Datacard®

9000/9000E/7000/7000E/5xx Series
Card Issuance Systems

Embosser Module
Maintenance Manual
February, 2004

Part No. 526392-001, Rev. J

Liability Statement
This product has been built to the high standards of Datacard Group. 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. Datacard 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 Datacard without notice.

Proprietary Notice
All drawings and information herein are the property of DataCard Corporation. All
unauthorized use and reproduction is prohibited.

Trademark Acknowledgments
Datacard is a registered trademark of DataCard Corporation.

Windows is a registered trademark of Microsoft Corporation.

All other product names are the property of their respective owners.

Datacard Group
11111 Bren Road West
Minnetonka, MN 55343-9015
952.933.1223
Fax: 952.933.7971
www.datacard.com

© 1992, 1994, 1996, 1998, 2001, 2002, 2003, 2004 DataCard Corporation.
All rights reserved. Printed in the United States of America.

ii
 Contents

Chapter 1: Introduction __________________________________________________________ 1-1

Intended Audience __________________________________________________________________ 1-2
Model Identification__________________________________________________________________ 1-2
Effective Serial Numbers ______________________________________________________________ 1-2
Related Documents__________________________________________________________________ 1-3
Use of This Manual ___________________________________________________________________ 1-3
Specifications________________________________________________________________________ 1-4
Electrical ________________________________________________________________________ 1-4
Physical _________________________________________________________________________ 1-4
Environmental ___________________________________________________________________ 1-4
ESD (electrostatic discharge) Susceptibility ________________________________________ 1-4
Wheel Characters _______________________________________________________________ 1-5
Supplies _____________________________________________________________________________ 1-6
Production Rates (Throughput)________________________________________________________ 1-7
700 CPH Embosser Module Throughput____________________________________________ 1-7
500 CPH Embosser/Topper Module Combination __________________________________ 1-8
Multiple Embosser Module Throughput ____________________________________________ 1-8
Examples of Throughput in Split Configuration _____________________________________ 1-9

Chapter 2: Installation ___________________________________________________________ 2-1

Site Preparation______________________________________________________________________ 2-2
Inspection Equipment ________________________________________________________________ 2-2
Unpacking Instructions _______________________________________________________________ 2-2
Installing the Embosser Module _______________________________________________________ 2-3
Installing Multiple Embossers in a System _______________________________________________ 2-4
Installing Option Kit(s) ________________________________________________________________ 2-4
Powering Up the Embosser Module____________________________________________________ 2-5
Installing Software____________________________________________________________________ 2-5
Backing Up Configuration and Setups _________________________________________________ 2-5
System Configuration CE Setups ______________________________________________________ 2-8
Functional Test: PC and System Software ______________________________________________ 2-9
Initial Checkout Procedures __________________________________________________________ 2-9
Running a Test Card _____________________________________________________________ 2-9
Initial Production Run ____________________________________________________________ 2-9

Chapter 3: Preventive Maintenance ______________________________________________ 3-1

Preventive Maintenance Procedures__________________________________________________ 3-2
Tools ________________________________________________________________________________ 3-2
Procedures for Powered-off Embosser _________________________________________________ 3-2

iii
 Procedures for Powered-on Embosser _________________________________________________ 3-5
Testing Module After Preventive Maintenance _________________________________________ 3-6

Chapter 4: Theory of Operations __________________________________________________ 4-1

Introduction _________________________________________________________________________ 4-2
System Overview_____________________________________________________________________ 4-2
General Functional Description _______________________________________________________ 4-4
Mechanical Sequence___________________________________________________________ 4-4
Electrical Sequence ____________________________________________________________4-17
Electrical Block Diagrams _______________________________________________________4-17
Optional Embosser OCR Indent Block Diagram ___________________________________4-22
Electrical Theory ____________________________________________________________________4-24
System I/O And Signal Flow______________________________________________________4-24
Circuit Schematics ______________________________________________________________4-30

Chapter 5: Troubleshooting_______________________________________________________ 5-1

