Datacard® Maxsys® Card

Issuance System

Embossing/Indent Module
Service Manual

October 2009

Part No. 539209-001, Rev G

Liability Statement
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.

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 and service mark of DataCard Corporation in
the United States and other countries.

Maxsys is a registered trademark of DataCard Corporation.

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

Datacard Group
11111 Bren Road West
Minnetonka, MN 55343-9015
Phone: 952-933-1223
Fax: 952-933-7971
www.datacard.com

© 2003-2009 DataCard Corporation. All rights reserved.

Printed in the United States of America.

ii
 Contents
Chapter 1: Introduction __________________________________________ 1-1
Module Description ___________________________________________________ 1-2
Component Functions_________________________________________________ 1-3
Card Transport ____________________________________________________ 1-3
Embossing Wheel Assembly ________________________________________ 1-3
Front and Rear Drivers _____________________________________________ 1-3
Indent Assembly __________________________________________________ 1-3
Device Specifications _________________________________________________ 1-4
General Specifications ____________________________________________ 1-4
Motors ____________________________________________________________ 1-5
Sensors and Encoders _____________________________________________ 1-7
Communication Boards ___________________________________________ 1-9
Microprocessor Board_________________________________________ 1-11
Control Boards _______________________________________________ 1-12
Resolver Board _______________________________________________ 1-13
Driver Board (48 V)____________________________________________ 1-14
AC Distribution/Communication Board ________________________ 1-15
Power-Plane Configuration _______________________________________ 1-16
Sequence of Operation ______________________________________________ 1-17
Safety Issues_________________________________________________________ 1-18
Electrical Power Lockout__________________________________________ 1-18
Electric Shock Warning ___________________________________________ 1-18
Electrostatic Discharge Precaution ________________________________ 1-19
Equipment Warning Labels _______________________________________ 1-19
Chapter 2: Troubleshooting_______________________________________ 2-1
Card Jam Recovery___________________________________________________ 2-2
Troubleshooting Symptoms/Problems __________________________________ 2-3
Cards Not Entering the Module Properly ____________________________ 2-3
Cards Not Transporting Through the Module Properly ________________ 2-5
Card Overshoots Intended Position_________________________________ 2-6
Uneven Character Positioning _____________________________________ 2-7
Characters Emboss on Top of Each Other __________________________ 2-8
Uneven Character Line Height _____________________________________ 2-9
Characters are Wavy, Form an Arch, or Droop Across the Card __ 2-9
Character Line Height Steadily Droops _________________________ 2-10
Vertical Lift Jumps Periodically_________________________________ 2-10
Character Line Steadily Decreases from Card to Card __________ 2-10
Character Positioning Errors Consistent from Card to Card ______ 2-10
Uneven Character Relief Height___________________________________ 2-11
Relief Height Problem Consistent on Certain Characters ____________ 2-11
Incorrect Horizontal or Vertical Margins ____________________________ 2-11
Excessively Bowed Cards _________________________________________ 2-12

iii
 Bowed Toward the Raised Characters _________________________ 2-12
Bowed Away from the Raised Characters______________________ 2-12
Wheel or Cam Home Error ________________________________________ 2-13
Modifying an Entire Column of Characters_________________________ 2-14
Modifying Selected Characters ___________________________________ 2-15
Diagnostics __________________________________________________________ 2-16
Accessing Diagnostics ____________________________________________ 2-16
Testing Sensors ___________________________________________________ 2-17
Exercising the Module ____________________________________________ 2-18
Saving an Exercise Routine________________________________________ 2-21
Configuring the Module ______________________________________________ 2-22
Setting the Tabbed Belt Type______________________________________ 2-22
Setting the Cam Motor Type ______________________________________ 2-22
Setting the Wheel Motor Revision__________________________________ 2-23
Setting High Resolution Motors ____________________________________ 2-23
Disabling/Enabling a Module _____________________________________ 2-23
Chapter 3: Adjustments __________________________________________ 3-1
Mechanical Adjustments ______________________________________________ 3-2
General Belt Tension Adjustment ___________________________________ 3-2
Card Guide Alignment ____________________________________________ 3-3
Debow Guide Position _____________________________________________ 3-5
Software Adjustments _________________________________________________ 3-6
Character Position Offset __________________________________________ 3-6
Tabbed Belt Home Setting Adjustment _____________________________ 3-7
Minimum Cam Position ____________________________________________ 3-8
Driver Cam Detent Position ________________________________________ 3-9
Wheel Home Offset ______________________________________________ 3-10
Wheel Table Configurations_______________________________________ 3-11
Wheel Lift Home Offset ___________________________________________ 3-12
Wheel VKPO Offset _______________________________________________ 3-13
Indent Tilt Offsets _________________________________________________ 3-14
Card Feature Gauge _________________________________________________ 3-15
Chapter 4: Removal and Replacement ___________________________ 4-1
Electrical Power Lockout ______________________________________________ 4-3
Servicing Guidelines __________________________________________________ 4-4
Major Assemblies _____________________________________________________ 4-5
Module Platform Assembly_________________________________________ 4-5
Embossing Wheel _________________________________________________ 4-7
Wheel Characters _________________________________________________ 4-9
Character Return Plates and Springs ______________________________ 4-12
Entry Roller Assembly _____________________________________________ 4-15
Tab Belt Drive Assembly___________________________________________ 4-16
Front Driver Assembly _____________________________________________ 4-18
Rear Driver Assembly _____________________________________________ 4-19

iv
Module Assemblies __________________________________________________ 4-20
Sensors and Encoders ________________________________________________ 4-21
Card Entry/Exit Sensors and Front/Rear Cam Home Sensors _________ 4-21
Tabbed Belt Home Sensor ________________________________________ 4-22
Wheel Home Sensor ______________________________________________ 4-24
Wheel Lift Home Sensor ___________________________________________ 4-25
Interlock Sensor __________________________________________________ 4-26
Wheel Lift Position Encoder _______________________________________ 4-27
Tabbed Belt Encoder _____________________________________________ 4-28
Motors, Belts, and Pulleys _____________________________________________ 4-30
Card Entry Motor _________________________________________________ 4-30
Card Entry Pulleys, Belt, Gears, and Bearings _______________________ 4-31
Tabbed Belt Drive Components (Earlier Revisions) __________________ 4-33
Motor, Pulley, and Tabbed Belt ________________________________ 4-33
Bearings______________________________________________________ 4-34
Tabbed Belt Drive Components (Revision 4) _______________________ 4-36
Motor, Pulley, and Tabbed Belt ________________________________ 4-36
Bearings______________________________________________________ 4-37
Wheel Lift Motor__________________________________________________ 4-38
Front Cam Motor and Cam _______________________________________ 4-39
Rear Cam Motor and Cam _______________________________________ 4-42
Wheel Motor _____________________________________________________ 4-45
Bearings and Gears __________________________________________________ 4-48
Driver Shafts and Return Springs ___________________________________ 4-48
Wheel Lift Leadscrew and Bearings________________________________ 4-51
Wheel Lift Drive Gears ____________________________________________ 4-55
Wheel Lift Linear Rails and Bearing Blocks __________________________ 4-56
Isolation Mounts __________________________________________________ 4-60
Electronics __________________________________________________________ 4-63
Control Boards ___________________________________________________ 4-63
Microprocessor Board and Memory Chip __________________________ 4-65
I-Button Board____________________________________________________ 4-68
300-Volt Driver Board _____________________________________________ 4-70
48-Volt Driver Board ______________________________________________ 4-72
AC Distribution Board _____________________________________________ 4-74
Embosser Resolver Board _________________________________________ 4-75
Power Supply ____________________________________________________ 4-77
Module Computer Enclosure______________________________________ 4-79
Indent Module Assemblies ___________________________________________ 4-82
Indent Assembly _________________________________________________ 4-82
Indent Assembly (Without Power) _________________________________ 4-84
Ribbon Diameter Encoders and Loading Springs ___________________ 4-87
Ribbon Encoder__________________________________________________ 4-89
Ribbon Replacement Procedure __________________________________ 4-91
Tilt Up and Tilt Home Sensors ______________________________________ 4-92

v
 Encoder Driver Board _____________________________________________ 4-94
Indent I-Button Board _____________________________________________ 4-96
Chapter 5: Preventive Maintenance ______________________________ 5-1
Service Engineer Maintenance Schedule_______________________________ 5-2
Checking Cam Driver Guide Bearing Clearance________________________ 5-3

vi
 Revision Log
Maxsys® System Embossing/Indent Module Service Manual

Revision Date Description of Changes

A June 2003 First release of this document.

B July 2003 Updated for final product release.

C April 2004 Update references to CUL.

D July 2004 General updates.

E May 2005 Updated for reorganization of information.

F November 2007 General updates.

G October 2009 Updated for tab belt assembly changes.

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 users, at their 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. The term "IC:" before the equipment
certification number only signifies that the Industry Canada technical
specifications were met.

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.

vii
Safety
All Datacard products are built to strict safety and reliability specifications in
accordance with UL60950-1 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 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 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.

viii
Chapter 1: Introduction

This chapter provides a description of the Maxsys Embossing/

Indent module. Information includes a description of the module
and its components, the sequence of operation, and specifications.

Module Description __________________________________________________ 1-2

Component Functions ________________________________________________ 1-3
Card Transport ____________________________________________________ 1-3
Embossing Wheel Assembly ________________________________________ 1-3
Front and Rear Drivers _____________________________________________ 1-3
Indent Assembly___________________________________________________ 1-3
Device Specifications ________________________________________________ 1-4
General Specifications_____________________________________________ 1-4
Motors ____________________________________________________________ 1-5
Sensors and Encoders______________________________________________ 1-7
Communication Boards____________________________________________ 1-9
Microprocessor Board _________________________________________ 1-11
Control Boards________________________________________________ 1-12
Resolver Board________________________________________________ 1-13
Driver Board (48V) ____________________________________________ 1-14
AC Distribution/Communication Board _________________________ 1-15
Power-Plane Configuration _______________________________________ 1-16
Sequence of Operation _____________________________________________ 1-17
Safety Issues ________________________________________________________ 1-18
Electrical Power Lockout __________________________________________ 1-18
Electric Shock Warning ___________________________________________ 1-18
Electrostatic Discharge Precaution ________________________________ 1-19
Equipment Warning Labels ________________________________________ 1-19

Maxsys Embossing/Indent Module Service Manual 1-1

Module Description
The basic function of the Maxsys Embossing/Indent module is to create
embossed characters on the front side of a plastic card, or to create indented
characters (with optional Indent module) on the front and rear side of a plastic
card. An Embossing module is capable of embossing a single line location per
card. One Embossing module is required for each line of data to be embossed.

