Evolis BadgePass NXT5000 User manual

280 Trace Colony Park • Ridgeland, MS 39157
601.499.2131
www.badgepass.com
Evolis Card Printer © 2012. All rights reserved.
September 2012.
Ref. KU-034-ENG Rev A1
Service Manual

Page 2
BadgePass Service Manual 1
Table of Contents 2
Introduction 3
Liability Statement 3
Proprietary Notice 3
Trademark Acknowledgments 3
Environmental information – recycling of end-of-life products 3
Operator 4
Mechanical Maintenance Personnel 4
Electrical Maintenance Personnel 4
Symbols 5
Safety 6
Safe Environment 6
Safe Human Interface 6
General Safety Regulations 7
Picture List 8
Description 10
Explode View 11
Spare Parts List 18
Available Tools 19
Step 1 - Reject Box - CI010222 20
Step 2 - Enclosure Side - CI010214 21
Step 3 - LCD Control Panel (With Cable) - S10086 22
Step 4 - Upper and Hopper Feeder - S10123 to S10126 23
Step 5 - Feeder Belts Kit - S10092 25
Step 6 - Tighting Belts Kit - S10094 26
Step 7 - Common Motor - S10097 ( Feeder) 27
Step 8 - Enclosure Base - CI011190 29
Step 9 - Flip Over Sensor - S10121 30
Step 10 - Ribbon Braking Kit - S10093 31
Step 11 - Transport Belts Kit - S10091 33
Step 12 - Ribbon Detection Kit - S10087 35
Step 13 - Stepper/Feeder Motor - S10098 36
Step 14 - Flip Over Module - S10128 37
Step 15 - Cleaning Roller - S10122 39
Step 16 - I/O Shield - CI010322 40
Step 17 - Enclosure Bottom Plate - SE010079 41
Step 18 - Main Board USB ETH - S10114 42
Step 19 - Common Motor - S10097 (Up and Down) 43
Step 20 - Common Motor - S10097 (Ribbon) 44
Step 21 - Stepper Motor - S10096 45
Step 22 - Head Roller Kit - S10099 47
Step 23 - Flex Sensor Kit - S10088 51
Step 24 - Print Head (KPE) - S10084 53
Step 25 - Ribbon Sensor - S10089 54
Step 26 - Enclosure Cover - CI010205 55
Step 27 - Enclosure Buttom - CI010206 56
Step 28 - Fan Kit - S10100 57
Step 29 - Print Head Cable - S10085 59
Step 30 - Head Bracket - S10138 60
BadgePass Contact 61
Table of Contents Service Manual

Page 3
Introduction Service Manual
The BadgePass printer is designed to
Liability Statement
This product has been built to the high standards of BadgePass. Please do not attempt to operate or repair this
equipment without adequate training. Any use, operation, or repair in contravention of this document is at your own
risk. By acceptance of this system you hereby assume all liability consequent to your use or misuse of this equipment.
BadgePass assumes no liability for incidental, special, or consequential damage of any kind. Equipment specifications,
applications, and options are subject to change at the sole discretion of BadgePass without notice.
Proprietary Notice
All drawings and information herein are the property of BadgePass. All unauthorized use and reproduction is prohibited.
Trademark Acknowledgments
Microsoft Windows, Windows Embedded, are registered or trademarks of Microsoft Corporation In the United States
or other countries.
Atom ® is a registered trademark of Intel Inc.
TrueType is a registered trademark of Apple Inc.
The information contained in this present document is subject to change without prior notice. All product or program
names mentioned in this document are registered trademarks owned by the respective companies. They are only
used in this document for editorial purposes.
Environmental information – recycling of end-of-life products
The manufacture of the equipment that you have purchased required the extraction and use of natural
resources. It may contain materials that are hazardous to health and the environment. To prevent the dispersal
of such materials into our environment and reduce the pressure on our natural resources, we recommend that
you use existing collection systems.
Note:
The crossed-out dustbin symbol on your device is a reminder to use these systems.
If you need further information on collection, re-use and recycling systems, contact your local or regional waste
management body.

Page 4
Introduction Service Manual
This manual describes the disassembly operation and trouble shooting of BadgePass NXT5000 printer. The manual
has been prepared in conformance with subsequent modifications and integrations and is composed of:
• Safety regulations for use and maintenance
• General machine specifications
• Machine installation
• Operating modes
• Repairs and adjustments
• Electrical diagrams
Personnel assigned to operating the machine, in addition to being professionally trained for their specific job must
read the manuals, pay careful attention to safety regulations and the sections pertinent to their job.
Individuals assigned to operating the machine are broken down as follows:
Operator:
Assigned to loading the elements to process, visual inspection of the work cycle, unloading of finished product and
cleaning of the machine.
Mechanical Maintenance Personnel:
Assigned to mechanical maintenance of the machine.
Electrical Maintenance Personnel:
Assigned to electrical maintenance of the machine.
Note:
BadgePass shall not be held responsible for any non-conforming use of equipment of its manufacture.
If you need further information on collection, re-use and recycling systems, contact your local or regional waste
management body.