Introduction _________________________________________________________________________ 5-2
Troubleshooting Guidelines ___________________________________________________________ 5-2
System Sequence ____________________________________________________________________ 5-3
Initialization Sequence ___________________________________________________________ 5-3
Production Cycle Sequence _____________________________________________________ 5-3
Card Feedthrough Sequence ____________________________________________________ 5-6
Power Down Sequence __________________________________________________________ 5-7
Common Fault Recovery _____________________________________________________________ 5-7
Incorrect Emboss Character Spacing ____________________________________________5-10
Missing/Light Indent _____________________________________________________________5-10
Diagnostic Routines _________________________________________________________________5-10
Embosser Diagnostics ___________________________________________________________5-11
Hardware Setup/Dwell __________________________________________________________5-11
Dwell Settings __________________________________________________________________5-13
Sensors _________________________________________________________________________5-15
EPROM/DLL Version _____________________________________________________________5-16
Offsets _________________________________________________________________________5-17
Exercise Diagnostic _____________________________________________________________5-18
Motor Diagnostic _______________________________________________________________5-18
Solenoid Diagnostic_____________________________________________________________5-19
Measuring Embossed Character Height ______________________________________________5-21
Error Code Message Procedures _____________________________________________________5-22
Accessing and Resetting the Error Log________________________________________________5-33

Chapter 6: Adjustments __________________________________________________________ 6-1

Introduction _________________________________________________________________________ 6-3
Initial Embosser Adjustments __________________________________________________________ 6-4
Card Guide Position Adjustment __________________________________________________ 6-4

iv
 Carriage Position Alignment Adjustment _________________________________________6-10
Card Gripper Opening Adjustment ______________________________________________6-12
Exit Beam Arm Adjustment ______________________________________________________6-14
Card Floor Plate Position Adjustment _____________________________________________6-16
Card Stop Solenoid Adjustment__________________________________________________6-18
Card Gripper Depth Adjustment _________________________________________________6-20
Card Carriage Movement Adjustment ___________________________________________6-22
Wheel Home Offset Adjustment _________________________________________________6-30
First Position (Emboss Margin) Offsets Adjustment__________________________________6-32
Module-to-Module Alignment ___________________________________________________6-34
Solenoid Hammer, Punch Side (Card Bow) Adjustment____________________________6-44
Solenoid Hammer, Die Side Adjustment __________________________________________6-46
Embosser Solenoid Noise Adjustment_____________________________________________6-50
Character Return Plate Pusher Adjustment _______________________________________6-52
Transport Cable Tension Adjustment _____________________________________________6-54
Transport Belt Tension Adjustment ________________________________________________6-56
Transport Output Roller Nip Pressure Adjustment __________________________________6-58
+24V DC Power Supply Output Adjustment ___________________________________________6-60
Mechanical Assembly Adjustments __________________________________________________6-62
Cam Solenoid Position Adjustment _______________________________________________6-62
Ribbon Low Flag Adjustment ____________________________________________________6-64
Drive Gear Backlash Adjustment_________________________________________________6-66
Ribbon Guide Clearance Adjustment ____________________________________________6-68
Ribbon Up Position Adjustment __________________________________________________6-70
Sense Arm Potentiometer Adjustment ____________________________________________6-72

Chapter 7: Removal and Replacement ___________________________________________ 7-1

Introduction _________________________________________________________________________ 7-3
Servicing Guidelines__________________________________________________________________ 7-4
Main Cabinet Assembly ______________________________________________________________ 7-5
Front and Rear Covers ___________________________________________________________ 7-5
Embosser Assembly ______________________________________________________________ 7-6
Solenoid Driver Assembly ________________________________________________________7-10
Embosser Controller Board Assembly _____________________________________________7-12
Horizontal Transport _________________________________________________________________7-14
Horizontal Transport Assembly ___________________________________________________7-14
Horizontal Transport Stepper _____________________________________________________7-16
Card Carriage/Carriage Cable__________________________________________________7-18
Card Carriage Rollers ___________________________________________________________7-20
Card Carriage Gripper Pins______________________________________________________7-22
Vertical Transport Assembly __________________________________________________________7-24
Transport Assembly _____________________________________________________________7-24
Vertical Transport Stepper _______________________________________________________7-26
Leadscrew/Split Nut ____________________________________________________________7-28
Embosser Wheel Assembly ___________________________________________________________7-30

v
 Wheel Assembly ________________________________________________________________7-30
Wheel Stepper _________________________________________________________________7-32
Wheel Punches or Dies __________________________________________________________7-34
Wheel Punch or Die Solenoids ___________________________________________________7-36
Card Transport Assembly ____________________________________________________________7-38
Transport Card Guide ___________________________________________________________7-38
Transport Card Stop/Solenoid ___________________________________________________7-40
Transport Drive Rollers/ Output Photocell _________________________________________7-42
Transport Nylon Gears___________________________________________________________7-44
Transport Drive Belt _____________________________________________________________7-46
Transport Stepper _______________________________________________________________7-48
Optional OCR Indent________________________________________________________________7-50
OCR Indent Assembly ___________________________________________________________7-50
OCR Indent Control Board ______________________________________________________7-52
OCR Indent Cam Solenoid and Cam ____________________________________________7-54
OCR Indent Ribbon Stepper Motor_______________________________________________7-56

