tolerance such as PVC cards are prone to warping due to re-heating during laminating. This is
especially prominent when laminating after printing on single-side. An example of warping for transfer energy during
single-side print is shown on Diagram 1. In consideration of such characteristic, temperature and speed conditions are
defined in CL-500 default settings to minimize warping while ensuring the adhesiveness. The required transfer energy
for adhesion is according to the thickness of the film to be transferred and follows the order of overlay<0.6mil patch<1mil
patch.
Card warping Convex

Example of PVC
on laminated surface
0.6mil patch card warping
Overlay area 1mil patch area
Warping limit
Transfer energy
Warping limit
Transfer energy
0.6mil patch setting
∝ temp / speed
temp 155
speed 8.5mm/sec
Concave on Overlay setting 1mil patch setting

laminated surface temp 130 temp 170
speed 8.5mm/sec speed 5.5mm/sec
Card temperature Card temperature
low high
Diagram 1. PVC card warping case during single-side printing
When the laminator is connected to a direct printer, setting area is limited left hand of diagram 1, and the cards have a
tendency to concave on laminated surface.
Depending on the card material, manufacturing method, environmental conditions where the card is used and the
setting conditions of the connected printer, the warping condition and most appropriate condition may differ. The following
section describes the method to set the most appropriate conditions.
(2) User Mode settings

1) Heat roller temperature : temp
2) Laminating speed : speed
Set the energy to transfer from the heat roller to the card via the film, based on a combination of both factors. The
higher the setting temperature and the slower the speed, the greater the energy becomes and this affects card
warping greatly. The lower the energy, the better it is to prevent the card from warping. However, as shown in
Diagram 1, as the warping behavior is different in the setting area for 0.6mil patch and overlay and the setting area
for 1mil patch, precaution is required. When the transfer energy is too low, this will damage the adhesion to the card.
Hence, be very careful when lowering transfer energy. Refer to Chapter4 Card Adhesiveness for the evaluation on
adhesiveness.
For high heat tolerance cards that do not warp easily, it does not matter if the energy is set high.
28
SET UP GUIDE
3) Card fan : Card Fan

During laminating, the reverse side of the card (the side that is not laminated) is cooled. Usually, the setting is OFF
but when the convexity is very prominent on the laminated side, the fan is set to LOW or more to prevent the card
from warping.
4) Card cooling time : Cooling Time
When the card is received from the re-transfer printer, the card is very hot. Even when the card is laminated after
Bend Remedy is performed at the printer, the results of the correction is not as expected. To ensure the results of
Bend Remedy, cooling time can be set before transfer. In the case of overlay film where the laminate energy is low,
effective results can be expected when the printer Bend Remedy is performed and card cooling is set before
laminating.
(3) Maintenance Mode settings

1) Temperature correction gain : Temp + Gain , Temp – Gain
The heat roller temperature is adjusted and influence to the environment temperature is reduced through the
temperature sensor inside the device. When influence to surrounding temperature is different depending on the
card, change the gain settings. The bigger the setting value, the bigger the adjustment volume of the heat roller
temperature is for the temperature changes.
+Gain : When the environment temperature is lower than 25°C, it functions to increase the heater temperature.
Standard setting : 2
When the Gain value is too big, warping increases during low temperature/
When the Gain value is insufficient, adhesiveness is insufficient during low temperature.
-Gain : When the environment temperature is higher than 25°C, it functions to decrease the heater temperature.
Standard setting : 1.5
When the Gain value is too big, warping increases during high temperature.
When the Gain value is insufficient, adhesiveness is insufficient during high temperature.
(4) Printer [CX-320 (CX210 and CX-3** series)] settings

1) Settings for duplex printing
When laminating after duplex printing is performed on re-transfer printer, both sides of the cards are balanced
and warping is less likely to occur. Set Bend Remedy in the printer to OFF. When 1mil is set, as the card
temperature is high during laminating, the card is more prone to convexity when compared to single-printing (no
Bend Remedy). Set the card fan wind increase.
2) Using with Bend Remedy function
When laminating 0.6mil patch or overlay film after single-side printing is performed on re-transfer printer, concave
warping on the laminated side cannot be avoided.
As such, when using 0.6mil patch and overlay, use the Bend Remedy function (User Mode Bend Remedy) on
the printer together to reduce concave warping. Refer to the User Mode settings in CX-320 (CX210 and CX-3**
series) User Guide for the printer settings.
When the card becomes convex due to Bend Remedy, you can lower the printer correction energy (lower temp,
increase speed) to control overheating of the card or set the laminator card fan wind increase to reduce the
amount of warping.
29
SET UP GUIDE
4. CARD ADHESIVENESS
The laminate adhesiveness to the card is evaluated as below. Always evaluate the adhesiveness when changing
conditional settings for transfer temperature.
(1) Patch film
Card folding test :
1) Fold the card equally into two and press hard at the folded line.
2) Unfold and fold along the folded line in the opposite side, and press hard at the folded line.
3) Flatten the card and check that the patch film does not lift at the folded line.
When folding is respected, a lift may occur at the center. When this happens, check that the patch is not easily
detachable (the patch breaks) at the starting point of the lifted section.
Peeling test :
For cards that do not bend easily such as IC cards, make a slit on the patch using the tip of a cutter, use that section
as a base point and perform the same check as the above folding test.
(2) Overlay film