The major mechanisms of the module are shown in the figure below.

Component Functions

1-2 Introduction
Component Functions
Card Transport
A pair of entry rollers brings a card into the Embossing/Indent module and
positions it at the entry position where control is passed to the tabbed belt. The
tabbed belt moves the card through the embossing area and to the module exit.

Embossing Wheel Assembly

The embossing wheel assembly consists of the character wheel, a servo motor,
and a wheel lift mechanism. The character wheel contains punch and die
characters for embossing, or punch and anvil characters for indenting. The
rotational position of the character wheel is controlled by a direct drive servo
motor. Wheel position feedback is provided by the servo motor’s built-in
resolver. (A resolver is similar to an encoder, except the signal is a 2-phase analog
sine wave instead of digital signals.)

To control the line height position of the embossed characters, the entire wheel
assembly is raised or lowered on a set of linear rails. The height is controlled by a
leadscrew and stepper motor. The line height can be adjusted on a card-by-card
basis, but cannot be adjusted during personalization of a card.

Front and Rear Drivers

The front and rear drivers impact on the wheel characters to create an embossed
(or indented) character on the card. The drivers are actuated by cam disks, which
are rotated by servo motors.

Indent Assembly
The Indent assembly is an optional addition to a module. It may be mounted on
the front and rear of the Embossing module for indenting the front and rear face
of a card.

The Indent assembly has imprinting ribbon that makes the indented characters
more visible.

Maxsys Embossing/Indent Module Service Manual 1-3

Device Specifications
General Specifications
Specification Type Value Comments

Electrical Requirements 2.7 Amps @ 230 V AC Without Indent Option

Electrical Requirements 2.9 Amps @ 230 V AC With Indent Option

Weight 157 pounds (71.2 kg) Without Indent Option

Weight 163 pounds (73.9 kg) With Indent Option

Module Width 9 inches (22.86 cm)

Module Speed 2000 cards per hour With a 16-character line

1-4 Introduction
Motors
The following motors are used in the Embossing/Indent module.

Motor Name Functional Description

Tab Transport Transports a card across the module and positions it for character
embossing.

Entry Roller Brings a card into the module.

Vertical Lift Raises and lowers the embossing assembly for a specific line
height.

Indent Ribbon Advance Controls ribbon movement in the optional Indent assembly.

Indent Tilt Lift the Indent assembly for ease in loading ribbon.

Cam Driver Servos Drives the front and rear cams (J23 on Control Board).

Wheel Lift Servo Drives the character wheel (J3 on Resolver Board).

Maxsys Embossing/Indent Module Service Manual 1-5

1-6 Introduction
Sensors and Encoders
The following sensors and encoders are used in the Embossing/Indent module.

Name Purpose

Card Entry Detects a card at the entry.

Card Exit Detects a card at the exit.

Tabbed Belt Home Detects the belt tabs on the Card Transport Belt to define home
positions.

Wheel Home Detects when the Embossing Wheel is in the home position.

Front Cam Home Detects when the cam is in the home (retracted) position.

Rear Cam Home Detects when the cam is in the home (retracted) position.

Wheel Lift Home Detects when the Vertical Lift Assembly is in the home (lowered)
position.

Indent Take-Up Arm Detects when the take-up roll is full.

Position Encoder

Indent Supply Arm Detects when the supply ribbon is low.

Position Encoder

Indent Ribbon Advance Tracks ribbon advances to protect against voids in the indented
Encoder characters.

Maxsys Embossing/Indent Module Service Manual 1-7

1-8 Introduction
Communication Boards
Several boards are located in slots of the module computer enclosure (card cage).
The following communication boards are used in the Embossing/Indent module.

Name Functional Description Location

Microprocessor Board Includes an Ethernet connection, and Slot 1

processes control signals to/from the AC
distribution board.

Resolver Board Powers all signals to/from the wheel motor, and Slots 2 and 3
the front and rear cam motors.

Control Boards Processes all module activity and system level Slots 4 and 5
communications. Powers all module functions
with an integrated power supply.

48 V Driver Board Provides the power for the servo motors. Left of enclosure

AC Distribution Board Controls power in the module. Back of frame

300 V Driver Board Board in the 24 V power supply to drive wheel Back of frame
home motor.

Indent Board Controls communication for the optional Indent Inside back cover
module. of Indent

Maxsys Embossing/Indent Module Service Manual 1-9

1-10 Introduction
Microprocessor Board
Connections to the module microprocessor board, located in slot 1 of the module
computer enclosure, are listed in the following table and shown in the following
diagram.

Connector Name

SER 0 From AC Distribution Board

Fast Ethernet To/from Controller

Maxsys Embossing/Indent Module Service Manual 1-11

Control Boards
Connections to the control boards, located in slots 4 and 5 of the enclosure, are
listed in the following table and shown in the following diagram with the part
numbers of cables that connect to them.

Connector Slot 4 Slot 5

J4 Compact PCI Backplane

J6 Misc. I/O Option Kit (566639-001)or Option Kit (566638-001) or

Front Indent (566595-001) Rear Indent (566596-001)

J15 Sensors Indent Cable (566504- Mechanism Cable

001) (566573-001)

J16 Voltage Regulator Board

J21 Encoders Indent (566636-001) Mechanism Cable

Non-Indent (566594-001) (566503-001)

J22 Servo Motors Cam (566635-001) Wheel (566633-001)

J23 Stepper Motors Indent (566502-001) Embosser (566501-001)

1-12 Introduction
Resolver Board
Connections to the resolver board, located in slots 2 and 3 of the enclosure, are
listed in the following table and shown in the following diagram.

Connector Name

J3 Wheel Motor

J4 Front/Rear Cam Motors and Control Board

Maxsys Embossing/Indent Module Service Manual 1-13

Driver Board (48 V)
Connections to the 48 V driver board, located on the left side of the enclosure, are
shown in the following diagram.

1-14 Introduction
AC Distribution/Communication Board
Connections to the AC distribution/communication board, located at the back of
the module, are listed in the following table and shown in the following figure.

Connector Name

J1 Power to Upstream J2

J2 Power to Downstream J1

J4 Power Supply

J5 Upstream Module Signal

J6 Downstream Module Signal

J7 Board Enclosure (Card Cage)

J9 LED

J10 SER 0 on Microprocessor Board

J12 Module VPD

J13 Interlock Switch

Maxsys Embossing/Indent Module Service Manual 1-15

Power-Plane Configuration
Functional Name Voltage Source Primary Purpose

V1 Interlocked 24V DC Parallel A and B power supplies Steppers 1 and 2

V2 Interlocked 24V DC Parallel A and B power supplies Steppers 3 and 4

Solenoids 1 and 2

V3 Interlocked 24V DC Interconnected to V2 Interlocked Servos 1 and 2

Solenoids 3 and 4

Cam Driver 48V DC Series C and D power supplies Cam Driver Board

Wheel Driver 300V DC Switched AC On Power Distribution Wheel Motor Driver

Board Board

Power-Plane Assignment
Device Function Device Name Power-plane

Entry Roller Motor Slot 5, Step Motor 1 V1 Interlocked

Tab Transport Motor Slot 5, Step Motor 2 V1 Interlocked

Vertical Lift Motor Slot 5, Step Motor 3 V2 Interlocked

Front Indent Take-up Motor Slot 4, Step Motor 3 V2 Interlocked

Front Indent Tilt Motor Slot 4, Step Motor 4 V2 Interlocked

Rear Indent Take-up Motor Slot 4, Step Motor 1 V1 Interlocked

Rear Indent Tilt Motor Slot 4, Step Motor 2 V1 Interlocked

1-16 Introduction
Sequence of Operation
The Embossing/Indent module uses punches and dies to emboss alphanumeric
characters onto plastic cards.

Main Process

This sequence assumes that the Embossing/Indent module has just been reset
and that no cards are present in the module.

1. Receive the Transfer-In command from production control.

2. Start the entry rollers and issue the Ready-To-Receive command.

3. Issue the Transfer-Complete command when the card is seen by the entry
sensor.

4. Advance the tabbed belt to position the card for the first character.

5. Rotate the character wheel to the appropriate character.

6. Simultaneously advance both front and rear drivers to emboss the current
character.
7. Advance the tabbed belt to the next character location.

8. Repeat the embossing process for each character in the line of text.

9. When the embossed text line is complete, transfer the card to the Exit Staging
area via the tabbed belt.

10. Issue Process-Complete command.

11. Receive Transfer-Out command.

12. Advance the tabbed belt to push the card into next module.

13. When the exit sensor detects the trailing edge of the card, issue the Transfer-
Complete command.

Maxsys Embossing/Indent Module Service Manual 1-17

Safety Issues
Electrical Power Lockout
Any time service is being performed on the Maxsys system, especially the rear
enclosure where high voltage power is present, the incoming power should be
locked out to prevent someone else from inadvertently energizing the electrical
system.

Procedure
1. Shut down the Controller and turn off the power.

2. Switch the main circuit breaker on the back of the Controller to the OFF
position.

3. Flip the lockout bar up to the locked position. Note that the circuit breakers
cannot be returned to the ON position when the lockout bar is in the locked
position.
4. Lock the lockout bar. The lockout bar will not stay in the locked position
without an external lock.

• Each person servicing the system should have a personal lock.

• Never remove someone else’s lock from a lockout.

Electric Shock Warning

To avoid a possible electric shock, always disconnect the power to the
Embossing/Indent module before servicing the module. Lock out the
system power as described above.

1-18 Introduction
Electrostatic Discharge Precaution
While working around circuit boards and other sensitive components, use proper
equipment and procedures to reduce the possibility of damaging the
components. Avoid electrostatic damage by wearing a grounded wrist strap
when removing a board. Place the board on a grounded, anti-static mat after
removal.

Equipment Warning Labels

When servicing the Embossing/Indent module, observe the following warning
and caution labels affixed to various areas of the equipment. For more safety
information, refer to “Maxsys Safety Rules” on the Maxsys Service Library CD.

Warning Label Description

High Voltage Power Supply

• This warning label is found on parts that contain a
high voltage current. To avoid a possible electric
shock, always remove power from the module (as
well as from the Controller) before servicing.

Pinch-Point
• This warning label is found on moving parts that
can potentially crush and cut. Do not operate
with the guard removed. Follow the shutdown
procedure before servicing.

Maxsys Embossing/Indent Module Service Manual 1-19

1-20 Introduction
Chapter 2: Troubleshooting

This chapter provides troubleshooting procedures for the Maxsys

Embossing/Indent module.