Chapter 8: Illustrated Parts _______________________________________________________ 8-1

112-Character Emboss Module (599381-001) ___________________________________________ 8-2
112-Character Emboss Module, 5xx Series (599381-002) _________________________________ 8-3
112 Character Emboss Assembly (593459-001), Rev AE ____________________________8-13
Embosser Solenoid Assembly, 5 Ohm (590057-003), Rev AB ________________________8-19
Transport Assembly (593456-001), Rev T ___________________________________________8-21
Vertical Emboss Assembly (593457-001), Rev AM __________________________________8-23
Blank Embosser Wheel Assembly (593454-101), Rev A______________________________8-58
Card Carriage Assembly (590054-003), Rev M ____________________________________8-60
Emboss Module Type (599383) _______________________________________________________8-63
Punch and Die Installation Kits (593742-001 to 593742-044)_________________________8-63
Wheel/Type Set Character Mapping Table _______________________________________8-76
112 Character Installation Kit (593742)____________________________________________8-79
Wheel/Type Character Mapping (593742-001 to 593742-044) ______________________8-80
Front/Back Indent Print Module (593785)_____________________________________________8-123
Indent Print Assembly, Pivot Mount (593555-002) _________________________________8-123
Back Indent Print Kit (593785-007) _______________________________________________8-128
Front Indent Print Kit (593785-008) _______________________________________________8-130

List of Figures
Figure 2-1: Embosser Module Installation Locations.........................................................................2-4
Figure 4-1: Major Mechanical Assemblies ...........................................................................................4-3
Figure 4-2: Embosser Production Cycle Mechanical Sequence ........................................................4-9
Figure 4-3: OCR Indent Production Cycle Mechanical Sequence ..................................................4-15
Figure 4-4: Embosser +24 VDC Power Supply Block Diagram ......................................................4-18
Figure 4-5: Embosser System Inputs Block Diagram .......................................................................4-20

