Entrust Datacard PB8500 Manual

October 2021
528302-001, Rev. A
Operator’s Guide
Datacard Passport Issuance System
PB8500

ii
Notice
Please do not attempt to operate or repair this equipment without adequate
training. Any use, operation or repair you perform that is not in accordance
with the information contained in this documentation is at your own risk.
Trademark Acknowledgments
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and/or service marks of the Entrust Corporation in the United States and other
countries.
Datacard is a registered trademark and service mark of Entrust Corporation in
the United States and other countries.
MasterCard is a registered trademark of MasterCard International Incorporated.
Visa is a registered trademark of Visa International Service Association.
All other product names are the property of their respective owners.
Proprietary Notice
The design and information contained in these materials are protected by US
and international copyright laws.
All drawings and information herein are the property of Entrust Corporation. All
unauthorized use and reproduction is prohibited.
Entrust Corporation
1187 Park Place
Minneapolis, MN 55379
Phone: [phone]
Fax: [phone]
www.entrust.com
© 2021 Entrust Corporation. All rights reserved.

3
Revision Log
Revision Date Description of Changes
A October 2021 First release of this document.

1
Contents
Chapter 1: Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Expansion Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Additional Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Auxiliary AC Power Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Specifications and Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical and Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Physical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Floor Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
System Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Module Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Module Status Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Module Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Computer BIOS Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 2: System Power On and Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Power On the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Power On Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Controller Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Module Boot Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power Off the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pause and Resume the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chapter 3: Load Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Booklets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Load Booklets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Adjust for Change of Booklet Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Printheads for Inkjet Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Overlay Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 4: Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Monitor the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Open the Production Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Module Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Supply Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Job Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Other Status Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Status Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2
Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Process Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Load Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Run Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
User Input Needed Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
View Job Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Preview Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Remake a Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pause/Stop/Abort Jobs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Split Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Advanced Split . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Search for Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Hold/Reject Passports from a Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Delete Jobs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Production Station Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Production Station Status Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Open Applications Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Ready Jobs Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
All Jobs Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Filtering Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Job Details Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Print Preview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Sort and Filter Records in the Job Details Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Sort by Table Heading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Filter by Production Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Filter by Record Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Choose Columns to Be Displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Group Jobs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Production Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
General Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Toolbars Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Tables Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
FIR Record Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Chapter 5: Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Cleaners, Tools, and Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
System Preventive Maintenance Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Chapter 6: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Reset the Controller or a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Reset the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Remove Jammed Booklets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Page Turning Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Booklet Opener Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

3
Multi-Book Chip Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Laser 450G Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Secure Overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Buffer/Closer/QA Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

1
Operator’s Guide 1
Chapter 1: Introduction
This chapter provides general information about the
Datacard® PB8500™ Passport Issuance system.
System Overview
The PB8500 passport issuance system has a series of modules that work
together to complete the personalization of elements on a passport.
Available modules are defined in the following table.
A system may contain duplicate modules or none of certain modules.

2 Introduction
Module Description
System Controller The Controller contains the primary computer that controls
the function of the individual modules in the system and is
also the primary interface point for the operator. It includes
the hardware necessary to power on and interact with the
modules in the system.
Each system has a dongle plugged into the Controller
computer. The dongle needs to be in place for the system to
work.
Passport Input The Passport Input module—always the first module in a
system—feeds booklets into the system from a stack. A
system can have multiple Input modules to hold more
booklets or multiple types of booklet stock.
Booklet Opening
Page Turning The Page Turning Module opens a booklet to a user-
specified page for downstream processing by other
modules. The module contains a page confirmation camera
to verify that the booklet is opened to the correct page.
Every system must have at least one Booklet Leafing
module near the Input module. Optional Leafing modules
installed throughout the system can open a booklet to other
pages during processing.
Multi-Book Chip
Laser 450G The Laser 450G module (with a Class 1 laser) have updated
electronics and cables to work with the new 50W laser
interface. They engrave a plastic page in a booklet for
secure, forgery-resistant personalization. The module is
capable of tilt-axis engraving for an even higher level of
security. Vision registration allows precise alignment
between engraved elements and preprinted elements on
the page. The PB8500 system can support multiple Laser
module for higher throughput.
Plasma Pre-treat Pretreatment of the booklet surface is used to increase the
booklet surface energy and improve the wetting and
adhesive properties of the polymer materials.