Similar to the adhesiveness of the re-transfer film, check that peeling does not occur for adhesive tape.
When transfer energy is insufficient during overlay film transfer, the surface of the card becomes cloudy. Pay attention
to the finishing on the surface.
Important :
When performing duplex printing on the re-transfer printer or when using 1mil patch, set Bend Remedy to
OFF and the correction roller before using. When performing printer correction with a 1mil patch setting, a
stable result cannot be expected as the card is too hot. When Bend Remedy is changed to OFF but the
correction roller is not sufficiently cooled even in READY state, an unstable convex warping occurs when
1mil patch laminating is performed in this state. In that case, leave the printer for 1 hour after changing the
settings to cool the correction roller fully.
30
MAINTENANCE
MAINTENANCE
1. CLEANING
Follow the instructions in the table below and perform cleaning during repair.
No Cleaning parts Cleaning method
1 Card transport roller Clean the roller surface with alcohol (absolute alcohol).
* Except heat roller
2 Fan filter Use vacuum cleaner to suck dust.
3 Cassette shaft Clean the dirt on the shaft with alcohol (absolute alcohol).
4 Card guide base Clean the card guide surface with alcohol (absolute alcohol).
5 Bobbin inner Use vacuum cleaner to suck dust.
2. LIST OF PARTS TO BE REPLACED

The following list is based on standard situation and it differs according to the environmental and usage conditions.
When appropriate maintenance and inspection are not performed, the life span of the parts will be greatly reduced and
it may also affect other parts. When rubber and sponge parts are kept for long periods of time without using, they may
change shape and deteriorate.
Part number Part name Estimate time for replacement Remarks

KLA5005-121 Halogen heater 2,000 hours
KJV46484-001 Fan filter About 2 years Depends on the usage environment
QAR0445-001 (KEF1043) Air intake fan 40,000 hours
QAR0429-001 (KEF1037) Card cooling fan 20,000 hours Only during laminating
CL-500-M01 Heater pressure motor 200,000 screens
CL-500-M01 Ink reeling motor 100,000 screens
QAR0444-001 (KBM1036) Card transport motor 200,000 screens
CL-500-HR1 Heat roller 200,000 screens
31
ADJUSTMENT
ADJUSTMENT
Adjustment
1. ARRANGEMENT OF ADJUSTMENT VOLUME
MAIN PWB
REAR
VR2
TP11
5VREF
VR1
GND
MAIN PWB VR1 : Adjustment of +5V

VR2 : Sensitivity adjustment of End Mark Sensor
2. HOW TO ADJUST THE VOLUME

1) Adjustment of VR1 (+5V)
TEST POINT 5VREF - GND
5V ± 0.01V
2) Adjustment of VR2 (End Mark Sensor)
TEST POINT TP11 -– GND
It is necessary to satisfy the following two conditions.
1 On condition that transparent part of a patch film was set in the End Mark Sensor.
1V or less
2 On condition that end mark (Black) part of a patch film was set in the End Mark Sensor.
4V or more
Note)
When not only the MAIN PWB but also the Mark Sensor PWB are exchanged, it is necessry to adjust
the VR2.
32
ASSEMBLY DIAGRAM AND PARTS TABLE

Important
symbol indicates that safety issues are important for this part. When replacing parts, always use the specified part
for safety reasons.
Do not supply parts not described in the parts table or parts displayed with a - sign in the parts column.
Parts for repair are at standard price (exclusive of tax). This price may change together with market changes.
The manufacturer and electricity version label is on the rear panel. As there may be parts that are not compatible,
check the version described on the label when ordering parts.
MECHANICAL REV. ELECTRICAL REV.

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
A A
B B
C C
KXL46623-001
For example, the revision number in the parts table is “M-B4” or “E-A3”.
33
MECH ASSY (PLATE R ASSY)
2 CL-500-SB1
QYREE
23 4000X
SLIDE BOBBIN SA
Q03093
21 -837
QYREE
4000X
QYREE
23 23 4000X
(CL-500-SB1) 13 20
SLIDE BOBBIN SA
20 11
18
2 1
19
KJJ46271 KJJ46271
22 10 22 -003
-003
6 (TPS0235-001-E)
22 KJJ46271
-003
10 7
KJJ46271 22
-003
9
KJJ46271 10 KJJ46271
-003 22 -003 14
12 15
22
KJJ46271
-003 x2
MARK SENSOR SA
23
KJJ46271 12 QYREE4000X
22 -003 x2
22
(TPS0235-001-C)
KJJ46271 15
3 -003 x2
16
24 17
x5 25
4
23
QYREE4000X
MM − 0 1
SYMBOL REVISED Price
PART NO. PART NAME QTY DESCRIPTION
NO. PART NO. Rev. (yen)
1 KJP11103-A0A LM PLATE R ASY 1
2 CL-500-SB1 SLIDE BOBBIN SA 1
3 KJP46506-001 MARK SENSOR BKT 1
4 TPS0235-001-C AC/SENSOR PWB ASY (1) KEP4101-C
5
6 TPS0235-001-E AC/SENSOR PWB ASY (1) KEP4101-E
7 KJP46516-001 CAS SENSOR BKT
8
9 KJP46518-001 RELEASE SPRING 1
10 KJP46517-001 GUIDE HOLD BKT 2
11 KJD46826-001 SLIDE BOBBIN SHAFT 1
12 KJM45493-002 INK BUSH 2
13 KJM33108-D01 I.BOBBIN INNER 2
14 KJD46495-001 INK GEAR SHAFT 1
15 KJM46481-001 TAKE UP GEAR 2
16 KJS46498-A01 COMP SPRING 1
17 KJP46520-A01 STOPPER BKT 1
18 KJM34396-001 SLIDE BOBBIN OUTER 1
19 KJM34397-001 SLIDE BOBBIN INNER 1
20 KJS34332-014 COMP SPRING 1
21 Q03093-837 QYWFM29550 SPACER 1
22 KJJ46271-003 TAP.SCREW 11
23 QYREE4000X E.RING 5
24 YMC-05H-O QZW0182-001 MINI CLAMP 2
25 EDS-2 QZW0006-002 EDGE SADDLE 5
TSS0223-1/3
34
MECH ASSY (CENTER FRAME ASSY)
Paste
6
3
5
1
3
After inserting the connector,
ensure that the wires are stored
neatly.
3 14 (Insert the red wire first.)
14 S Check part number