Card Jam Recovery __________________________________________________ 2-2

Troubleshooting Symptoms/Problems _________________________________ 2-3
Cards Not Entering the Module Properly ____________________________ 2-3
Cards Not Transporting Through the Module Properly ________________ 2-5
Card Overshoots Intended Position _________________________________ 2-6
Uneven Character Positioning______________________________________ 2-7
Characters Emboss on Top of Each Other ___________________________ 2-8
Uneven Character Line Height _____________________________________ 2-9
Characters are Wavy, Form an Arch, or Droop Across the Card __ 2-9
Character Line Height Steadily Droops _________________________ 2-10
Vertical Lift Jumps Periodically _________________________________ 2-10
Character Line Steadily Decreases from Card to Card __________ 2-10
Character Positioning Errors Consistent from Card to Card ______ 2-10
Uneven Character Relief Height ___________________________________ 2-11
Relief Height Problem Consistent on Certain Characters ____________ 2-11
Incorrect Horizontal or Vertical Margins ____________________________ 2-11
Excessively Bowed Cards _________________________________________ 2-12
Bowed Toward the Raised Characters _________________________ 2-12
Bowed Away from the Raised Characters ______________________ 2-12
Wheel or Cam Home Error ________________________________________ 2-13
Modifying an Entire Column of Characters _________________________ 2-14
Modifying Selected Characters ___________________________________ 2-15
Diagnostics _________________________________________________________ 2-16
Accessing Diagnostics ____________________________________________ 2-16
Testing Sensors ___________________________________________________ 2-17
Exercising the Module ____________________________________________ 2-18
Saving an Exercise Routine ________________________________________ 2-21
Configuring the Module _____________________________________________ 2-22
Setting the Tabbed Belt Type ______________________________________ 2-22
Setting the Cam Motor Type ______________________________________ 2-22
Setting the Wheel Motor Revision __________________________________ 2-23
Setting High Resolution Motors_____________________________________ 2-23
Disabling/Enabling a Module______________________________________ 2-23

Maxsys Embossing/Indent Module Service Manual 2-1

Card Jam Recovery
The Maxsys system is designed to recover automatically from card jams.
However, if automatic jam recovery is unsuccessful, manual intervention is
needed to remove the card(s). As long as the system integrity remains intact, the
remaining cards in the system will be retained.

As soon as a module reports a card jam, the Controller notifies all modules to
prepare for jam recovery. All modules must park their cards under a sensor so
that the system can detect if the card has been moved by the user. To maintain
system integrity, all modules are placed on alert to watch for sensor transitions
that indicate cards have been tampered with.

Every module within a Maxsys system is designed so that a jammed card can be
removed directly from the module without impacting other modules. To remove
a card from the embossing module, lift the upper card track and remove the card.

2-2 Troubleshooting
Troubleshooting Symptoms/Problems
This section is intended to provide the trained technician with general fault
isolation procedures based on known Embossing/Indent module problem
symptoms, the possible cause(s) of the problem, and the corrective action(s) to be
taken.

After taking any corrective action, you should run cards through the module to
test whether the problem has been solved.

More detailed procedures for identifying possible causes and corrective action for
the symptom or problem may be found in:

• Other chapters of this manual

• The Maxsys System and Controller Service Manual

Cards Not Entering the Module Properly

Improper card entry to the Embossing/Indent module is usually due to failure of
the entry rollers and associated drive components, or to module-to-module
misalignment.

Maxsys Embossing/Indent Module Service Manual 2-3

 Possible Causes Corrective Actions

Entry Rollers 1. Inspect and clean the entry rollers.

2. Make sure the retaining pins are in place on each entry
roller.
3. Inspect the coupling gears
• Separate the entry rollers so they do not touch each
other.
• While holding one roller fixed, gently try to rotate the
second entry roller. Be careful not to apply too much
force.
• If the roller turns, one or both coupling gears are loose.
• Tighten the clamping screw

Drive Belt and Pulleys 1. Inspect the drive belt and pulleys. While holding the motor
pulley to prevent it from turning, gently try to rotate the
entry roller. If the roller turns, the pulley on the bottom of the
entry roller shaft is loose.
2. Tighten the clamping screw.
3. Inspect the drive belt for missing or damaged teeth.
4. Make sure the pulley clamping screw on the card entry
motor is tight.

Drive Motor Troubleshoot the drive motor according to procedures in the

Maxsys System and Controller Service Manual.

Module-to-Module Perform the Card Guide Alignment procedure described in

Misalignment chapter 3.

2-4 Troubleshooting
Cards Not Transporting Through the Module Properly
Card transport faults are typically related to the tabbed belt and associated drive
components. (The version 1 assembly is pictured here.) See also “Uneven
Character Positioning” on page 2-7.)

Open the system interlock to disable all motors before beginning troubleshooting.

Possible Cause(s) Corrective Action(s)

Tabbed belt 1. Inspect the tabbed belt for wear and damage such as
missing tabs or partially torn tabs.
2. Inspect the tabbed belt for missing or damaged teeth.
3. Make sure the clamping hubs on the drive pulley and
encoder pulley are tight.

Drive and encoder pulleys Make sure the clamping hubs on the drive pulley and encoder
pulley are tight.

Idler pulley bearings 1. Inspect the bearings on the two idler pulleys, and make sure
the bearings are not worn.
2. Make sure the shoulder screw is not compressing the
bearings.

Maxsys Embossing/Indent Module Service Manual 2-5

 Possible Cause(s) Corrective Action(s)

Damaged lower card Make sure the lower card guide is not bent or distorted.
guide

Drive motor Troubleshoot the drive motor according to the procedures listed
in the Maxsys System and Controller Service Manual.

Card Overshoots Intended Position

The upper card guide may not be applying enough drag on the card. If so,
perform the Card Guide Alignment procedure described in chapter 3.

2-6 Troubleshooting
Uneven Character Positioning
The primary cause of uneven character positioning is improper transport of the
card through the Embossing module. See the following table for spacing
problems. A secondary cause may be related to the character wheel position.

If these actions do not correct the problem, an upgrade kit for the version 4 tabbed
belt assembly (Part No. 546838-001) is available as a purchaseable option.

Possible Cause(s) Corrective Action(s)

Upper card guide pressure If present, adjust the screw on the top of the right end of
the upper card guide to change the pressure, and/or
adjust the two bias spring screws.

Tabbed belt may not be Inspect the tab transport system.

advancing the card properly.

Sliced belt tab Replace the tabbed belt

The upper card guide may not be 1. Inspect the two bias springs and make sure both
applying enough drag force on springs are attached and not distended.
the card. 2. Temporarily disconnect both bias springs and
observe if the card guide pivots freely (It should fall
to its bottom position by its own weight.)
3. Reconnect the bias springs.

The card guides may be applying 1. Temporarily disconnect both bias springs, and
too much drag force on the card, check to see that the card guide pivots freely.
perhaps deforming the belt tabs or 2. Inspect the lower card guide and make sure it is
stalling the motor. straight, that it has no burrs on its edges, and that it
is not pinching the card.

The character wheel is not 1. Perform the Wheel Home Offset adjustment
advancing to the correct described in chapter 3.
character position. 2. Go to Diagnostics and run the “Calibrate Wheel
VKPO” primitive described in the table on page
2-19.

The wheel lift linear rails may have 1. Grasp the embossing assembly and rock it back
excessive play allowing the and forth. If play is felt or seen between the
embossing assembly to shift during bearings and linear rails, skew the pillow blocks as
large wheel movements. described in Chapter 4, “Removal and
Note: This is unlikely to noticeably Replacement”.
affect character position. 2. Refer to the “Removal and Replacement chapter 4,
and loosen the pillow block mounting screws.
3. Bias the pillow blocks toward each other.

Maxsys Embossing/Indent Module Service Manual 2-7

Characters Emboss on Top of Each Other
Possible Cause(s) Corrective Action(s)

Not enough tension on the upper 1. Ensure the upper card guide is not binding, and
card guide. that it “snaps” easily into position when it is
raised and released.
2. Check under the upper card guide for debris or
obstructions on the Card Guide Brackets.
3. Inspect the card guide pins for excess thread
locking compound

Card guide brackets improperly Loosen the mounting fasteners from the belt drive
positioned. plate and re-align the card guide brackets.

2-8 Troubleshooting
Uneven Character Line Height
Uneven character line height can take many forms. See the following table for
specific problems.

Characters are Wavy, Form an Arch, or Droop Across the Card

Possible Cause(s) Corrective Action(s)

Upper card guide pressure If present, adjust the screw on the top of the right end of the
upper card guide to change the pressure, and/or adjust the
two bias spring screws.

The card is not constrained 1. Inspect the leadscrew, leadscrew nut, and the leadscrew
properly. housing, and make sure they are firmly constrained.
• Make sure the two screws that secure the Nut Housing
to the base of the wheel are tight.
• Make sure the retaining screw on the bottom of the
Leadscrew is in place and tight.

Maxsys Embossing/Indent Module Service Manual 2-9

Character Line Height Steadily Droops

Possible Cause(s) Corrective Action(s)

Leadscrew components may be Tighten all leadscrew components.

loose.

Vertical Lift Jumps Periodically

Possible Cause(s) Corrective Action(s)

The character wheel is unbalanced. Re-balance the character wheel.

Character Line Steadily Decreases from Card to Card

Possible Cause(s) Corrective Action(s)

One of the leadscrew drive gears is Tighten the leadscrew drive gears on their shafts.
loose on its shaft, causing the vertical
lift mechanism to shift or sag.

The upper card guide may not be 1. Make sure the two bias springs are attached and
applying enough downward force on not distended.
the card, allowing the card to rise off 2. Temporarily disconnect both bias springs and
the lower card guide. observe if the card guide pivots freely, (It should
fall to its bottom position by its own weight).
3. Reconnect the two bias springs.

Worn character(s). Replace the worn character(s).

Worn emboss wheel Replace the worn emboss wheel.

Character Positioning Errors Consistent from Card to Card

Possible Cause(s) Corrective Action(s)

The lower card guide could be 1. Make sure the lower card guide is straight.
deformed 2. Make sure there are no burrs on the edges of
the lower card guide.
3. Make sure the lower card guide is not
collapsed and pinching a card.

2-10 Troubleshooting
Uneven Character Relief Height
Possible Cause(s) Corrective Action(s)

Cam drivers are not striking the 1. Perform the Wheel Home Offset adjustment described
the characters properly. in chapter 3.
2. Perform the Driver Cam Detent Position adjustment
described in chapter 3.
3. Inspect the rear of the characters (return tab) for
uneven wear caused by off-center impact.
4. Using “Diagnostics”, advance the wheel to several
character positions, and make sure the characters
are centered under the drivers.
5. Troubleshoot the cam driver motors as described in
the Maxsys System and Controller Service Manual.