Operator’s Guide 3
Single Passport
Buffer
This module is used to synchronize multiple Laser Engraving
modules in one system to increase throughput when using
teamed (ganged) engraving. Single Passport Buffer
modules must be installed in pairs except when the module
is directly before a Booklet Closing module.
Drop On Demand
(DoD)
The Color Inkjet Printing module uses pigment to print 1200
dpi full-color, tonal, or black and white images and text on
the paper pages of a passport booklet. Vision registration
allows precise alignment to preprinted elements or the edge
of the page.
Secure Overlay The Secure Overlay module applies a protective coating to
the surface of the passport booklet page. The thin film
overlay serves as a protective barrier for personalized data
printed on the page and can have holographic or other
designs for protection from tampering.
Quality Assurance The Quality Assurance module captures digital images of
the horizontal and/or vertical page of a booklet as it passes
through the system. It can also verify the chip encoding in
the eBook and close the booklet before transporting it to
the next module.
Booklet Closing The Booklet Closing module closes the booklet after all
personalization is complete, and then passes it to the
Output module. This module is not needed when the system
includes the Quality Assurance module or the Contactless
Chip module.
Passport Output The Passport Output module—always the last module in the
core system—stacks booklets after processing. The module
contains a primary stack for completed booklets and a
secondary stack for rejected booklets. The system can have
multiple Output modules to hold more booklets or to group
booklets in separate stacks.
Module Description

4 Introduction
Expansion Kits
The following kits are included in your shipment automatically if your
configuration requires additional cooling fans or power inlets.
Additional Cooling Fans
Larger systems may require an additional cooling fan in the Output module.
The cooling fan is available as an installation kit. This kit is shipped with a
system or additional modules if one is required.
Auxiliary AC Power Inlet
The auxiliary AC power inlet is shipped with expansions that exceed the power
limit. Refer to the kit for installation instructions.
Each power inlet and power cord requires a dedicated power drop
with a 15-amp breaker (U.S.) or 16-amp breaker (non-U.S.).

Operator’s Guide 5
Specifications and Requirements
System specifications and site requirements are as follows.
Electrical and Environmental Specifications
 Electrical, Operating, and Storage
Refer to the PB8500 Passport Issuance System data sheet on the Datacard
website (www.entrust.com).
 Power Consumption
The power consumption of the system is the sum of the power consumption
of the Controller and all of the modules in the system. To see the maximum
current draw for each module, refer to the PB8500 Passport Issuance
System data sheet on the Datacard website (www.entrust.com).
 Permissible Current Load
Because the system is modular, it is possible to exceed the permissible load
on the main Controller power cord. If the calculated load on the Controller
power cord or an auxiliary power cord exceeds 12 amps, add more power
inlets and cord(s) to the system.
 Electrostatic Discharge Susceptibility
A system can withstand an electrostatic discharge of 15 kV, 330 pF storage,
and 1.5 kW series resistance in tests simulating a human discharge to the
outer surface of the machine. This does not include direct discharge on
printed circuit boards.
 Audible Noise
The audible noise level of a system is dependent on the installed modules
and passport personalization data. A system with Controller, Passport Input,
Leafing, Inkjet, Overlay, and Passport Output modules is measured as
follows.
Front Bystander
Position
65.5 dBA to 68.0 dBA
Front Operator
Position
67.5 dBA to 69.5 dBA
Measurements are sound pressure measurements with a handheld
sound meter at the front bystander (1.0 meter from machine, 1.5
meters high) or operator (0.25 meter from machine, 1.5 meters high)
positions per ANSI S12.10-1985, Section 11. All measurements are
averages over 60 seconds (60 L equiv.).

6 Introduction
Physical Requirements
The following section contains the physical site requirements needed for a
PB8500 system.
Floor Space
The floor space required to install the system is dependent on the number and
type of modules included. To determine how much floor space is required,
calculate the following:
1. Controller width + [number of input and output modules x input/output
width] + [number of inkjet modules x inkjet width)] + (number of standard
modules x standard width) = Total width of system
2. Total width x 33.8-inch (85.9-cm) depth = Floor space used by system
3. Floor space used + 36-inch (45.72-cm) clearance on all sides for service
access and airflow = Total floor space
The floor must be level and flat within ± 0.1 inch per foot (1 mm per 10 cm) in
any direction.
System Dimensions
The dimensions and footprint values for the overall system are the sum of those
for the Controller and each module. Dimensions are as follows:
Module Width/Height/Depth
Controller 24 x 37.1 x 31.7 inches
(61 x 94.2 x 80.5 cm)
Standard PB8500 Module 10 x 50.3 x 26.9 inches
(25.4 x 127.8 x 68.3 cm)
Input and Output Modules
(The final Output module has an
end panel that makes the module 11
inches wide.)
10 x 42 x 33.7 inches
(25.4 x 106.7 x 85.6 cm)
Pretreat Module 10 x 50.3 x 42.8 inches
(25.4 x 127.8 x 108.7 cm)
DOD Module 50 x 53.8 x 35.3 inches
(127 x 136.7 x 89.7 cm)

Operator’s Guide 7
Weight
To determine the system weight, calculate the sum of the weights for each
module, the Controller, and any additional casters (11 lbs/5.0 kg).
For the weight of the controller and each module, refer to the PB8500 Passport
Issuance System data sheet on the Datacard website (www.entrust.com).