15
15 2
TPS0235-
001-F
13
12 (3p side)
CN501 KWS0718-001
CN502
7
QYSPSP (2p side)

9 H3012NA x2
16 17
KWR18202-001 KWR18303-001 E-CO only
MM − 0 2
SYMBOL REVISED Price QTY G.No.
PART NO. PART NAME DESCRIPTION
NO. PART NO. Rev. (yen) E-CO U-CO
1 KJP23131-A01 CENTER FRAME 1 1
2 KEF1037 QAR0429-001 DC FAN (24V) 1 1
3 EDS-1 QZW0006-001 EDGE SADDLE 3 3
4 HL-18-0 QZW0183-001 HARNESS LIFTER 1 1
5 YMC-05-H-0 QZW0182-001 MINI CLAMP 1 1
6 KJU44639-002 BRUSH 1 1
7 KWS0718-001 WIRE ASY 1 1 Fan
8
9 QYSPSPH3012NA ASY SCREW 2 2
10 KJJ46271-003 TAP SCREW 3 3
11 KWR17613-001 WIRE ASY 1 1 Front panel
12 KJU46679-001 COVER SHEET 1
13 TPS0235-001-F PROTECT PWB (1) KEP4101-F
14 PHD-08 QZW0301-002 PIERCE HOLDER 2
15 KGES-8 QZW0309-001 CARD EDGE SPACER 2
16 KWR18202-001 WIRE ASY 1
17 KWR18303-001 WIRE ASY 1
18
19
20
21
22
23
24
TSS0223-2/3
35
MECH ASSY Inset Diagram 1
Insert the front plate

inside the rear plate.
KWR KJJ46271-003x2
17613-001
12
8
12 Clamp
KJJ46271
-003 x2
Clamp to the wire

clamp of the center plate
KJJ46271 Clamp
-003x3
12
(Front)
1
Pull tightly
CDO
CDI,LAM
4
HR1
HR2
Y
x2
6
3
Inset Diagram 2 15
QYREE 5 After combining the FRAME, paste the BRUSH.
5000X
Paste near Paste from above
Cut to the ratio the bracket. the half cut
of 4:6 to paste.
Front plate SA Inset Diagram 1
10
Four teeth
Six teeth
For the bottom side, align the edge of double-sided

tape of BRUSH and the edge of bracket. MM − 0 3
1 KJP11105-B0A LMPLATE F ASY 1
2
3 KJM33124-A02 CASSETTE BUTTON 1
4 KJS33103-002 TENSION SPRING 1
5 QYREE5000 X E.RING 1
6 EDS-2 QZW0006-002 EDGE SADDLE 2
7
8 KWR17613-001 WIRE ASY 1 Front panel
9
10 KJU44639-002 BRUSH 1 Cut to the ratio of 4:6 for use
11
12 KJJ46271-003 TAP SCREW 7
13
14
15 KWS0701-001 WIRE ASY 1
16
17
TSS0223-3/3
36
CARD GUIDE IN ASSY
QYSDSF3008N x2
13
Inset Diagram 2
Inset Diagram 1
8 (TPS0235-001-B)
QYSDSF3008N x2 7
13
QYREE3000X
5
12
QYREE3000X 3 2
12
3
8
Inset Diagram 2 7 5 QYREE3000X
(TPS0235-001-B)
12
Inset Diagram 1 3
Insert the sensor sheet between 6

the mold and sensor when installing 3
the sensor board. Inset Diagram 1
1
12
2 QYREE3000X
6
Inset Diagram 2 Inset Diagram 1
Mount it onto Attach the spring as below.

the innermost
of the boss tightly 1 Rotate the spring in the direction
as shown by the arrow and
attach it to the mold.
2 Mount it on the boss.
3 Attach the bearing.
3
2
1
Inset Diagram 1
MM − 0 4
1 KJM23129-B01 CARD GUIDE BASE 1
2 KJM34270-001 PRESS SHAFT 2
3 KJM46478-001 DRY BEARING 4
4
5 KJS46497-A01 TORSION SPRING 2
7 TPS0235-001-B PHOTO SENSOR PWB (1) TPS0235-001
8 KJU46536-001 CARD SENS SHEET 2
9
10
11
13 QYSDSF3008N TAP.SCREW 4
14
TSS0224
37
CARD GUIDE OUT ASSY
Inset Diagram 2 Inset Diagram 1
QYSDSF 13 Inset Diagram 2
3008N x2 (TPS0235
8 -001-B) Insert the sensor sheet between
9 the mold and sensor when installing
7 the sensor board.
5 QYREE3000X
12
11 15
Inset Diagram 1
12 11 11
QYREE3000X
QYREE3000X
12
Taper side 6
16 1
11
Inset Diagram 1
18 12
Push it in right to the end. 5 Inset Diagram 1
Taper side QYREE3000X
17
18 Push it in right to the end.
Attach the spring as below.