Page 5
Generic Warning:
This symbol indicates the need to read the manual carefully or the necessity of an important maneuver or
maintenance operation.
Symbols Service Manual
The symbols used in this manual along with their meaning are shown below. The symbols are repeated within the
chapters and/or sections and have the following meaning:
Electricity Warning:
This symbol indicates dangerous voltage associated with the powerful enough to constitute an electrical
risk. This symbol may also appear on the machine at the risk area.
Temperature Warning:
This symbol indicates high temperature associated to some components. Wait the module to cool down
completely before removing some component. This symbol may also appear on the machine at the risk area.

Page 6
Safety Service Manual
The following basic safety tips are given to ensure safe installation, operation, and maintenance of BadgePass
equipment and are not to be considered as comprehensive on matters of safety. The tests performed demonstrate
the safety and reliability of heating components when used correctly. It is necessary that the operator be informed of
precautionary regulations aimed at avoiding injury or damage to the equipment.
Safe Environment
• Connect equipment to a grounded facility power source. Do not defeat or bypass the ground lead.
• Place the equipment on a stable surface, and ensure that the floors in the work area are dry and non-slip. Insulated
rubber floor mats are preferred.
• Know the location of equipment branch circuit interrupters or circuit breakers and how to turn them on and off in
case of emergency.
• Know the location of fire extinguishers and how to use them. Use only ABC type extinguishers on electrical fires.
• Know local procedures for first aid and emergency assistance at the customer facility.
• Use adequate lighting at the equipment.
• Maintain the recommended range of temperature and humidity in equipment area.
• Do not use this product in an environment containing volatile or flammable compounds.
Safe Human Interface
• Use proper lifting techniques when moving or installing the equipment.
• Use standard electrostatic discharge (ESD) precautions when working on or near electrical circuits.
• Do not defeat or disconnect safety interlocks on covers.

Page 7
Safety Service Manual
General Safety Regulations
The User must comply with the regulations and work in the best possible safety conditions to prevent decreasing the
degree of machine safety. Therefore it is necessary to develop a Standard Operating Procedure (S.O.P.) related to
maneuvers to effect for turning on and off the equipment. This procedure, which shall be prepared around the time
of installation, shall serve as a reference for the Operator and shall be written in his/her language. Training is essential
and must include:
Familiarization with system operating procedures.
Understanding of the necessity for Individual Protection Devices (I.P.D.)
Note:
It is advisable not to change the intended use without previously contacting the Manufacturer.
Note:
Do not subject materials other than those the equipment was designed for.
Note:
Do not work on the electrical part if you are not trained to do so. Do not remove protection devices.
An additional risk may be represented by fire caused by processing materials other than those the equipment is
designed for.
The most serious collateral risk associated, which may be fatal, is electricity. This may occur when the manufacturer’s
warning and procedures are not followed. Unauthorized and untrained personnel must never do any work on the
electrical part. The safety devices must never be removed and their operation must be periodically checked.

Page 8
Picture List Service Manual
Drawing 1 11
Drawing 2 12
Drawing 3 12
Drawing 4 13
Drawing 5 14
Drawing 6 15
Drawing 7 16
Drawing 8 16
Drawing 9 17
Picture 1: BadgePass NXT5000 Printer 10
Picture 2: Tools 19
Picture 3: Reject Box 20
Picture 4: Top Cover 21
Picture 5: Side Bolt 21
Picture 6: Enclosure Side 21
Picture 7: Control Panel 22
Picture 8: Feeder inside Right Side 23
Picture 9: Feeder inside Left Side 23
Picture 10: Feeder Front Side 23
Picture 11: Feeder Right Side 24
Picture 12: Feeder Left Side 24
Picture 13: Feeder Belt 25
Picture 14: Feeder Tighting Belt 26
Picture 15: Feeder Tighting Belt-1 26
Picture 16: Feeder E-ring & pulley 27
Picture 17: Feeder Motor Cable 27
Picture 18: Feeder Motor-1 28
Picture 19: Feeder Motor-2 28
Picture 20: Enclosure Base side 29
Picture 21: Enclosure Base clip-1 29
Picture 22: Enclosure Base clip-2 29
Picture 23: Flip Sensor 30
Picture 24: Ribbon lock 31
Picture 25: Ribbon lock details 31
Picture 26: Ribbon lock gear 32
Picture 27: Transport Belt 33
Picture 28: Black Ribbon Belt 33
Picture 29: Tansport Belts 34
Picture 30: MLX Transport Belt 34
Picture 31: Ribbon Detection 35
Picture 32: Ribbon Detection Rivet 35
Picture 33: Motor Flip 36
Picture 34: Flip Sensor 37
Picture 35: Flip Motor 37
Picture 36: Flip Support 38
Picture 37: Flip Over 38
Picture 38: Cleaning Roller 39
Picture 39: I/O Shield 40
Picture 40: Bottom Plate 41
Picture 41: MainBoard Connections 42