8 Introduction
Module Interlocks
Module interlocks are a safety feature that prevent operator injury. Lifting a
hood causes the motors to be disabled and the interlock indicator light for the
module(s) to go off. Interlock lights for the adjoining modules go off, but the
adjoining modules finish processing passports and then sit idle with motors
enabled.
Most systems have connected hoods so that all or many modules lose power to
the motors when hoods are opened. Wider modules have one interlock on the
upstream side.
The Output module has its own hood and a Pause/Resume switch. When the
hood is opened, motors in the upstream module are disabled. The Input module
also has its own hood. When the hood is opened, it disables the motor of the
module adjacent to it.

Operator’s Guide 9
Module Status Lights
Each module (except for the Input and Output modules) has a status light
located on the front panel to alert the operator when the module needs
attention. When the light is either flashing or solid on, refer to the error
message on the Controller screen for more information.
Module Warning Labels
When working around the system, observe the following warning and caution
labels affixed to various areas on the equipment.
Computer BIOS Battery
The motherboard in the Controller computer contains a battery backup for the
system BIOS. If the battery is improperly connected, damage to the
motherboard can result. Replace the battery with only the same or equivalent
type recommended by the manufacturer. Dispose of used batteries according
to the manufacturer’s instructions.
Flashing light—Module error
or failure in normal operation;
failure in module firmware.
Light on, but not flashing—
Supplies are low or the
module is in a paused state.
No light—Module is running
normally or power is off.
When a module error occurs, the other modules process their current
tasks until completed. At that point, the system enters a paused state
(all module status lights are on, but not flashing).

10 Introduction
Supplies
Find the current supplies information on the Entrust website
(www.entrust.com):
Datacard Home > Product & Solutions > Supplies
Related Documents
The following documents provide additional information for the PB8500
system.
Description Part No. Available on CD
PB8500 Passport Issuance
System Data Formatting Manual
539684-001 This library
PB8500 Passport Issuance
System Software Administrator’s
Guide
527378-001 This library
Illustrated Parts Manuals for Each
Module
Mulitple This library
System Safety Rules 539614-001 This library
Preventive Maintenance Tools and
Supplies List
--- This library
Datacard Certified Supplies --- This library and TrustedCare

2
Operator’s Guide 11
Chapter 2: System Power
On and Power Off
This chapter provides procedures for starting, stopping and
pausing the Datacard® PB8500™ Passport Issuance system.
Power On the System
The system has a button for starting the Controller computer and an E-Stop
switch for powering on the system modules.
Perform the following procedure to start the system.

12 System Power On and Power Off
Procedure
1. Plug the system into AC power.
2. Turn on the Controller PC by pressing the power button on the front of the
computer. Allow the Controller PC to boot up completely.
3. Log on to Windows.
4. Start the Controller software, and go to the Production screen. It displays
the progress of the system during startup and, eventually, a diagram of the
system.
5. Power on the system hardware by rotating the E-stop switch on the front of
the Controller module clockwise to the ON position. This switch controls all
AC power to the modules, the cooling fans, and all additional power cords
that are installed on the system.
Do not use the keyboard or mouse during Windows start-up.
You can use the E-stop switch to stop the system in an
emergency.

Operator’s Guide 13
Power On Troubleshooting
If the system fails to start properly, use the following guidelines to isolate the
most likely cause. Some of these troubleshooting scenarios may require a
trained technician to isolate and correct the problem.
Controller Problems
If the Controller computer cannot be turned on:
 Verify that the main power cord is connected to the system and the facility
outlet.
 Verify that the facility power is available and is of the correct voltage for the
system. The system requires single-phase, grounded, 180 to 264-volt, AC
power at 47 to 63HZ.
 Make sure the power cord on the back of the Controller computer is
properly connected.
If the Controller computer starts, but does not properly boot up, follow the
diagnostic procedures for Microsoft® Windows®.
Module Boot Problems
If none of the modules boot up:
 Verify that the red E-Stop switch on the front of the Controller is on.
 Verify that the power cable between the Controller and the first module
(Input module) is connected.
 Verify that the Ethernet connection between the Controller computer and
the Ethernet switch is correct. Also verify that the Ethernet switch has
power.
If all modules boot up except for one, the most likely cause is a bad Ethernet
connection.
If all modules downstream from a module fail to boot up, the most likely cause
is a disconnected power jumper between modules, or an auxiliary power cord
on that module that is not plugged in to facility power.

14 System Power On and Power Off
Power Off the System
Remove AC power from the system any time service is being performed.
1. Wait until all production tasks are complete.
2. Select the Windows Shutdown command, and wait for the Controller PC to shut
down.
3. Turn the E-Stop switch counterclockwise to OFF. The word OFF is then visible
in the dial cutout. This removes power from the following:
 All modules
 The system fans
 Modules that are supplied by additional power cord inlets
4. If you are performing service on the PB8500 system:
a. Unplug the power cord(s) from the AC power source.
b. Capture the female end of the AC cord into a certified lock-out device,
such as the sample shown here, and lock it with a padlock.
Each person servicing the system should have their own
personal lock.
Caution: Never remove someone else’s lock from a lockout.