1 Rotate the spring in the direction
as shown by the arrow and attach
it to the mold.
2 Mount it on the boss.
3 Attach the bearing.
3
2
Inset Diagram 1 1
MM − 0 5
1 KJM23128-A01 CD BASE GUI.OUT 1
2
3
4
7 TPS0235-001-B PHOTO SENSOR PWB (1) KEP4101-B
8 KJU46536-001 CARD SENS SHEET 1
9 KJU46626-001 PROTECT SHEET 1
10
11 KJM46478-001 DRY BEARING 4
13 QYSDSF3008N TAP.SCREW 2
14
15 KJM34270-001 PRESS SHAFT 1
16 KJD46541-001 FEED SHAFT 1
17 KJM46542-001 FLAT TUBE ROLL 1
18 CM45069-020 OILES BEARING 2
19
TSS0225
38
MEDIA T.UP MOTOR ASSY
15
QYSPSPH
2006N x2
21
TPS0235
-001-D
1 Inset Diagram 1
Check part number S
20
QYSPSPL
Inset Diagram 2 13
3004NA x2
5
Apply grease
Apply grease also on the tip
to the worm gear After installing the motor
Press with jig
(gear and tip). 6
(Apply evenly)
18
Inset Diagram 1
10
E.RING
not required
14
8
QYREE3000X
18
16 Apply grease
Inset Diagram 2 to the bigger cog.
KJJ46271-003 (Apply evenly)
MM − 0 6
1 CL-500-M01 MOTOR 1
2
3
4
5 KJP34284-B0A T.UP MTR BKT ASY 1
6 KJY32775-021 BEARING 1
7
8 KJM46627-00A ENCODE GEAR ASY 1
9
10 KJM45492-001 DOUBLE GEAR 1
11
12
13 QYSPSPL3004NA ASY SCREW 2
14 QYREE3000X E. RING 1
15 QYSPSPH2006NA ASSY SCREW 2
17
18 GB-TS-1 Grease (1) Supplementary material
19
20 KJP46519-A01 ENCODE SENSOR BKT 1
21 TPS0235-001-D ENCODE SENSOR PWB (1) KEP4101-D
TSS0226
39
HEATER MOTOR ASSY
QYSPSPL
13 3004NA x2
Apply grease
also on the tip
5
Apply grease
to the worm gear
(gear and tip). 6 Press with jig
(Apply evenly)
After installing the motor
18
Inset Diagram 1
10
E.RING
not required
9
QYREE4000X
14
18
Inset Diagram 1 18 Apply grease
Apply grease to the smaller cog.
to both cogs. (Apply evenly)
(Apply evenly)
Check part number S
MM − 0 7
1 CL-500-M01 MOTOR ASY 1
2
3
4
5 KJP34282-A0A PRESS MTR BKT ASY 1
6 KJY32775-021 BEARING 1
7
8
9 KJM46475-001 WORM WHEEL 2 1
10 KJM45507-001 DOUBLE GEAR 1
11
12
13 QYSPSPL3004NA ASY SCREW 2
14 QYREE4000X E. RING 1
15
16
17
18 GB-TS-1 Grease (1) Supplementary material
20
21
TSS0228
40
HEATER ASSY Inset Diagram4
Batch bonding x2
S
11
Align the protruding section
of the contact plate with the S Solder the wire
Check part number horizontally as
contact point of the heater. shown in the diagram.
13
Thermostat SA
Thermostat SA
S
Check part number
Clean the glass surface with
17 alcohol and thread inside the
heat roller.
Do not touch the glas surface
with bare hands.
Hook the claw section,

press it against the plate
and tighten the screws.
MM − 0 8
1 CL-500-HR1 HEAT ROLLER ASY 1
2
3
4
5
6
7
8
9
10
11 KUU107J-102 THERMISTOR ASY (1)
12
13 CL-500-TS1 THERMOSTAT ASY (1)
14
15
16
17 KLA5005-121 HEATER 1
18
19
20
21
22
23
24
25
26
27
28
29
TSS0227-1/2
41
HEATER UNIT
QYREE6000X
18 6
KJJ46271-003
17 x2
3
Apply lots of heat

resistance grease.
5
13
Inset Diagram 1
QYREE3000X
19
Install after installing
the cover and main
machine 3 18
Inset Diagram 2 QYREE6000X
Wiring
13 Long
Apply a thin coat of grease on the Short

outside of the BKT shaft hole,
thread through the shaft and Inset Diagram 3 10
move it about to blend it.
Hitch the spring

Apply lots of heat resistance in advance. Thread through
Long portion
(12mm) Short portion 13 grease on the press cam. the tip of the spring
(10mm)
Ensure that the direction
Press the thermostat wire of the head does not Join
against the plate and ensure protrude. 14
2
that it does not bob too much.
Join
14
Pull over the cable covering
QYSPSP to the terminal and join it.
16 H4008NA x2 1 (Distance between the
terminal and the covering
is approx. 0mm)
About center
Inset Diagram 1 Join
14
QYREE Arrange the wires and join them such
3000X 19 that they do not protrude or float out of
the plate.
Approx. 5mm
Stepped side
9 Approx. 50 mm from
the edge of the contact base Inset Diagram 2 Wiring
Inset Diagram 3
MM − 0 9
1 KJD34279-001 HT PRESS SHAFT 1
2 KJM46480-001 HT PRESS CAM 1
3 KJU46499-A02 DRY BEARING 2
4
5 KJP34280-A02 HT FRAME BKT 1
6 KJP34286-A02 HT FRONT PLATE 1
7
8
9 KJD46494-001 HEATER BKT SHAFT 1 Interchangeable from
10 KJS46724-001 TORSION SPRING 1 KJS46496-001
11
12
13 SUMITECH F931 Heat resistant flouride grease (white) (1) Sumico Lubricant Co., Ltd. Supplementary material
14 TYZ-23M QZW0293-001 BINDER 3 Heat resistance, green
15
16 QYSPSPH4008NA ASSY SCREW 2
17 KJJ46271-003 TAP.SCREW 2 TP type S type 3x6
20
TSS0227-2/2
42
FEED MOTOR ASSY QYSPSPH3006NA
10
QYSPSPH3006NA
10 13
13
Tap hole
QYSPSPH3006NA
QYSPSPH3006NA
10 10
14
11 4
Take note of the
KJJ46271-003
direction when installing
Ensure that the extracting hole