vi
Figure 4-6: Optional OCR Indent System Inputs/Outputs Block Diagram .................................4-23
Figure 4-7: Embosser 115V AC Power Interconnect Wiring Diagram ..........................................4-24
Figure 4-8: Embosser 230V AC Power Interconnect Wiring Diagram ..........................................4-25
Figure 4-9: Embosser Photocells/Hall Switch Input Wiring ..........................................................4-26
Figure 4-10: Embosser Stepper Motor Output Wiring.....................................................................4-27
Figure 4-11: Embosser Solenoids Output Wiring .............................................................................4-28
Figure 4-12: Optional OCR Indent Input/Output Signals Wiring.................................................4-29
Figure 4-13: +24V DC Power Supply Primary Circuits ...................................................................4-32
Figure 4-14: +24V DC Power Supply Secondary Circuits ...............................................................4-34
Figure 4-15: Embosser Control Board Block Diagram .....................................................................4-36
Figure 4-16: Embosser Control Board 80188 Processor Circuits.....................................................4-37
Figure 4-17: Embosser Control Board Gate Array Circuits.............................................................4-38
Figure 4-18: Embosser Control Board Emboss Solenoid IF Circuits..............................................4-39
Figure 4-19: Embosser Control Board Sensor Circuits.....................................................................4-40
Figure 4-20: Embosser Control Board 80C152 Circuits....................................................................4-41
Figure 4-21: Embosser Control Board Topper IF Circuits ...............................................................4-42
Figure 4-22: Embosser Control Board SLDC IF Circuits .................................................................4-43
Figure 4-23: Embosser Control Board Vertical Motor Circuits.......................................................4-44
Figure 4-24: Embosser Control Board Horz. & Vert. Motor Circuits.............................................4-45
Figure 4-25: Embosser Control Board +5V DC Supply & OCR IF Circuits ..................................4-46
Figure 4-26: Optional OCR Indent Control Board Circuits.............................................................4-50
Figure 4-27: Optional OCR Indent Control Board Circuits.............................................................4-51
Figure 6-1: Card Guide Position Adjustment......................................................................................6-5
Figure 6-2: View of Card Guide Relationship to Emboss Wheel .....................................................6-6
Figure 6-3: View of Card Guide Adjustment Screws and Procedures ............................................6-7
Figure 6-4: Card Carriage Position Alignment .................................................................................6-11
Figure 6-5: Card Gripper Opening Adjustment ...............................................................................6-13
Figure 6-6: Exit Beam Arm Adjustment.............................................................................................6-15
Figure 6-7: Card Floor Plate Position Adjustment ...........................................................................6-17
Figure 6-8: Card Stop Solenoid Adjustment......................................................................................6-19
Figure 6-9: Card Gripper Depth Adjustment....................................................................................6-21
Figure 6-10: Card Carriage Movement Adjustment.........................................................................6-23
Figure 6-11: Input Position (Card Pick) Offsets Adjustment ..........................................................6-25
Figure 6-12: Card Carriage Bump Springs Position Adjustment ...................................................6-27
Figure 6-13: Wheel Stepper Gear Backlash Adjustment..................................................................6-29
Figure 6-14: Wheel Home Offset Adjustment...................................................................................6-31
Figure 6-15: First Position (Emboss Margin) Offsets Adjustment..................................................6-33
Figure 6-16: Module-to-Module Alignment......................................................................................6-35
Figure 6-17: Output Position (Card Exit) Offsets Adjustment........................................................6-39
Figure 6-18: Solenoid Bumper Compression Tension Adjustment................................................6-43
Figure 6-19: Solenoid Hammer, Punch Side (Card Bow) Adjustment ..........................................6-45
Figure 6-20: Die Side Solenoid Hammer Adjustment......................................................................6-47
Figure 6-21: Solenoid Noise Adjustment ...........................................................................................6-51
Figure 6-22: Character Return Plate Pusher Adjustment ................................................................6-53
Figure 6-23: Horizontal Transport Cable Tension Adjustment ......................................................6-55
Figure 6-24: Transport Belt Tension Adjustment .............................................................................6-57
Figure 6-25: Transport Output Roller Nip Pressure Adjustment...................................................6-59
Figure 6-26: +24V DC Power Supply Output Adjustment..............................................................6-61
Figure 6-27: Cam Solenoid Position Adjustment..............................................................................6-63