Improper Wheel Table Settings. 1. Adjust the Wheel Table settings.

2. Inspect the specific characters for wear, damage,
and proper lubrication.

Worn driver or punch/die Replace worn cam driver or worn punch/die.

Wrong plastic cards loaded. Load the correct plastic cards.

Relief Height Problem Consistent on Certain Characters

Possible Cause(s) Corrective Action(s)

Improper Wheel Table settings Perform the Wheel Home Offset adjustment described in
chapter 3.

Incorrect Horizontal or Vertical Margins

Possible Cause(s) Corrective Action(s)

Horizontal/Vertical Offsets are Perform the “Horizontal/Vertical Offset Adjustment”

incorrect described in chapter 3.

Incorrect Wheel Home Offset Perform the Wheel Home Offset adjustment as described
in chapter 3.

Broken tabbed belt tab Replace the tabbed belt according to the procedure
described in chapter 4.

Defective encoders Identify the defective encoder and replace it.

Maxsys Embossing/Indent Module Service Manual 2-11

Excessively Bowed Cards
While some bowing of the cards is unavoidable, excessive bowing may be caused
by an improperly adjusted debow guide and improper cam driver settings in the
Wheel Table.

Possible Cause(s) Corrective Action(s)

Improperly adjusted debow guide. Perform the Debow Guide Position adjustment
as described in chapter 3.

Improper cam driver settings in the Adjust the Driver Cam Detent Position in the
Wheel Table. Wheel Table as described in chapter 3.

Excessive character relief height Refer to “Uneven Character Relief Height” on

page 2-11.

Wrong plastic for setup. Load the correct plastic cards.

Bowed Toward the Raised Characters

This is the most common situation. Increase the front position, and decrease the
rear position by the same amount.

Bowed Away from the Raised Characters

Decrease the Die position and increase the Punch position by the same amount.

2-12 Troubleshooting
Wheel or Cam Home Error
After system bootup with power applied to the Embossing\Indent module, the
system reports a wheel home or cam home error.

Possible Cause(s) Corrective Action(s)

Poor cable connection, 1. Verify stable resolver counts for the wheel motor and
damaged cable, or Defective the front/rear cam motors.
resolver board. • Disconnect power from the 48-V driver board.
• Start the Diagnostics software and select the
Embossing module as described in “Diagnostics” on
page 2-16.
• Display the Sensors tab.
• Verify that the resolver count for the wheel motor
and front/rear cam motors has minimal fluctuation
and no high count (64000).
2. Perform the Wheel VKPO Offset adjustment
(described in chapter 3) three times in a row and take
the average (to correct a wheel home error).

Caution: Do not reconnect power to the 48-V driver board with system power
on. Turn off system power, reconnect the power cable to the 48-V driver
board, then power up the system.

Maxsys Embossing/Indent Module Service Manual 2-13

Modifying an Entire Column of Characters
1. In Diagnostics, open the Wheel Table Configurations tab.

2. Right-click on the top of the column to be modified and select Modify All
Cell Values In Column.

3. In the popup window, set a value to be added to the whole column.

4. Repeat the procedure for the other column, except subtract a value.

2-14 Troubleshooting
Modifying Selected Characters
1. In Diagnostics, display the Wheel Table Configurations tab.

2. Select the characters to be modified by dragging the cursor over them.

3. Right-click over the selected items and select Modify Selected Cell Values.

4. In the popup window, set a value to be added to the selected characters.

5. Repeat the procedure for the other column, except supply a minus value to be
subtracted.

Maxsys Embossing/Indent Module Service Manual 2-15

Diagnostics
The diagnostics software interface for the embossing/indent module has tabs
with options for:

• Adjusting and testing the module (as described in this chapter and chapter 3,
“Adjustments”).

• Testing the sensors (see “Testing Sensors” on page 2-17).

• Exercising the motors and other components (see “Exercising the Module” on
page 2-18).

• Configuring the module (see “Configuring the Module” on page 2-22).

• Viewing the Vital Product Data (VPD) information. For information about the
VPD information, refer to the System and Controller Service Manual.
It is recommended that you make a backup copy of the Embossing/
Indent module VPD information, so it can be reloaded if problems occur
or if the microprocessor board is replaced.

Accessing Diagnostics
Use the following procedure to access the module Diagnostics for
troubleshooting and adjustments.

Exercises and adjustments cannot be run while a job is still active.

Procedure
1. Power on the Controller and the modules.

2. Choose Applications | Utilities | Diagnostics to access Diagnostics.

The installed modules are listed in the left pane of the screen in their order of
appearance in the system.

3. Select Embossing Module to display its Adjust and Test tab and other
diagnostic information.

2-16 Troubleshooting
Testing Sensors
Use the Sensors tab in Diagnostics to view sensor feedback and to test the
module’s sensors. The Sensors tab displays the current value of board and
encoder sensors and the on or off condition of proximity sensors.

• Board and encoder sensor names are displayed in blue-grey letters (or
in bold, black letters when the sensor is active).

• Sensor names are displayed in the normal grey background of the

interface. The display will inverse when the sensor changes state.

Testing Procedure
1. After starting the Diagnostics program for the appropriate module (refer to
“Accessing Diagnostics” on page 2-16), display the Sensors tab.
The sensors on the upper part of the screen are displayed in a large,
readable font that is useful when you are working at the opposite end
of the machine.

2. To display only the sensors you want to test, click the names of other sensors
to move them to the bottom of the window. (You can move them back up at
any time by clicking them again.)

3. When only the sensors you want to test remain at the top, manipulate cards or
use other means to block and unblock sensors to determine if they are
detecting changes.

4. If the card sensors or interlocks do not change on screen, the problem may be:

• The sensor or interlock may be faulty.

• A sensor cable may be faulty.

• The microprocessor board may be faulty.

Maxsys Embossing/Indent Module Service Manual 2-17

Exercising the Module
Use the Exerciser tab in Diagnostics to activate individual module components or
to run the module through a set of predefined exercises. The functions that
activate individual components are called diagnostic primitives. Each diagnostic
primitive includes one or more parameters that can be modified as required. Two
or more primitives can be linked together in sequences to create custom exercises.
You can save these custom sequences and run them as needed.

The Embossing/Indent module has several components that can be exercised

from Diagnostics to confirm correct component operation.

Exercising Procedure
1. After starting the Diagnostics program for the appropriate module (refer to
“Accessing Diagnostics” on page 2-16), display the Exerciser tab.

The predefined exercises (primitives) are listed in the Diagnostic

Primitives menu.

2. Select a primitive, change its parameters as needed, and then add it to the
Sequencer list on the right.

• Click Add First or Add Last to place the primitive at the top or
bottom of the list.

• Click Add Above or Add Below to place it above or below the

currently highlighted primitive.

• Change a primitive and click Replace if you want to change the

parameter for the primitive.

• Click Run if you want to run only the one primitive.

3. Arrange the items in the Sequencer list on the right in the order they should
be run.

4. Set a delay in milliseconds and a number of cycles to repeat the exercise.

5. Click Run to perform all the primitives as a set or click Step to run one
primitive at a time.

2-18 Troubleshooting
 Create your procedure using the following list of primitives for the Embossing/
Indent module.

Primitive Function Actions

User Dialog Allows a user to create a dialog 1. Enter a title for the dialog
box containing a title, message, box.
and single button (OK) or two 2. Enter a message that will
buttons (OK and Cancel). display in the dialog box.
Use this primitive to stop the 3. Select either the OK
exercise sequence to perform an
button (used to dismiss the
action (for example, to look at
box) or the OK and
the position of a card) and then
Cancel buttons.
continue with the exercise. When
the exercise reaches the primitive,
the exercise will stop, display the
customized dialog box, and
remain paused at that point until
the user clicks OK or (if available)
Cancel.

Motor Enable/Disable Enables or disables any motor Select a motor to act on, and
within the Embossing/Indent then supply a parameter to
module. enable (true) or disable (false)
the motor.

Motor Home Homes devices (tabbed belt, You must indicate the device
wheel, punch and die, vertical lift or motor to home.
mechanism, and indent tilt) and
motors.

Clear Resolver Allows vertical lift mechanism, This primitive clears the
(Encoder) Counts tabbed belt transport encoders, encoder value. It can be used
and optional front and rear in conjunction with the Sensor
ribbon advance encoders to be mode to check encoder
cleared. function.

Home All Homes all devices using flags and The devices are homed in the
sensors to detect specific following order:
locations. 1. Tabbed belt
2. Front indent tilt
3. Rear indent tilt
4. Vertical lift mechanism
5. Cams (Die and then
punch)
6. Wheel

Enable All Motors Enables all motors

Disable All Motors Disables all motors

Maxsys Embossing/Indent Module Service Manual 2-19

 Primitive Function Actions

Rotate Rear/Front Cam Allows the punch or die to be The punch or die cam motor
Relative moved a relative distance from parameter must be set in the
their present position. range of -870 to +870 steps with
a default setting of 850 steps.

Tilt Rear/Front Indent To These primitives raise the Indent

Load mechanism to the raised position
for easier ribbon loading.

Tilt Rear/Front Indent To These primitives lower the Indent

Home mechanism to the down position
for indenting characters.

Tilt Rear/Front Indent These primitives move the Indent Set the relative distance
Relative mechanism a defined relative parameter from -15000 to
distance. +15000 in steps of 1 (default=0).

Move Wheel Lift Allows the vertical lift mechanism The lift motor parameter must
Relative to be moved up or down a be set with range of -100 to
relative distance. +100 steps with a default
setting of 0 steps.

Advance Rear/Front These primitives move the indent Set the relative distance
Ribbon Relative tape a parameter-defined parameter from 1 to 100 in
relative distance. steps of 1 (default=0).

Move to Wheel Position Allows the emboss character The wheel motor parameter
wheel to be moved to a (slot number) must be set with
designated wheel slot. a range of 1 to 64 with a
default setting of 1.

Rotate Entry Rollers Allows the card entry rollers to spin

at a high speed for approximately
3 seconds.

Cycle Both Cams Allows the punch and die pair to The following three parameters
be exercised a relative distance. must be defined:
Cycles: 1 to 100 in steps of 1
(default=1)
Steps: 1 to 870 in steps of 1
(default=850)
Dwell: 2 to 500 in steps of 2
(default=50)

Advance Tabbed Belt This primitive advances the card The clockwise advance is set
Relative transport belt. from -3000 (CCW) to +3000
steps (CW) (default=1000)

2-20 Troubleshooting
 Primitive Function Actions

Rotate Wheel Slowly Moves the punch and die wheel The cam sensors must be
in the clockwise direction at a blocked (cams home) before
slow speed for one revolution. the wheel is allowed to move.