is aligned to the motor side.
MM − 1 0
1 KBM1036 QAR0444-001 STEPPING MOTOR 1
2
3
4 WM46269-A01 MOTOR DAMPER 1
5
6
7 KJP46505-001 FEED MTR BKT 1
8
9
10 QYSPSPH3006NA ASY SCREW 4
11 KJJ46271-003 TAP.SCREW 1 TP type S type 3x6
12
13 HL-18-0 QZW0183-001 HARNESS LIFTER 2
14 CS-8U QZW0173-001 CORD CLIP L 1
TSS0229
43
FEED ROLLER ASSY
3 e
5 x2
c d
x2 4
QYREE6000X
19 9
QYREE5000X x4
20 2 E-CO
1 U-CO
(TSS0223)
e Coat with grease

d Apply thread lock and
c
7
QYREE6000X tighten the screw.
b Tighten with extra torque.
10 x4 19 (Tighten hard to ensure
a that it is not loose)
x4
10
x4
9 11
x2
18
23
QYYASPW4004F
x4
LAM Thread the wire back

CDI
and forth the roller as 12 x4
shown in the diagram.
13 14 x2
21
B QYREE4000 X
x2
7
Coat with grease
15
x2
22 QYREE
3000X x2
MM − 1 1
1 TSS0223-001 MECHA FRAME ASY 1
2 TSS0223-002 MECHA FRAME ASY 1
3 KJV34276-00A HT BACK ROLLER 1 1
4 KJV34278-00A FEED ROL R ASY 2 2
5 KJV34277-00A FEED ROL L ASY 2 2
6
7 GB-TS-1 Grease (1) (1) Supplementary material
8
9 KJU46499-A02 DRY BEARING 2 2
10 KJU46499-A01 DRY BEARING 8 8
11 KJJ44854-001 WASHER 4 4
12 KJM46126-00A PULLEY 4 4
13 KJM46476-001 MAIN DRIVE GEAR 1 1
14 KJM46477-001 ROL DRIVE GEAR 2 2
15 KJM45504-A01 MOTOR GEAR 2 2
16
17
18 KJY32771-037 TIMMING BELT 2 2
19 QYREE6000X E.RING 2 2
23 QYYASPW4004F SET SCREW 4 4
TSA0135-1/3
44
AC BLOCK ASSY
For E-CO
KWS0720-001
12
For E-CO 15
QYSPSPH4008NA x2
For U-CO KWS0715
KWS0721-001 5 -001
KWR17704-001
4
S For E-CO
Check part number
For U-CO
KWS0722-001 11
9 3
KJJ46271-003 x2
14
(TPS0235-001-A)
MM − 1 3
1 KJP34288-A01 AC PWB BKT 1 1
2 TPS0235-001-A AC PWB ASY 1 1 KEP4101-A
3 KMF51A2-2R0S QMF51W2-2R0-S FUSE(2A) 1 1
4 KWR17704-001 WIRE ASY 1 1
5 KWS0715-001 WIRE ASY 1 1
6
7
10
11 KTPB004-002 TRANS 1
13
14 KJJ46271-003 TAP SCREW 2 2
16
TSA0136
45
BOTTOM ASSY
Inset Diagram 4
9 KJJ46271-003
KEP4101-G
21 22
Inset Diagram 4
KJJ46271
-003
Check part number S 9

4 20
Ensure that the faston is
tightly and securely inserted.
KWS0713-002
16 1
K
W
B Inset Diagram 1
KJJ46271
17 -003
Inset Diagram 2 KWS0712-001 7
x4 9
Inset Diagram 3 Torque management S 11 QYSPSPH
4016NA x4
12 QYSPSPH
4008NA
K
O S Check part number
10
13
QYWBS 6 Inset Diagram 1 Inset Diagram 3 QYSHSP
438505NA
3008NA x2
5 Inset Diagram 2
Tighten the screws KWS0714-001

without hiding
the earth mark
O 18
Br
Ensure that the faston is tightly Y

and securely inserted. R
MM − 1 4
1 KJP11107-A01 BOTTOM ASY 1 1
2
3
4 KEN2315-003 QNC0112-001 AC INLET 1 1
5 KJP46522-001 POWER SWITCH BK 1 1
6 KSE1521 QSW1221-001 POWER SWITCH 1 1
7 KJY44287-047 TRAN LEG 4 4
8
9 KJJ46271-003 TAP.SCREW 11 9
10 QYSHSP3008NA ASY SCREW 2 2
13 QYWBS438505NA T.L.WASHER 1 1
14
15
16 KWS0713-002 WIRE ASY 1 1
17 KWS0712-001 WIRE ASY 1 1
18 KWS0714-001 WIRE ASY 1 1
19
20 KJP46557-001 SW. BRACKET 1
21 KJZ46558-001 INS. SHEET 1
22 TPS0235-001-G SW PWB 1 KEP4101-G
23
TFA0021-1/2
46
MECH FRAME ASSY
Install the GUIDE after KJJ46271-003 x2 KJJ46271-003 x2