vii
Figure 6-28: Ribbon Low Flag Adjustment........................................................................................6-65
Figure 6-29: Drive Gear Backlash Adjustment..................................................................................6-67
Figure 6-30: Ribbon Guide Clearance Adjustment...........................................................................6-69
Figure 6-31: Ribbon Up Position Adjustment ...................................................................................6-71
Figure 6-32: Sense Arm Potentiometer Adjustment.........................................................................6-73
Figure 7-1 : Front and Rear Covers.......................................................................................................7-5
Figure 7-2: Embosser Assembly ............................................................................................................7-9
Figure 7-3: Solenoid Driver Assembly ...............................................................................................7-11
Figure 7-4: Embosser Controller Board..............................................................................................7-13
Figure 7-5: Horizontal Transport Assembly......................................................................................7-15
Figure 7-6: Horizontal Transport Stepper .........................................................................................7-17
Figure 7-7: Card Carriage/Carriage Cable........................................................................................7-19
Figure 7-8: Card Carriage Rollers .......................................................................................................7-21
Figure 7-9: Card Carriage Gripper Pins .............................................................................................7-23
Figure 7-10: Vertical Transport Assembly .........................................................................................7-25
Figure 7-11: Transport Stepper............................................................................................................7-27
Figure 7-12: Vertical Transport Lead Screw/Split Nut....................................................................7-29
Figure 7-13: Wheel Assembly..............................................................................................................7-31
Figure 7-14: Wheel Stepper..................................................................................................................7-33
Figure 7-15: Wheel Punches and Dies ................................................................................................7-35
Figure 7-16: Punch or Die Solenoid ....................................................................................................7-37
Figure 7-17: Card Guide.......................................................................................................................7-39
Figure 7-18: Card Stop/Solenoid ........................................................................................................7-41
Figure 7-19: Drive Roller ......................................................................................................................7-43
Figure 7-20: Nylon Gears .....................................................................................................................7-45
Figure 7-21: Transport Drive Belt .......................................................................................................7-47
Figure 7-22: Transport Stepper............................................................................................................7-49
Figure 7-23: OCR Indent Assembly....................................................................................................7-51
Figure 7-24: OCR Indent Control Board ............................................................................................7-53
Figure 7-25: OCR Indent Cam Solenoid and Cam............................................................................7-55
Figure 7-26: OCR Indent Stepper Motor............................................................................................7-57
Figure 8-1: Embosser Module to Upstream Module Attachment ....................................................8-4
Figure 8-2: Solenoid Power Supply .....................................................................................................8-5
Figure 8-3: Solenoid Cabling .................................................................................................................8-6
Figure 8-4: Power Supply Terminal Wiring ........................................................................................8-7
Figure 8-5: AC Distribution PWB Assy and Power Supply Locations ............................................8-8
Figure 8-6: Distribution and I/O Board and Power Cabling...........................................................8-9
Figure 8-7: I/O and Serial Bus Cable Routing ..................................................................................8-10
Figure 8-8: Solenoid Driver Cover ......................................................................................................8-11
Figure 8-9: Shipping Bracket Locations .............................................................................................8-12
Figure 8-10: Embosser Frame Foam Strips and Hardware .............................................................8-14
Figure 8-11: Embosser Module to Frame Attachment .....................................................................8-15
Figure 8-12: Emboss PWB Assembly EPROM’s ...............................................................................8-16
Figure 8-13: Emboss PWB Assembly Installation Location ............................................................8-17
Figure 8-14: Embosser Module Cable Routing .................................................................................8-18
Figure 8-15: Embosser Solenoid Assembly (590057-003).................................................................8-20
Figure 8-16: Transport Assembly (593456-001).................................................................................8-22
Figure 8-17: Vertical Mount Subassembly.........................................................................................8-26
Figure 8-18: Spring Mount Subassembly...........................................................................................8-27

viii
Figure 8-19: Left Emboss Guide Bracket Subassembly (sheet 1) ....................................................8-28
Figure 8-20: Left Emboss Guide Bracket Subassembly (sheet 2) ....................................................8-29
Figure 8-21: Exit Stepper Motor Attachment ....................................................................................8-30
Figure 8-22: Exit Motor and Solenoid Subassembly ........................................................................8-31
Figure 8-23: Pressed Pins and Bearings .............................................................................................8-32
Figure 8-24: Embosser Module Pressed Parts ...................................................................................8-33
Figure 8-25: Embosser Card Guide Assembly ..................................................................................8-34
Figure 8-26: Embosser Frame Subassembly ......................................................................................8-35
Figure 8-27: Front Frame Attachments ..............................................................................................8-36
Figure 8-28: Rear Frame Attachments (sheet 1) ................................................................................8-37
Figure 8-29: Rear Frame Attachments (sheet 2) ................................................................................8-38
Figure 8-30: Card Guide and Solenoid Installation Locations........................................................8-39
Figure 8-31: Card Guide Adjustment .................................................................................................8-40
Figure 8-32: Output Rollers Adjustment Locations .........................................................................8-41
Figure 8-33: Embosser Module Support Beams................................................................................8-42
Figure 8-34: Front Emboss Solenoid Wiring......................................................................................8-43
Figure 8-35: Rear Emboss Solenoid Grounding................................................................................8-44
Figure 8-36: Pivot Shaft Assembly......................................................................................................8-45
Figure 8-37: Transport and Motor Shaft Collar Clamp Assembly .................................................8-46
Figure 8-38: Carriage Position Adjustment .......................................................................................8-47
Figure 8-39: Card Floor Plate Adjustment.........................................................................................8-48
Figure 8-40: Carriage Anti-Rotate Block Adjustment ......................................................................8-49
Figure 8-41: Card Gripper Adjustment..............................................................................................8-50
Figure 8-42: Solenoid Collar Grip Adjustment .................................................................................8-51
Figure 8-43: Exit Roller Arm Adjustment ..........................................................................................8-52
Figure 8-44: Card Stop Solenoid Adjustment....................................................................................8-53
Figure 8-45: Embosser Module Wiring ..............................................................................................8-54
Figure 8-46: Embosser Module Wiring Routing (sheet 1) ...............................................................8-55
Figure 8-47: Embosser Module Wiring Routing (sheet 2) ...............................................................8-56
Figure 8-48: Fan Assembly and Label Locations ..............................................................................8-57
Figure 8-49: Blank Embosser Wheel Assembly (593454-101)..........................................................8-59
Figure 8-50: Card Carriage Roller Subassembly, 590054-003 (sheet 1)..........................................8-61
Figure 8-51: Card Carriage Roller Subassembly, 590054-003 (sheet 2)..........................................8-62
Figure 8-52: Wheel/Type Character Mapping List, Revision Levels, and Notes ........................8-78
Figure 8-53: Wheel Character Slot Order...........................................................................................8-79
Figure 8-54: TYPE, FAR 7B/STD GOTHIC (593742-001) ................................................................8-80
Figure 8-55: TYPE, 7B/SG/OCR A INDENT (593742-002).............................................................8-81
Figure 8-56: TYPE, 7B/SG/OCR B INDENT (593742-003) .............................................................8-82
Figure 8-57: TYPE, HOSPITAL (593742-004) ....................................................................................8-83
Figure 8-58: TYPE, OCR B 4 (593742-005)..........................................................................................8-84
Figure 8-59: TYPE, LARGE GOTHIC (593742-006) ..........................................................................8-85
Figure 8-60: TYPE, JAPAN, 104 CHAR (593742-007), Inactive.......................................................8-86
Figure 8-61: TYPE, JAPAN, 112 CHAR (593742-008), Inactive.......................................................8-87
Figure 8-62: TYPE, OCR B 4 INDENT –FRONT (593472-009) ........................................................8-88
Figure 8-63: TYPE, OCR A 1 INDENT –FRONT (593742-010) .......................................................8-89
Figure 8-64: TYPE, JAPAN, 52 CHAR (593742-011).........................................................................8-90
Figure 8-65: TYPE, 7B S, GOTH/OCR B4 (593742-012)...................................................................8-91
Figure 8-66: TYPE, 7B S, GOTH/OCR B4/L (593742-013) ..............................................................8-92
Figure 8-67: TYPE, 7B/S, GOTH/OCR B4 (593742-014) .................................................................8-93