Calibrate Wheel VKPO Calibrates the wheel drive Use this primitive to calibrate
components. wheel drive components that
have been replaced, and
when character spacing
problems or wheel following
errors are observed.
Note: Since the analog
circuitry should be at operating
temperature, run the Exercise
Module primitive a few times
first or this primitive a minimum
of 3 times.

Emboss Attention Light Similar to Motor Enable/Disable

On/Off primitive, but toggles the
attention light on (true) or off
(false).

Exercise Module Simulates normal module

operation without cards.

Saving an Exercise Routine

After you have run or stepped through a sequence of primitives, you can
save the routine for future use.

1. Choose the File | Save options on the main menu.

The file is saved as an XML file in the default Maxsys\Exercise directory.

2. Use File | Open to retrieve the exercise routine file and use it again.

Maxsys Embossing/Indent Module Service Manual 2-21

Configuring the Module
Setting the Tabbed Belt Type
Four revisions of the Tabbed belt assembly have been used on modules. If you
change the assembly, use this procedure to set the tabbed belt type.
If you have upgraded the module revision 4 tab belt assembly, see additional
instructions for setting high resolution motor parameters in the upgrade
manual (Part No. 546838-901).

1. Identify the type of card transport belt installed on the Embossing/Indent

module.
2. Start the Diagnostics software and select the Embossing Module as described
in “Diagnostics” on page 2-16.
A. Display the Adjust and Test tab.

B. Enter the number (0, 1, 2, or 4) associated with the belt type.

Value Belt/Assembly Type

0 Five wide tabs and no homing tab

1 Five wide tabs and one narrow homing tab

2 Four wide tabs and one narrow homing tab

4 New tab belt drive assembly (562712-002 in upgrade kit 546838-001)

C. When finished, click on Commit to save the setting.

Setting the Cam Motor Type

The cam motors originally were Baldor motors. When you replace either cam
motor with a new Hurst motor, use this procedure to set the correct Servo Motor
Type.

Procedure
1. After starting the Diagnostics program for the appropriate module (refer to
“Accessing Diagnostics” on page 2-16), display the Module Config tab.

2. Near the bottom of the list is one for Servo Motor Type. Click on the New
Value column for that item and choose the correct type. (Values are either
Baldor or Hurst.)

2-22 Troubleshooting
Setting the Wheel Motor Revision
The RoHS-compliant 300 V driver board in the power supply is being released. If
you install the new replacement board (Part No. 568151-00x), display the Module
Config tab for the Embosser, find the Wheel Motor Revision row, and change the
value to Rev_B.

Setting High Resolution Motors

See instructions for setting these values in the upgrade manual for revision 4 (Part
No. 546838-901). It requires use of a special spreadsheet.

Disabling/Enabling a Module
The Module Configuration tab in Diagnostics includes options to disable or
enable the module, only the Embosser, or only the Indent. (It also displays
information about the ports and module speed; that information cannot be
changed here.) When the module is disabled, only operations required to pass a
card are active.

Use the following procedure to disable a module and assembly for isolating a
problem.

Procedure
1. After starting the Diagnostics program for the appropriate module (refer to
“Accessing Diagnostics” on page 2-16), display the Module Config tab.

Each configuration name and its number in the system is displayed.

2. If the Module Enable configuration value is set to True, use the up or down
arrows in the New Value column to change it to False. Or if you want to
disable just the Embosser or the Indent, set the value for Enable Embossing or
Enable Indenting to False.

3. Click Commit to save your modifications (and disable the module).

Be sure to enable the module again and use Commit when you are done
isolating a problem.

Maxsys Embossing/Indent Module Service Manual 2-23

2-24 Troubleshooting
Chapter 3: Adjustments

This chapter provides procedures for making adjustments to the

Maxsys Embossing/Indent module.

Mechanical Adjustments _____________________________________________ 3-2

General Belt Tension Adjustment ___________________________________ 3-2
Card Guide Alignment_____________________________________________ 3-3
Debow Guide Position _____________________________________________ 3-5
Software Adjustments ________________________________________________ 3-6
Character Position Offset __________________________________________ 3-6
Setting the Tabbed Belt Type _______________________________________ 3-7
Tabbed Belt Home Setting Adjustment ______________________________ 3-8
Minimum Cam Position ____________________________________________ 3-9
Driver Cam Detent Position________________________________________ 3-10
Wheel Home Offset_______________________________________________ 3-11
Wheel Table Configurations _______________________________________ 3-12
Wheel Lift Home Offset ___________________________________________ 3-13
Wheel VKPO Offset _______________________________________________ 3-14
Indent Tilt Offsets _________________________________________________ 3-15
Card Feature Gauge ________________________________________________ 3-16

Maxsys Embossing/Indent Module Service Manual 3-1

Mechanical Adjustments
General Belt Tension Adjustment
Many of the motors in the Maxsys system have belt tensioning springs. Some are
compression and some are extension, but they operate in the same manner.

• When adjusting belt tension, loosen the motor mounting screws only enough
to allow the tensioning spring to apply tension to the belt.

• When tightening the motor mounting screws (during belt tensioning), always
tighten the screw(s) closest to the direction of the drive belt first. This
prevents the motor from tilting as shown below.

3-2 Adjustments
Card Guide Alignment
Perform this procedure after adding or removing an Indent module or after
replacing the isolation mounts.

Four isolator assemblies are mounted under the module base plate to absorb
vibration. Incorrect adjustment of the assemblies will effect vertical and
horizontal alignment of the card track with adjacent modules.

Alignment Procedure
This adjustment must be performed with the isolator assemblies under full
load with the Indent assembly installed.
1. Turn off power to the system.

2. Loosen the retaining nuts on the four isolation mounts.

3. Slide the main embosser platform forward or backward until the four
alignment pins are centered in the alignment holes.

Maxsys Embossing/Indent Module Service Manual 3-3

 4. Adjust the height of each stud until the alignment pin is flush with the top of
the main embosser platform.

5. Tighten the retaining nuts.

3-4 Adjustments
Debow Guide Position
The card debow bracket is mounted on the top of the rear cam driver assembly to
minimize bowing of the card during the embossing process. Perform this
procedure after removing the rear cam driver or the transport platform.

Adjustment Procedure
1. Open the upper card guide, and place a standard 30-mil card in the track.

2. Loosen the debow guide mounting screws.

3. Adjust the debow guide so it is parallel to the card face and a few thousandths
of an inch away from the card.

Maxsys Embossing/Indent Module Service Manual 3-5

Software Adjustments
Character Position Offset
Use this procedure to shift character positions upstream or downstream for
special purposes. In most cases, this offset value should be left at the factory set
value of zero.

Adjustment Procedure
1. Print an embossing test card.

2. Compare the first character on the test card with the card feature gauge.
3. If the character does not line up with the sight gauge, adjust the character
position offset. (The center of the first character should be 0.401  0.010 inch
(0.25 mm) from the left edge of the card.)

A. Start the Diagnostics software and select the Embossing Module as

described in “Diagnostics” on page 2-16.

B. Display the Adjust and Test tab.

• If the character is too far to the left, decrease the offset value.

• If the character is too far to the right, increase the offset value.

C. When finished, click Commit to save the changes.

4. Print another test card to verify the adjustment.

3-6 Adjustments
Tabbed Belt Home Setting Adjustment
Since it is impossible to manufacture perfect card transport belts with consistent
belt teeth for advancing the belt, horizontal embossing margins may vary slightly
between cards. For this reason, the “home” setting for the card transport belt may
need to be adjusted. Adjust the tabbed belt home setting by performing the
following procedure.

Tools Required
• Digital Calipers

• Blank Cards

Adjustment Procedure
1. Sample all belt tabs by embossing five (5) identical consecutive cards.

2. Measure the horizontal margin on each card and compare it to the target
horizontal margin.

3. Start the Diagnostics software and select the Embossing Module as described
in “Diagnostics” on page 2-16.

A. Display the Adjust and Test tab.

• If most of the margins are less than the target value, increase the
Tabbed Belt Home Offset value.

• If most of the margins greater than the target value, decrease the
Tabbed Belt Home Offset value.

B. When finished, click on Commit to save the changes.

4. Repeat steps 1 through 3 until the horizontal embossing margins are centered
around the target value.

Maxsys Embossing/Indent Module Service Manual 3-7

Minimum Cam Position
Use this procedure to set the minimum cam position.

1. Start the Diagnostics software and select the Embossing Module as described
in “Diagnostics” on page 2-16.

2. Display the Adjust and Test tab.

3. Set the Minimum Cam Position to 780.

4. When finished, click on Commit to save the changes.

3-8 Adjustments
Driver Cam Detent Position
Use this procedure to calibrate the front and rear cam resolvers at the detent
position. This allows the system to accurately determine the home position of the
cams.

Adjustment Procedure
1. Start the Diagnostics software and select the Embossing Module.

2. Disable the cam motors.

A. Display the Exerciser tab.

B. Select Disable All Motors from the drop-down list.

C. Click Run.

3. Manually rotate the front and rear cams until the driver’s bearing snaps into
the detent position of the cam.

4. Display the Sensors tab and record the cam resolver counts for both motors.

5. Display the Adjust and Test tab, and enter the cam resolver counts for each
motor in the Cam Detent Position adjustments.

Maxsys Embossing/Indent Module Service Manual 3-9

Wheel Home Offset
The Wheel Home Offset sets the position of the embossing wheel so that the face
of the driver is directly aligned with the tails of the punches and dies in the
Embossing module.

Use this procedure to fine-tune the Embossing Wheel position so characters are
directly centered over the Character Drivers.

Adjustment Procedure
1. Start the Diagnostics software and select the Embossing Module.

2. Home the embossing wheel.

A. Display the Exerciser tab.

B. Select Home All Motors from the drop-down list.

C. Click Run.
3. Examine the position of the character punch and die.

4. If the character is not centered over the drivers, adjust the offset value.

A. Display the Adjust and Test tab.

• If the character is too far to the left, decrease the Wheel Home Offset
value.

• If the character is too far to the right, increase the Wheel Home Offset
value.

B. Click Commit to save the changes.

5. Re-home the embossing wheel to verify the adjustment.

3-10 Adjustments
Wheel Table Configurations
This procedure should be performed whenever any wheel characters are
replaced.

Adjustment Procedure
1. Print an embossed test card and check the character relief height.