installing the HEATER. 7 16 16
7 (TSS0224)
Paste
KJJ46271 5 4 1
-003 x2 QYSDSP
(TSS0225)
16 3006NA x2 Inset
Diagram 2
15 2
CDO
LAM
CDI
11
12
3 (TSS0227) Inset
Diagram 1
HR1,HR2
Inset
Diagram 2
Tighten the fix screws

x 3 on the rear side Inset
Diagram 1
first, then tighten the KJJ46271-003
front side.
16
9
Note: Procedures for installation 10

1. CARD GUIDE IN,OUTASY
2. HEATER ASY
3. GUIDE
4. Installing the GEAR QYREE4000X
5. Installing the SENSOR 17
16
KJJ46271
Pay attention not to clamp the -003x3
Inset
wire when installing the CARD Diagram 1
16
GUIDE IN ASY. In addition, KJJ46271-003
perform wire arrangement so that
the wire will not block the
transport of card.
CAUTION
• Screws should be tightened.
• Do not wedge the wire into sharp edges. In addition, the
wire is not clamped.
5 1
PART NO. PART NAME (yen) QTY DESCRIPTION
NO. PART NO. Rev.
1 CARD GUIDE IN ASY 1
2 CARD GUIDE OUT ASY 1
3 HEATER UNIT 1
4 KJU46535-001 HT PROTECT SHEET 1
5 KXC46539-001 HT CAUTION LABEL 1
6
7 KJM33159-B03 GUIDE 2
8
9 WM46541-001 PRESS GEAR 1
10 KJM46482-001 HEATER CAM SENS 1
11 KJP46507-001 HT CAM SEN BKT 2
12 GP1S09J0000F PHOTO SENSOR 2
13
14
15 QYSDSP3006NA SCREW 2
16 KJJ46271-003 TAP SCREW 11
17 QYREE4000X E RING 1
TSA0135-2/3
47
MECH FRAME ASSY
Check that the heater rises naturally when Trail the wire so that it does not
you release your hand after pressing down touch the tip of the screws. Ensure
the heater on the front side. that the heat resistance binder is not
Rearrange the wires at the rear side when caught and hinders the movement of Thread under CASSETTE SW SA.
they are taut, or are caught on and cause the heater.
constrained movements. Clamp
Wind the wire tightly

As the wiring around the heater is very with cord clip and
important, check the assembly fasten.
immediately if there is an error.
Inset
Diagram 1 Ensure the wirings
HEATER ASY wiring do not touch sharp
edges.
Clamp the wire of the heater and the

wire from the rear plate.
Clamp Pay attention to the direction of
threading the wire.
Wire arrangement of HEATER

ASY should be performed after
The wire of the motor should installing FEED MOTOR
not touch the gear.
Inset
Diagram 1
2 (TSS0226)
12 KJJ46271-003x2
HR1
Yell
Clamp
Apply thread lock cream
after tightening the screws
HR2
14
11 QYSDSP
4008NA
(TSS0229)
4
Put this right