ix
Figure 8-68: TYPE, S, GOTH/L. GOTH (593742-015) ......................................................................8-94
Figure 8-69: TYPE, VIN & STD GOTHIC (593742-016) ...................................................................8-95
Figure 8-70: TYPE, FAR 7B/STD GOTHIC MC INDENT/OCR A INDENT (593742-017)........8-96
Figure 8-71: TYPE, STD GOTHIC KAT, OCR B4 MC INDENT (593742-018), Inactive ..............8-97
Figure 8-72: TYPE, 7B/SG/OCRA/OCRA INV (593742-019) ........................................................8-98
Figure 8-73: TYPE, 7B/SG/MC INDENT /MC IND INV (593742-020)........................................8-99
Figure 8-74: TYPE, 7B/SG/OCRA/OCRA INV/MC/MC INV (593742-021) ...........................8-100
Figure 8-75: TYPE, 7B/SG/OCRA/OCRA INV/MC INV (593742-022) ....................................8-101
Figure 8-76: TYPE, 7B/SG/OCR A AND INV (593742-023).........................................................8-102
Figure 8-77: TYPE, 7B/SG/MC INDENT (593742-024).................................................................8-103
Figure 8-78: TYPE, 7B/SG/MC INDENT INV (593742-025) ........................................................8-104
Figure 8-79: TYPE, 7B/SG/KAT/OCR B4/OCR A1 IND (593742-026), Inactive......................8-105
Figure 8-80: TYPE, 7B/SG/KAT/OCR B4/MC IND INV (593742-027), Inactive .....................8-106
Figure 8-81: TYPE, 7B/SG/KAT/OCR B4/OCR A1 INV (593742-028), Inactive......................8-107
Figure 8-82: TYPE, 7B/SG/MC IND INV/OCR A1 INV (593742-029).......................................8-108
Figure 8-83: FAR 7B STD GOTHIC/8 PT HELVETICA IND –FRONT (593742-030)................8-109
Figure 8-84: TYPE, JAPAN 104 CHA KAT II (593742-032) ...........................................................8-110
Figure 8-85: TYPE, JAPAN 112 CHA KAT II (593742-033) ...........................................................8-111
Figure 8-86: TYPE, STD, GOTHIC KAT II OCRB4 MC INDENT (593742-034) .........................8-112
Figure 8-87: TYPE, 7B/SG/KAT II/OCRB4/OCR A1 IND (593742-035) ...................................8-113
Figure 8-88: TYPE, 7B/SG/KAT II/OCRB4/MC IND INV (593742-036)...................................8-114
Figure 8-89: TYPE, 7B/SG/KAT II/OCRB4/OCR A1 INV (593742-037) ...................................8-115
Figure 8-90: TYPE, OCRB1 INDENT (593742-038).........................................................................8-116
Figure 8-91: TYPE, CYRILLIC (593742-039) ....................................................................................8-117
Figure 8-92: TYPE, 7B/SG/OCR B1 IND/OCR B4 IND (593742-040) ........................................8-118
Figure 8-93: TYPE, 7B/SG/MC/MC INV/OCR A1 (593742-041) ...............................................8-119
Figure 8-94: TYPE, FAR 7B, VIND (593742-042).............................................................................8-120
Figure 8-95: TYPE, INDENT B1, INDENT B4, HELV (593742-043) .............................................8-121
Figure 8-96: TYPE, IND B1, B4, FAR, STD GOTH (593742-044)..................................................8-122
Figure 8-97: Adapter Plate Assembly...............................................................................................8-126
Figure 8-98: Indent Print Assembly..................................................................................................8-127
Figure 8-99: Rear Indent Print Kit.....................................................................................................8-129
Figure 8-100: Front Indent Print Kit .................................................................................................8-131