2. If the character relief height is incorrect, start the Diagnostics software and
select the Embossing module.

3. Display the Wheel Table Configurations tab.

4. Highlight the character to be modified by dragging the cursor over it.

5. Right-click over the selected item and select Modify Selected Cell Values.

6. In the popup window, set a value to be added to the selected characters.

7. Click OK.

8. Repeat the procedure for the next column whose value is to be changed.

Maxsys Embossing/Indent Module Service Manual 3-11

Wheel Lift Home Offset
Use this procedure to set the minimum embossing height. The Wheel Lift Home
Offset controls the Target Vertical Emboss Margin on the card. This is defined as
the distance from the bottom edge of the card to the center of the target line.

Adjustment Procedure
1. Print an embossed test card using the lowest line height.
2. Compare the test card to the card feature gauge.

3. The bottom of the lowest character location should be at or above the bottom
of the Name and Address area which is 0.125  0.005 inch (3.175  0.127 mm)
above the bottom of the card).

4. If the character location is outside of the specifications, adjust the Vertical Lift
Home Offset.

A. Start the Diagnostics software and select the Embossing Module.

B. Display the Adjust and Test tab.

• If the character is too high, decrease the value.

• If the character is too low, increase the value.

C. Click Commit to save the changes.

Caution: Before testing the adjustment, make sure the punch and
die will clear the lower card guide.

5. Pre-test the adjustment.

A. Display the Exerciser tab.

B. Select Home All Motors from the drop-down list.

C. Click Run.
D. Manually press the punch and die characters inward and ensure that they
will not strike the lower card guide.

6. Print a test card to verify the adjustment.

3-12 Adjustments
Wheel VKPO Offset
The VKPO Offset value is determined by running the “Calibrate Wheel VKPO”
primitive within the Exerciser Diagnostic. This procedure should be performed to
correct wheel following errors, or whenever any wheel drive components such as
the wheel servo motor or the 300v amplifier board are replaced.

Adjustment Procedure
1. Start the Diagnostics software and select the Embossing module.
2. Display the Adjust and Test tab, and note the current VKPO setting.

3. Select the Exerciser tab.

4. Select the Calibrate Wheel VKPO primitive from the menu.

The VKPO Offset typically ranges from 1600 to 2200 on a total allowable
range of 1000 to 3000.

5. Change the VKPO Offset parameter as needed and click Replace.

6. Click Run to test.

Note: The VKPO offset may also be set manually using the Diagnostics
Adjust and Test tab.

Maxsys Embossing/Indent Module Service Manual 3-13

Indent Tilt Offsets
The Front and Rear Indent Tilt Offset is used to fine tune the vertical position of
the punch impact on the indent print ribbon.

1. Start the Diagnostics software and select the Embossing module.

2. Display the Exerciser tab.

3. Select the Tilt Front (or Rear) Relative primitive from the menu.

4. Change the relative distance parameter as needed and click Replace.

Try to set the Indent Tilt Offset to center the indent printing on the ribbon
without bottoming out the vertical travel of the Indent Assembly on the top of
the Embossing module (approx. 0.005 inch or 0.127 mm gap).

5. Click Run to test.

6. Print a test card to verify the adjustment.

3-14 Adjustments
Card Feature Gauge
The Card Feature Gauge is a glass template for calibrating the positions of various
card features. (Refer to the Embossing/Indent Module Illustrated Parts List for part
numbers for the Card Feature Kit and Replacement Gauges.)

The image below illustrates the ISO 7811-1 embossing feature locations used for
setting the character and feature positions.

Maxsys Embossing/Indent Module Service Manual 3-15

3-16 Adjustments
Chapter 4: Removal and
Replacement
This chapter describes the processes for removing and replacing
components and service assemblies on the Maxsys Embossing/
Indent module.

Electrical Power Lockout______________________________________________ 4-3

Servicing Guidelines _________________________________________________ 4-4
Major Assemblies ____________________________________________________ 4-5
Module Platform Assembly _________________________________________ 4-5
Embossing Wheel__________________________________________________ 4-7
Wheel Characters _________________________________________________ 4-9
Character Return Plates and Springs_______________________________ 4-12
Entry Roller Assembly______________________________________________ 4-15
Tab Belt Drive Assembly ___________________________________________ 4-16
Front Driver Assembly _____________________________________________ 4-18
Rear Driver Assembly _____________________________________________ 4-19
Module Assemblies _________________________________________________ 4-20
Sensors and Encoders _______________________________________________ 4-21
Card Entry/Exit Sensors and Front/Rear Cam Home Sensors _________ 4-21
Tabbed Belt Home Sensor_________________________________________ 4-22
Wheel Home Sensor ______________________________________________ 4-24
Wheel Lift Home Sensor ___________________________________________ 4-25
Interlock Sensor___________________________________________________ 4-26
Wheel Lift Position Encoder________________________________________ 4-27
Tabbed Belt Encoder _____________________________________________ 4-28
Motors, Belts, and Pulleys ____________________________________________ 4-30
Card Entry Motor _________________________________________________ 4-30
Card Entry Pulleys, Belt, Gears, and Bearings _______________________ 4-31
Tabbed Belt Drive Components (Earlier Revisions) __________________ 4-33
Motor, Pulley, and Tabbed Belt ________________________________ 4-33
Bearings ______________________________________________________ 4-34
Tabbed Belt Drive Components (Revision 4) ________________________ 4-36
Motor, Pulley, and Tabbed Belt ________________________________ 4-36
Bearings ______________________________________________________ 4-37
Wheel Lift Motor __________________________________________________ 4-38
Front Cam Motor and Cam _______________________________________ 4-39
Rear Cam Motor and Cam _______________________________________ 4-42
Wheel Motor _____________________________________________________ 4-45

Maxsys Embossing/Indent Module Service Manual 4-1

 Bearings and Gears __________________________________________________ 4-48
Driver Shafts and Return Springs ___________________________________ 4-48
Wheel Lift Leadscrew and Bearings________________________________ 4-51
Wheel Lift Drive Gears ____________________________________________ 4-55
Wheel Lift Linear Rails and Bearing Blocks __________________________ 4-56
Isolation Mounts __________________________________________________ 4-60
Electronics __________________________________________________________ 4-63
Control Boards ___________________________________________________ 4-63
Microprocessor Board and Memory Chip __________________________ 4-65
I-Button Board____________________________________________________ 4-68
300-Volt Driver Board _____________________________________________ 4-70
48-Volt Driver Board ______________________________________________ 4-72
AC Distribution Board _____________________________________________ 4-74
Embosser Resolver Board _________________________________________ 4-75
Power Supply ____________________________________________________ 4-77
Module Computer Enclosure______________________________________ 4-79
Indent Module Assemblies ___________________________________________ 4-82
Indent Assembly _________________________________________________ 4-82
Indent Assembly (Without Power) _________________________________ 4-84
Ribbon Diameter Encoders and Loading Springs ___________________ 4-87
Ribbon Encoder__________________________________________________ 4-89
Ribbon Replacement Procedure __________________________________ 4-91
Tilt Up and Tilt Home Sensors ______________________________________ 4-92
Encoder Driver Board _____________________________________________ 4-94
Indent I-Button Board _____________________________________________ 4-96

4-2 Removal and Replacement

Electrical Power Lockout
Any time service is being performed on the Maxsys system, especially the rear
enclosure where high voltage power is present, the incoming power should be
locked out to prevent someone else from inadvertently energizing the electrical
system.

Procedure
1. Shut down the Controller and turn off the power.

2. Switch the main circuit breaker on the back of the Controller to the OFF
position.

3. Flip the lockout bar up to the locked position. Note that the circuit breakers
cannot be returned to the ON position when the lockout bar is in the locked
position.

4. Lock the lockout bar. The lockout bar will not stay in the locked position
without an external lock.

• Each person servicing the system should have a personal lock.

• Never remove someone else’s lock from a lockout.

Maxsys Embossing/Indent Module Service Manual 4-3

Servicing Guidelines
Use the following guidelines for replacement and service of Embossing/Indent
module parts:

• For brevity, most procedures in this chapter describe only the removal
portion of a procedure. Unless otherwise noted, replacement procedures
follow the reverse of the removal procedure.

• Prior to servicing, remove power from the Controller and the modules and
disconnect the power cords from facility power.

• Observe the warning and caution labels affixed to various areas of the
equipment. (For more information, refer to “Major Assemblies” on page 4-5).
• Motor, sensor, and encoder cables can be disconnected either at the connector
or from the board.
• Follow standard ESD procedures whenever you touch a circuit board or any
electrical components.
• When plugging in cable connectors, examine the connector to make sure the
pins are straight and mate properly with the receptacle.

• Always perform preventive maintenance as described in “Preventive

Maintenance” after part replacement.

4-4 Removal and Replacement

Major Assemblies
Module Platform Assembly
Removing the module platform allows easier access to some of the Embossing/
Indent module components.

Removal Procedure
1. Shut down the Controller and turn off the power.

2. Remove the front panel from the module frame as described in the Maxsys
System and Controller Service Manual.

3. Remove the rear panel from the module frame as described in the Maxsys
System and Controller Service Manual.

4. Disconnect the wheel motor cable from the 300-volt driver board as described.

5. Disconnect all connectors from the module computer. This includes:

• Stepper motors (2)

• Servo motors (2)

• Encoders (2)
• Sensors (2)

• Serial data (2)

• Cables from the resolver board (2)

• Cables from the 48-volt driver board (4)

6. Open the cable guide latches on the front of the frame and remove the cables
from the guides.

7. For safety, to prevent the cables from catching on the system during removal,
drape the cables over the top of the module platform.

Maxsys Embossing/Indent Module Service Manual 4-5

 8. Verify that no additional cables need to be removed.

9. Remove the four mounting screws that secure the module platform to the pier
brackets, and carefully lift the assembly out of the system.

4-6 Removal and Replacement

Embossing Wheel

Removal Procedure
1. Shut down the Controller and turn off the power.
2. Disconnect the front cam home sensor cable connector.

3. Remove the four screws that secure the front driver assembly to the vertical
standoffs, and lift the assembly (including the cam motor) out of the module.

Maxsys Embossing/Indent Module Service Manual 4-7

 4. While holding the wheel motor shaft stationary with the 5/16-inch wrench,
unscrew the 3/4-inch retaining nut from the shaft, and remove the nut, lock
washer, flat washer, and embosser wheel from the shaft.

5. Rotate the embosser wheel until the notch in the character return plate lines
up with the rear driver, and carefully pull the wheel off the motor shaft.

4-8 Removal and Replacement

Wheel Characters
Use this procedure to replace or rearrange characters in the embossing wheel.

Removal Procedure
1. Shut down the Controller and turn off the power.
2. Remove the embossing wheel from the wheel motor as described on page 4-7.