at the end
and tighten 5
the screws.
Tighten screws at the flat

surface of the platen roller 6
shaft. 10
(S2M240)
1 12 QYSPSPH
(TSS0228) 4008NA x2
KJJ46271-003x2
5 2
PART NO. PART NAME (yen) QTY DESCRIPTION
NO. PART NO. Rev.
1 HEATER MTR ASY 1
2 MEDIA T.UP MTR ASY 1
3
4 FEED MOTOR ASY 1
5 KJM33004-A0C PULLEY 1
6 KJY32771-038 TIMMING BELT 1 S2M240
7
8
9
13
14 1401B Thread lock (1) Supplementary material
TSA0135-3/3
48
MECH FRAME ASSY
Motor wires should not
touch the gears Clamp
KWS0704-001
3
KWS0702-001
1
Clamp
Clamp
FILMM
KWS0703-001
4
Clamp
CAMM
Y
Inset Diagram 1 CN6
CN13
Y
CN6 2 CN1
CN8
KWR
CN3
17502-001
CN201
Clamp
Connector black
8 12
KJJ46271
-003 x4
Clamp
Ensure that this is
well separated from
the platen pulley
screw.
Join cable
(0236-1)
11
6
CN202 KWR17806-001
14
Approx. 70mm
15
CN11
CN6
CN10
Inset Diagram 1
Thread CN6 wire through
the outside of other wires
as it is to be kept away from
heat generating parts.
MM − 1 5
1 KWS0702-001 WIRE ASY 1 FEED MTR
2 KWR17502-001 WIRE ASY 1 HEATER
3 KWS0704-001 WIRE ASY 1 INTERLOCK SW
5
6 KWR17806-001 WIRE ASY 1
7
8 KBS14116-002 QAL0935-001 POWER SUPPLY 1
9
10
11 AN-1 QZW0297-001 BINDER 1
13
14 TPS0236-001 MAIN PWB ASY 1
15 KJP34287-001 CONNECTOR PANEL 1
TFA0021-2/2
49
FRONT PANEL ASSY (FRONT)
5 x2
Take note of the direction
7 Paste 2
QYSDSF3008NA x2
QYSDSF3008NA x2
2
<C
A
U
T
IO
N
:F
itt
in
g
of
th
e
la
If e s
m
th la
in
th
e ck
at
la m
io
m a
n
in y
fil
at c
m
io au
to
n s
th
fil e
e
m b
ca
is ad
ss
no la
et
t t mi
te
ig na
>
ht ti
ly on
w
ou
nd
,
K
X
L3
42
90
-0
01
QYSSSF3006NA x2
3
Paste
6
(Do not peel off
the protective sheet)
1
MM − 1 6
1 KKM23130-002 FRONT DOOR 1
2 QYSDSF3008NA TH.TAP.SCREW 4
3 QYSSSF3006NA TH.TAP.SCREW 2
4
5 KJY46525-001 MAG CATCHER 2
6 KKU46527-003 OP SHEET 1
7 KXL34290-001 MEDIA CAUTON LABEL 1
8
9
10
11
12
TFS0125-1/2
50
FRONT PANEL ASSY (REAR)
QYSDSF3008NA x2 QYSDSF3008NA x2
12
12 Inset Diagram 2
Inset Diagram 2
12 QYSDSF3008NA x5
2 x2
5
a
Inset Diagram 1 a
a
Mat processing
a
3
Peel off both sides
of the protective sheet
(green/transparent).
Important) Peel off when protective
Glossy surface sheet is attached.
Use two for one set
7
Inset Diagram 1 4 1
Remove lock on both sides, White
The SHAFT can be
insert FFC and return inserted from either
the lock. the left or right
Unlock 8
6 Lock Liquid crystal
surface HINGE HOLDER SA Inset Diagram 2
(TPS0236-001-B)
MM − 1 7
1 KKM11102-001 FRONT PANEL 1
2 KKM46490-001 LED LENS 2
3 KKU46524-001 SHEET 1
4 KLX2010 QLD0477-001 LCD 1
5 KKM34273-002 PUSH BUTTON 1
6 TPS0236-001-B FRONT PWB (1) KEP3160-B
7 KJP46523-001 DOOR HINGE 2
8 KJP46157-A01 HINGE HOLDER 2
9 KJD46158-001 SHAFT 2
10
11
12 QYSDSF3008NA TH.TAP.SCREW 9
13
TFS0125-2/2
51
FAINAL ASSY(PANEL) (TFA0021)
E-CO 2
U-CO 1
Paste the
manufacturer's
number
13
(TFS0125)
QYSDSP3006Nx4
10 Inset Diagram 1
(TFS0126)
Insert to shaft
Inset Diagram 2
CN02
Inset Diagram 2 Insert to FRONT board CN02

Insert the claws on both sides
of the front panel to the plate
and fasten with screws.
Inset Diagram 1
MM − 1 8
1 TFA0021-001 LM COMMON ASY 1
2 TFA0021-002 LM COMMON ASY 1
3
4 TFS0125-001 FRONT PANEL ASY 1 1
5 TFS0126-001 CASSETTE ASY 1 1
6
7 KJP46521-001 DIAL PLATE 1 1
8 KJM34272-001 JOG DIAL 1 1
9
10 QYSDSP3006NA SCREW 4 4
11
12
13 _________ White label (1) (1) Supplementary material
14
T0162-1/3
52
FINAL ASSY(REAR) Inset Diagram 2
Check that the filter is not misaligned Paste

and the wire that fixes the filter is not
out of position. 13
Approx.
1mm
Align with center
Inset Diagram 2
QYSDSP3006NA
15
12
QYSDSP4008NA
x6
CN2 17
Inset Diagram 1
Inset Diagram 1 The four locations should be

attached to the innermost of the
REAR PANEL SA
notch as shown in the diagram.
17
QYSDSP
4008NA
(Same for
bottom side)
(Same for
bottom side)
7
8
11
Inset Diagram 2
6
S
Check part number
5 x2
1
Check part number S KWR17903-001
After inserting the connector, 4
ensure that the wires are
stored neatly.
(Insert the orange wire first.)
3 16 QYSPSPH
4030NA x2
Check part number S
MM − 1 9
1 KKP11108-A01 REAR PANEL 1
2
3 KEF1043 QAR0445-001 FAN MOTOR 1
4 KWR17903-001 WIRE ASY 1
5 KJV46484-002 AIR FILTER P 2
6 KKM34274-002 FILTER COVER 1
7 KJV46484-001 AIR FILTER P 1
8 KJT34289-001 WIRE 1
9
10
11 KKP11109-002 TOP COVER 1
12 KKM34105-006 MENTE COVER 1
13 KJU44639-002 BRUSH 1
14
18
T0162-2/3
53
ANNEX ASSY
E-CO only U-CO only

S VM0303B,VM0306B,H05VV-F S VM0233,VM0089,VW-1
2 POWER CORD 3
(200V/EU) POWER CORD
(120V/UL)
Secure with tape

Secure with tape 16 11
11
(-011)
(-011)
7 Caution sheet
Cleaning card
8
19
Inst
manual
(-012)
Secure with tape 16
12
10
Secure with tape 16
(-006)
14
CONNECT PLATE 18
10
Secure with tape 16
MM - 2 0
1
2 QMP4908-200R QMPL338-250-R POWER CORD 1 220V-240V
3 KDH40058 POWER CORD 1 100V-120V/UL
4 _________ Twist tie (Black) Supplementary material
5
6
7 KAT-T165 INST MANUAL 1 1
8 LS41112-001A CAUTION SHEET 1 1
9
10 KD41811-006 POLY BAG 2 2
11 KD41811-011 POLY BAG 2 2
12 KD41811-012 POLY BAG 1 1
13
14 KJM33109-004 CORE BOBBIN 1 1
15
16 NO.29-18 NITTO C.TAPE (1) (1) Supplementary material
17
18 KJP23132-00A CONNECT PLT ASY 1 1
19 KJZ46528-001 CLEAN. CARD 1 1
20
TFS0127-008
54 -009
FINAL(PACKING) ASSY
2 (POWER CORD)
(CONNECT PLATE)
U-CO . . . AC100-120V
E-CO AC100-120V/AC220-240V
2 (Instructions)
MODEL (Cleaning card)
NO.
VOLT
FREQ. 50/60 Hz
GR 13kg
For KXZ44568-001
Inset Diagram 1 Check the printed
contents and paste 5 U-CO
6 E-CO
Secure with tape 17