Page 9
Picture List Service Manual
Picture 42: Fixing MainBoard 42
Picture 43: Gear Motor 43
Picture 44: Motor Clip 43
Picture 45: Common Motor Left Side 44
Picture 46: Common Motor clip 44
Picture 47: Stepper Motor 45
Picture 48: Transport Belt 45
Picture 49: Belt Idler screws 46
Picture 50: Stepper Motor 46
Picture 51: Black gears position 46
Picture 52: Left Side Components 47
Picture 53: Stepper Belt 47
Picture 54: Transport Belt 48
Picture 55: Disassembly Chassis screws 48
Picture 56: Separation of Chassis 49
Picture 57: Synchro Ribbon Support 49
Picture 58: Option roller & springs 50
Picture 59: Heat Roller -1 50
Picture 60: Heat Roller - 2 50
Picture 61: Flex connector 51
Picture 62: Flex Rivets 51
Picture 63: Flex Card Sensor 52
Picture 64: Print Head – 1 53
Picture 65: Print Head - 2 53
Picture 66: Print Head - 3 53
Picture 67: Ribbon Sensor - 1 54
Picture 68: Ribbon Sensor - 2 54
Picture 69: Ribbon Sensor - 3 54
Picture 70: Enclosure Cover - 1 55
Picture 71: Enclosure Cover - 2 55
Picture 72: Enclosure Button 56
Picture 73: Fan - 1 57
Picture 74: Fan Connector 57
Picture 75: Fan Cable Path 58
Picture 76: Fan - 2 58
Picture 77: Print Head Cable – Print Head Connector 59
Picture 78: Print Head Cable – Mainboard Connector 59
Picture 79: Print Head Cable Path 59
Picture 80: Head Bracket Connectors 60
Picture 81: Head Bracket Cables Path 60
Picture 82: Head Bracket Axis 60

Page 10
Description Service Manual
Picture 1: BadgePass NXT5000 Printer

Page 11
Explode View Service Manual
Drawing 1

Page 12
Spare Parts List Service Manual
Drawing 3
BELTS: FEEDER KIT
S10092
BELTS: TIGHTING KIT
S10094
FEEDER: EXIT HOPPER BLUE
S10126
MOTOR: COMMON
S10097
FEEDER: UPPER BLUE
S10124

Page 13
Spare Parts List Service Manual
Drawing 4
BELTS: TRANSPORT KIT
S10091
MOTOR: COMMON
S10097
MOTOR: STEPPER
S10096
SENSOR: FLEX KIT
S10088
RIBBON: BRAKING KIT
S10093

Page 14
Spare Parts List Service Manual
Drawing 5
MOTOR: STEPPER, FEEDER
S10098
MOTOR: COMMON
S10097
BELTS: TRANSPORT KIT
S10091
RIBBON: DETECTION KIT (WITH CABLE)
S10087

Page 15
Spare Parts List Service Manual
FLIP-OVER: MODULE
S10128
ROLLER: CLEANING
S10122
SENSOR: FLIP OVER
S10121
ROLLER: HEAD KIT
S10099
Drawing 6

Page 16
Spare Parts List Service Manual
Drawing 7
PRINT HEAD: KPE
S10084
SENSOR: RIBBON
S10089
HEAD BRACKET
S10135
FAN: KIT
S10100
CABLE: PRINT HEAD
S10085

Page 17
Spare Parts List Service Manual
MAIN BOARD: USB ETH USB-HUB
S10114
Drawing 8
PACKAGING: BOX AND FOAM
S10127
Drawing 9

Page 18
Spare Parts List Service Manual
Product Code
CI010222
CI010214
S10086
S10124
S10126
S10092
S10094
S10097
CI011190
S10121
S10093
S10091
S10087
S10098
S10128
S10122
CI010322
SE010079
S10114
S10096
S10099
S10088
S10084
S10089
CI010205
CI010206
S10100
S10085
S10138
S10136
S10134
A5008
A5017
A5010
S10127
Name
Reject Box
Enclosure Side
LCD and Control Panel with Cable
Upper Blue Feeder
Exit Hopper Blue Feeder
Feeder Belts Kit
Tighting Belts Kit
Common Motor
Enclosure Base
Flip Over Sensor
Ribbon Braking Kit
Transport Belts Kit
Ribbon Detection Kit
Stepper/Feeder Motor
Flip Over Module
Cleaning Roller
I/O Shield
Enclosure Bottom Plate
Main Board: USB ETH USB HUB
Stepper Motor
Head Roller Kit
Flex Sensor Kit
Print Head (KPE)
Ribbon Sensor
Enclosure Cover
Enclosure Buttom
Fan Kit
Print Head Cable
Head Bracket
Universal Rivet Kit
Primacy WiFi Card
Power Supply
Data USB Cable
Power Cord Cable
Packaging: Box and Foam
Description
Without Power Cord
USB-1.80M Length
US Plug
Step
1
2
3
4
4
5
6
7-19-20
8
9
10
11
12
13
14
15
16
17
18
21
22
23
24
25
26
27
28
29
30

Page 19
Available Tools Service Manual
Flat screwdriver AR 2.5X75
Precision clamp
Torx
Flat Bolt
Picture 2: Tools

Page 20
Step 1 - Reject Box - C1010222 Service Manual
Picture 3: Reject Box
1. Lift the box to remove it.