3. While holding the backing nut from turning, loosen the clamping screw from
the retaining band.

Do not remove the screw, or the characters will fall out.

4. Rotate the band until the split is over the character to be removed.

5. Slide the band away from the character head.

Maxsys Embossing/Indent Module Service Manual 4-9

 6. Tilt the character up and slide it toward the center to remove it.

7. Repeat the procedure for the opposing character. (Replace the characters in
pairs to avoid mismatches.)

4-10 Removal and Replacement

Reassembly Procedure
1. After the characters are replaced, rotate the retaining band until the split is
located over a wheel tooth.

2. Slide the band toward the center of the wheel until it is flush with the front
edges of the wheel teeth. (Examine the whole band.)

3. While holding the backing nut from turning, tighten the clamping screw. (Do
not overtighten the screw.)

4. Make sure each character moves freely, and that the return plate retracts the
character.

Follow-up Adjustment

Run a test card and check the replaced character relief height. If the character
relief height is incorrect, use this procedure.
1. Perform the Wheel Table Configurations as described in chapter 3, and adjust
the dwell and velocity values for the replaced character.

2. Run another test card and recheck the character relief height.

Maxsys Embossing/Indent Module Service Manual 4-11

Character Return Plates and Springs

Removal Procedure
1. Shut down the Controller and turn off the power to the system.

2. Remove the embossing wheel from the wheel motor.

3. While holding the backing nut from turning, loosen the clamping screw from
one of the retaining bands.

Do not remove the screws, or the characters will fall out.

4-12 Removal and Replacement

 4. Lay the wheel flat on a table and slide the lower retaining band down until it
is flush with the bottom of the characters, and retighten the clamping screw.

5. Slide the upper retaining band down until it touches the lower band..
The character heads should be covered by the band; otherwise the characters
may fall out.

6. While pressing down on the return disk, splay out the characters so their
return tabs clear the flange on the return disk.

Maxsys Embossing/Indent Module Service Manual 4-13

 7. Lift the return disk off the wheel, and replace the springs.

8. Even if the return disk is not replaced with a new disk, the bearing sleeves
should be replaced.

9. Set the return disk over the springs, and make sure all four springs are resting
properly over the bearing sleeves.

10. While pressing down on the return plate, lift each character’s return tab over
the flange of the return plate.

11. Slide the retaining band up to hold the assembly together.

12. Repeat the process for the other side of the embossing wheel.

4-14 Removal and Replacement

Entry Roller Assembly

Removal Procedure
1. Shut down the Controller and turn off the power.
2. Use instructions in “Tab Belt Drive Assembly” on page 4-16 to remove the tab
belt platform from the module.
3. Remove the two screws that secure the entry roller assembly to the vertical
standoff plate, and lift the assembly straight up out of the bearing pockets.

Replacement Note

Release the tabbed belt tension before tightening the screws that secure the
transport platform to the vertical standoffs. After the screws are tight, re-tension
the belt.

Maxsys Embossing/Indent Module Service Manual 4-15

Tab Belt Drive Assembly

Removal Procedure
1. Shut down the Controller and turn off the power.

2. Remove the four screws that secure the tab belt drive assembly platform to
the vertical standoffs.

3. Remove the two screws that secure the vertical lift slide post brackets to the
platform.

4. Disconnect the following connectors:

• Card exit sensor

• Tab belt home sensor
• Tab belt drive motor
• Tab belt encoder (plugs into the back of the encoder)

5. Remove the transport platform. (The Version 1 platform is depicted in the

figure.)

4-16 Removal and Replacement

Replacement Notes
• Release the tabbed belt tension before tightening any of the screws that secure
the assembly to the vertical standoffs. When the screws are tightened, re-
tension the belt. This prevents the assembly from being distorted by the
tension of the tabbed belt.

• Perform the Debow Guide Position adjustment described in chapter 3.

Maxsys Embossing/Indent Module Service Manual 4-17

Front Driver Assembly

Removal Procedure
1. Shut down the Controller and turn off the power.

2. Remove the front panel from the module as described in the System and
Controller Service Manual.

3. Disconnect the cam home sensor and cam motor connectors.

4. Remove the four screws that secure the front driver assembly to the vertical
standoffs, and lift the assembly (including the cam motor) out of the module.

4-18 Removal and Replacement

Rear Driver Assembly

Removal Procedure
1. Shut down the Controller and turn off the power.
2. Remove the rear panel from the module as described in the System and
Controller Service Manual.
3. Disconnect the cam home sensor and cam motor connectors.

4. Remove the four screws that secure the rear driver assembly to the top of the
wheel motor, and lift the assembly (including the cam motor) out of the
module.

Follow-up Adjustment

Perform the adjustment described in “Debow Guide Position” on page 3-5.

Perform the adjustment described in “Driver Cam Detent Position” on page 3-9.

Maxsys Embossing/Indent Module Service Manual 4-19

Module Assemblies
The drawing below shows the names and positions of some of the major
components in the Maxsys Embossing module.

4-20 Removal and Replacement

Sensors and Encoders
Card Entry/Exit Sensors and Front/Rear Cam Home Sensors

Removal Procedure
1. Shut down the Controller and turn off the power.

2. Remove the screw(s) that secure the sensor to the module. (The tabbed belt
home sensor is in another position on the newer tab belt drive assemblies.)

Maxsys Embossing/Indent Module Service Manual 4-21

Tabbed Belt Home Sensor
This sensor pair’s location changed for the newest tab belt assembly revision.

1. Shut down the Controller and turn off the power.

2. Remove the screw (1 in the figure below) that secures the tabbed belt home
bracket to the platform.
3. Remove the two screws each that secure the sensor pair.

4-22 Removal and Replacement

Replacement Notes
• When replacing the sensor, place the receiving unit on the bottom so the
indicator light is visible for routine inspections.

• Place the aperture over the receiving head with the smaller hole over the
receiver.

• Adjust the sensor bracket to get a 0.01 to 0.02-inch (0.25 to 0.5-mm) gap
between the sensor aperture cover and the flange of the pulley.

Maxsys Embossing/Indent Module Service Manual 4-23

Wheel Home Sensor

Removal Procedure
1. Shut down the Controller and turn off the power.

2. Remove the embossing wheel from the wheel motor as described in

“Embossing Wheel” on page 4-7.

3. Loosen the two screws that secure the sensor cable to the wheel motor
mounting plate, and free the cable from the cable guide slot.

4. Remove the screw that secures the sensor to the wheel motor mounting plate.

5. To make reassembly easier, carefully pull the cable connector (male/female

pair) through the routing hole and into the wheel area before disconnecting
the sensor cable.
During reassembly, reconnect the sensor cable, and carefully feed the
connector pair back through the routing hole.

4-24 Removal and Replacement

Wheel Lift Home Sensor

Removal Procedure
1. Shut down the Controller and turn off the power.
2. Remove the rear panel from the module frame as described in the System and
Controller Service Manual.
3. With a long screw driver, reach in through the opening between the driver
housing and the transport platform, and remove the screw that secures the
sensor to the module platform.

4. Remove the sensor by reaching in from the rear of the module.

Maxsys Embossing/Indent Module Service Manual 4-25

Interlock Sensor
The interlock switch is actuated by opening the top cover. See replacement
instructions in the System and Controller Service manual.

4-26 Removal and Replacement

Wheel Lift Position Encoder
The encoder determines the height of the vertical lift assembly based on the home
position.

Removal Procedure
1. Shut down the Controller and turn off the power.

2. Remove the module platform assembly from the module as described on page
4-5, and lay it on its side on a work table.

3. Rotate the leadscrew gear counterclockwise to raise the wheel lift assembly as
high as possible.

4. Loosen the setscrew on the encoder gear, and remove the gear.

5. Remove the retaining nut from the encoder shaft, and remove the encoder
from the top side of the module.

Follow-up Adjustment

Perform the Wheel Lift Home Offset as described on page 3-12.

Maxsys Embossing/Indent Module Service Manual 4-27

Tabbed Belt Encoder
The tabbed belt encoder helps verify the belt position during each process move.

Special Tools
• Shorting tool (Part No. 580197-901) to protect from ESD damage

• Very small hex wrench supplied in encoder kit

Removal Procedure
1. Shut down the Controller and turn off the power.

2. If you want to reach in from the back for the procedure, remove the rear
panel(s) from the module frame as described in the System and Controller
Service Manual and disconnect the tabbed belt encoder cable from the back of
the encoder. Otherwise, remove the Tab Belt Drive Assembly as described on
page 4-16.

3. Loosen the clamping screw (1) on the collar (2) to remove the encoder collar
and pulley (3).

4. Remove the two screws (4) that attach the encoder assembly to the belt drive
plate (5).

4-28 Removal and Replacement

 5. Use the supplied hex wrench (6) to loosen the encoder body (7) from the base
(8).

6. Remove the two phillips screws (9) that attach the encoder base to the encoder
block assembly.

Replacement
1. Place the shorting tool on the pins of the new encoder. (Keep it on until final
cable assembly is attached.)

2. Attach the encoder base to the block assembly with the phillips screws.

3. Slide the encoder body down on the base and snap it into position.
4. Securely tighten the encoder set screw to affix the encoder to the shaft.

Do not rotate or move the shaft until the next step is completed.

5. Use a flat-blade drive to rotate the top of the encoder slotted disk from the
one-dot to two-dot position.

• The encoder pulley should be flush with the end of the shaft but have a
0.030 inch (0.76 mm) gap between the pulley and the plate.

Maxsys Embossing/Indent Module Service Manual 4-29

Motors, Belts, and Pulleys
Card Entry Motor

Removal Procedure
1. Shut down the Controller and turn off the power.

2. Remove the front panel from the module frame as described in the System and
Controller Service Manual.

3. Remove the three screws that secure the card entry motor to the module
platform, and remove the motor out the front of the module.

4-30 Removal and Replacement

Card Entry Pulleys, Belt, Gears, and Bearings
To remove the card entry motor components, it is necessary to remove the tab belt
drive assembly and the entry roller assembly.

1. Remove the tab belt drive assembly as described in “Tab Belt Drive
Assembly” on page 4-16.

2. Remove the two screws that secure the entry roller assembly to the vertical
standoff plate, and lift the assembly straight up out of the bearing pockets.

3. To gain access to the entry rollers and upper bearings, remove the two screws
that secure the entry sensor platform and remove the platform.

4. Remove the components as necessary according to the drawing below.

Maxsys Embossing/Indent Module Service Manual 4-31

Replacement Notes
• Install the drive pulley on the motor shaft with 0.060-inch (1.524 mm)
clearance to the motor housing.