(TFS0127) Inset Diagram 1
[Always operate after the heat roller has cooled down.]
3 Cut into 1/4.

11
2 x4 16
Length approx. 60mm
Put in cushion
in advance
Inset Diagram 1
1
Insert the black surface, facing down,
between the heat roller and platen roller.
Put in the cushion, insert the cassette and stick

tapes on the cassette.
MM − 2 1
1 KPA11110-001 PACKING CASE ASY 1 1
2 KPC11111-00A CUSHION ASY 1 1
3 WP45008-001 HEAD CUSHION 1/4 1/4
4
5 TFS0127-008 ANNEX ASY 1
6 TFS0127-009 ANNEX ASY 1
7
8
9
10
11 KD40875 POLY BAG 1 1
12
13 KPL32735-005 CARE MARK LABEL 2 2
14 KXT44142-001 PACKING LABEL 2 2 Label printer
15
16 NO.3800A TAPE(NittoDenko) (1) (1) Supplementary material
17 NO.29-18 NITTO C TAPE (1) (1) Supplementary material
18 NO.375 NITTO D TAPE (1) (1) Supplementary material
T0162-3/3
55
SERVICE MANUAL
LAMINATOR FOR CARD PRINTER
CL-500
Importer and distributor : GRUPO COSMOCOLOR,S.A.DE C.V.

Prol. Paseo de la Reforma 5295
Col. Santa Fe, Deleg. Cuajimalpa C. P.
Phone : 55-50-81-64-40
Facsimile : 55-52-92-1416
SPECIFICATIONS
Item Content
Transfer method Halogen lamp built-in heat roller method
Transfer time Approx. 20 seconds
The time varies according to settings.
Usage environment Temperature 15°C - 30°C
Humidity 30 % - 70% (without condensation)
Storage environment Temperature –15°C - 55°C
Humidity 20 % - 80%
Power supply AC 100 V - 120 V (tolerance ±10%)
Power consumption Approx. 200 W
Unit mass Approx. 8 kg
Compatible specification VCCI-B
Accessories Power cord x 1 (for Europe or US market)
Instructions
Unit joining plate
Cleaning card x 1
Option Cleaning card set x 1 [10p/set (CX210-CC1)]
Changes may be made to the specifications and external appearance of this machine for product improvement
without prior notice.
KAS-T082-004
December 2006

Manual CL 500

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SERVICE MANUAL

LAMINATOR FOR CARD PRINTER

Importer and distributor : GRUPO COSMOCOLOR,S.A.DE C.V.

MODEL NAME ................................................................................. 1 ASSEMBLY DIAGRAM AND PARTS TABLE ............................ 33

USING SERVICE MODE ............................................................. 12

MECHANISM OPERATION ......................................................... 17

SET UP GUIDE ............................................................................. 25

•Precautions during Servicing

4. Use specified internal wiring. Note especially:

(3) Align the lengths of the wires to be connected. Insert the

Fig.1 Metal sleeve

7. Observe that wires do not contact heat producing parts (heatsinks,

• Safety Check after Servicing

1. Insulation resistance test

2. Dielectric strength test

4. Leakage current test

5. Grounding (Class 1 model only)

Table 1 Specifications for each region

Table 2 Leakage current specifications for each region

ID label display: CL-500*1-CO

AC 100 V/200 V switching model

Card insert detection

Laminate position External machine

Film FG sensor *1 Not available for AC 100 V model

MAIN COMPONENTS LAYOUT DIAGRAM

Thermostat Film mark sensor and

Card ejecting sensor

Card insert detection sensor

2. REAR : MOTOR, FAN, SENSORS AND SWITCHES

Film reeling motor

Heater cam motor

Card transport motor

3. VARIOUS CIRCUIT BOARDS AND POWER SUPPLY

AC board Main board AC select SW board

REMOVING MAIN PARTS

2.3 WIRING REFERENCE DIAGRAM

3. REMOVING MAIN PARTS 3.1.2 Separating Chassis and Mechanical Unit

pull out the power supply 8.

• Ensure that the faston

2) Remove each connector on the cable, remove three

Do not allow wires to come near

4) While paying attention to the wires from the heater

Put this right

3.2.4 Removing Transport Roller

Pull over the cable Join

3.2.3 Removing Heat Roller e

ASSY. Detach the connect base claw from the heater x4

bracket 6 to remove the connect base. The halo- 4 x2

Press down the terminal 12 x4

Press down the terminal wire

USING SERVICE MODE

Setting Items Setting value

3.1 Connecting with CX210

(2) Turn on the power of laminator.

3.2 Connecting with CX-120 and CX-1** series

(2) Turn on the power of laminator.

3.3 Connecting with CX-320 and CX-3** series

(2) Turn on the power of laminator.

2.1 When Cool Time is set 2 Using 0.6mil, Overlay