List of Tables
Table 3-1: Embosser Power-off PM Procedures..................................................................................3-3
Table 3-2: Embosser Module Power-on PM Procedures ...................................................................3-5
Table 3-3: Evaluating Test Cards ..........................................................................................................3-6
Table 5-1: Common Problems, Causes, Adjustments ........................................................................5-8
Table 5-2: Dwell and Amp Settings for Vendor Punches and Dies ...............................................5-13
Table 5-3: Error Code Message Recovery Procedures .....................................................................5-23

x
 Revision Log
Embosser Module Maintenance Manual

Revision Date Affected Description of Changes

Pages

A June 1992 All First release of this document.

B Nov. 1994 Chapters 4 Updated mechanical procedures to reflect

and 6 new menu items.

C Nov. 1996 Chapter 6 Revised adjustment procedures.

D Oct. 1998 All Complete manual recovery.

E March 2001 Chapter 6 Repair graphics.

F January 2002 All Update for Indent module changes.

G November Chapters 5 Change the wording of error messages; fix

2002 and 8 colored drawings; add information about new
punch and die kits and dwell times.

H January 2003 Pages 3-6 Fixed ISO character height and added
and 5-21 measuring procedure to Chapter 5.

J February Chapters 5 Updated error messages and illustrated parts.

2004 and 8

Regulatory Compliance
Notice for USA (FCC Notice)
This equipment generates, uses, and can radiate radio frequency energy. If it is not
installed and used in accordance with this instruction manual, it may interfere with
radio communications. This equipment has been tested and found to be within the
limits for Class A computing devices, pursuant to Title 47 CFR Part 15 Subpart B of
FCC rules, designed to provide reasonable protection against radio interference in a
commercial environment. Operation of this equipment in a residential environment
may possibly cause interference. In the event of interference, the user, at his/her
own expense, will be required to take whatever measures are necessary to correct the
problem.

Notice for Canada

This digital apparatus does not exceed the Class A limits for radio noise for digital
apparatus set out in the Radio Interference Regulations of the Canadian Department
of Communications.

xi
 Le présent appareil numérique n'émet pas de bruits radioélectriques dépassant les
limites applicables aux appareils numériques de la classe A prescrites dans le
Règlement sur le brouillage radioélectrique édicté par le ministère des
Communications du Canada.

Safety
All Datacard products are built to strict safety and reliability specifications in
accordance with UL1950 and CUL requirements; therefore, safety issues pertaining
to operation and repair of Datacard equipment are primarily environmental and
human interface.

The following basic safety tips are given to ensure safe installation, operation and
maintenance of Datacard equipment and are not to be considered as comprehensive
on all matters of safety.

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 floors in 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.

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.

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