• Release the tabbed belt tension before tightening any of the screws that secure
the platform. When the screws are tightened, re-tension the tabbed belt.

4-32 Removal and Replacement

Tabbed Belt Drive Components (Earlier Revisions)
Thess procedures are for the earlier version tabbed belt drive assemblies. See
instructions on page 4-16 for version 4 components.

Motor, Pulley, and Tabbed Belt

See replacement notes after the section on bearings.

Removal Procedure
1. Shut down the Controller and turn off the power.

2. If the motor or pulley need replacement, remove the rear panel(s) from the
module frame as described in the System and Controller Service Manual.

3. Loosen the three screws (1 in the figure below) that secure the tab belt drive
motor (2) to the tab belt drive assembly, de-tension the belt, and remove the
belt from the pulleys.

4. To replace the motor, fully remove the three screws (1) and catch the motor (2)
and pulley (5) with motor plate (3) on the underside.

5. To replace the pulley, loosen the clamping screw (4) on the collar and lift off
the pulley.

Maxsys Embossing/Indent Module Service Manual 4-33

Bearings
Use this procedure to replace the bearings in the two forward (front of module)
idler pulleys.

Removal Procedure
1. Remove the belt as described on page 4-33.

2. Remove the forward idler pulleys:

A. Remove the shoulder screw from the top of the pulley, and remove the
pulley assembly.

B. Unscrew the captive washer from the shoulder screw.

C. Remove the shoulder screw, spacers, spring washer, and bearings from
the pulley.

4-34 Removal and Replacement

Replacement Notes
• Use thread-locking compound to reattach the forward idler pulley assemblies.
• The motor pulley should be flush with the top of the motor shaft.

• The tab belt must be installed as indicated in the figure below.

• The motor should be tensioned as indicated in the figure.

• The encoder pulley should have a 0.030 inch (0.76 mm) gap between the
pulley and the transport platform.

Maxsys Embossing/Indent Module Service Manual 4-35

Tabbed Belt Drive Components (Revision 4)
This procedure is for the newer Embosser modules or those updated with a tab
belt drive assembly upgrade kit (Part No. 546838-001).

Motor, Pulley, and Tabbed Belt

Removal Procedure
1. Shut down the Controller and turn off the power.

2. If the motor or pulley need replacement, remove the rear panel(s) from the
module frame as described in the System and Controller Service Manual.

3. Loosen the three screws (1 in the figure below) that secure the tab belt drive
motor (2) to the tab belt drive assembly, de-tension the belt, and remove the
belt from the pulleys.

Bottom of Assembly

4. Disconnect the motor cable.

5. To replace the motor, fully remove the three screws (1) and catch the motor
(2) and pulley (5) with the motor plate (3) on the underside.
Be careful not to damage the tabbed belt sensor pair as you remove the
motor pulley and collar.

6. To replace the pulley, loosen the clamping screw (4) on the collar (using a
3/32-inch hex key) and lift off the pulley.

4-36 Removal and Replacement

Bearings
Use the following procedure to replace the bearings in the two forward (front of
module) idler pulleys.

Removal Procedure
1. Remove the tabbed belt as described in “Motor, Pulley, and Tabbed Belt” on
page 4-36.

2. Remove the forward idler pulleys:

A. Remove the shoulder screw from the top of the pulley, and remove the
pulley assembly.

B. Unscrew the captive washer from the shoulder screw.

C. Remove the shoulder screw, spacers, spring washer, and bearings from
the pulley.

Replacement Notes
• Use thread-locking compound to reattach the forward idler pulley assemblies.

• The tab belt must be installed as indicated in the figure below (the belt’s part
number will be on top).

• The motor should be tensioned as indicated in the figure.

Maxsys Embossing/Indent Module Service Manual 4-37

Wheel Lift Motor

Removal Procedure
1. Shut down the Controller and turn off the power.

2. Remove the wheel motor as described in “Wheel Motor” on page 4-45. (This
also includes removing the two driver assemblies.)

3. Remove the four screws that secure the wheel lift motor to the module
platform, and lift the motor straight out of the opening.

Follow-up Adjustments
• Perform the Debow Guide Position adjustment as described in chapter 3.

• Perform the Wheel Lift Home Offset adjustment as described in chapter 3.

4-38 Removal and Replacement

Front Cam Motor and Cam
This cam motor may be a Hurst or Baldor servo motor. When you replace this
motor, check the setting in Diagnostics on the Module Configuration tab to be
sure the Servo Motor Type matches the replacement.

Removal Procedure
1. Shut down the Controller and turn off the power.

2. Remove the front panel from the module frame as described in the Maxsys
System and Controller Service Manual (to gain access to the motor cable
connector).
3. Disconnect the cam home sensor and cam motor connectors.

4. Remove the four screws that secure the front driver assembly to the vertical
standoffs, and lift the assembly (including the cam motor) out of the module.

5. Loosen the clamping screw on the driver cam.

6. Remove the four screws that secure the cam motor to the driver housing, and
slide the motor out the bottom of the assembly.

Maxsys Embossing/Indent Module Service Manual 4-39

 7. Slide the clamping sleeve out of the driver housing, and remove the cam.

Replacement Notes
• When inserting the cam into the driver housing, rotate the cam so the etched
line (shown below) is pointing toward the driver. This will minimize the
amount of force needed to align the cam with the bore in the housing.

• Align the notches of the clamping sleeve with the split in the driver cam. This
maximizes the clamping force applied to the shaft.

4-40 Removal and Replacement

 • The bottom of the notch in the sleeve should be flush with the face of the
driver housing.

Follow-up Adjustment

Perform the Driver Cam Detent Position adjustment as described in chapter 3.

Maxsys Embossing/Indent Module Service Manual 4-41

Rear Cam Motor and Cam
This cam motor may be a Hurst or Baldor servo motor. When you replace this
motor, check the setting in Diagnostics on the Module Configuration tab to be
sure the Servo Motor Type matches the replacement.

Removal Procedure
1. Shut down the Controller and turn off the power.
2. Remove the rear panel from the module (to gain access to the motor cable
connector).
3. Disconnect the cam home sensor and cam motor connectors.

4. Remove the four screws that secure the rear driver assembly to the top of the
wheel motor, and lift the assembly (including the cam motor) out of the
module.

5. Loosen the clamping screw on the driver cam.

6. Remove the four screws that secure the cam motor to the driver housing, and
slide the motor out the bottom of the assembly.

7. Slide the clamping sleeve out of the driver housing, and remove the cam.

4-42 Removal and Replacement

Replacement Notes
• When inserting the cam into the driver housing, rotate the cam so the etched
line (shown below) is pointing toward the driver. This will minimize the
amount of force needed to align the cam with the bore in the housing.

• Align the notches of the clamping sleeve with the split in the driver cam. This
maximizes the clamping force applied to the shaft.

• The bottom of the notch in the sleeve should be flush with the face of the
driver housing.

Maxsys Embossing/Indent Module Service Manual 4-43

Follow-up Adjustments
• Perform the Debow Guide Position adjustment described in chapter 3.

• Perform the Driver Cam Detent Position adjustment described in chapter 3.

4-44 Removal and Replacement

Wheel Motor

Removal Procedure
1. Shut down the Controller and turn off the power.
2. Disconnect the card exit sensor.

3. Remove the two screws that secure the card guide assembly to the transport
platform, and remove the card guide assembly.

4. Disconnect the front and rear cam home sensor cable connectors.

5. At your discretion, you may disconnect the cam motor cable connectors.
6. Remove the four screws that secure the front driver assembly to the vertical
standoffs, and lift the assembly (including the cam motor) out of the module.

Maxsys Embossing/Indent Module Service Manual 4-45

 7. Remove the four screws that secure the rear driver assembly to the top of the
wheel motor, and lift the assembly (including the cam motor) out of the
module.

8. While holding the wheel motor shaft stationary with the 5/16-inch wrench,
unscrew the 3/4-inch retaining nut from the shaft, remove the nut, lock
washer, flat washer, and embosser wheel from the shaft.

4-46 Removal and Replacement

 9. Remove the four screws that secure the wheel motor to the wheel motor
mounting plate, and remove the motor.

Follow-up Adjustment
• Perform the Debow Guide Position adjustment as described in chapter 3.

• Perform the Wheel VKPO Offset adjustment as described in chapter 3.

Maxsys Embossing/Indent Module Service Manual 4-47

Bearings and Gears
Driver Shafts and Return Springs

Removal Procedure
1. Shut down the Controller and turn off the power.

2. Remove the front and rear panels from the module (to gain access to the cam
motor connectors).

3. Disconnect the front and rear cam home sensor cable connectors.

4. Disconnect the cam driver motor connectors.

5. Remove the four screws that secure the front driver assembly to the vertical
standoffs, and lift the assembly (including the cam motor) out of the module.

4-48 Removal and Replacement

 6. Remove the four screws that secure the rear driver assembly to the top of the
wheel motor, and lift the assembly (including the cam motor) out of the
module.

7. From each driver assembly, rotate the driver cam until the split in the cam
lines up with the driver. You should feel the cam snap into position as the
driver falls into the detent.

8. Remove the two shoulder screws that secure the driver sleeve to the driver
assembly.

9. Slide the driver sleeve forward so the guide bearing clears the cam home
sensor, and carefully lower the sleeve out of the assembly.

Guide Tip of
Bearing Sensor

Shoulder Screw
Mounting Holes

MCEB-14

Maxsys Embossing/Indent Module Service Manual 4-49

 10. Remove the retaining ring from the driver shaft, and slide the shaft out of the
sleeve block.

Follow-up Adjustments
• Perform the Debow Guide Position adjustment as described in chapter 3.

• Perform the Driver Cam Detent Position adjustment as described in chapter 3.

4-50 Removal and Replacement

Wheel Lift Leadscrew and Bearings

Removal Procedure
1. Shut down the Controller and turn off the power.
2. Remove the module platform assembly from the system as decribed on page
4-5, and lay it on its side on a work table.
3. Remove the retaining screw from the bottom of the leadscrew shaft, loosen
the clamping screw on the leadscrew drive gear, and remove the gear.

4. Turn the leadscrew shaft clockwise as far as you can without driving the
leadscrew into the bottom of the character wheel.

Maxsys Embossing/Indent Module Service Manual 4-51

 5. Turn the module platform right side up, and disconnect the front cam home
sensor.

6. Remove the four screws that secure the front driver assembly to the vertical
standoffs, and lift the assembly (including the cam motor) out of the module.

7. While holding the wheel motor shaft stationary with the 5/16-inch wrench,
unscrew the 3/4-inch retaining nut from the shaft, remove the nut, lock
washer, flat washer, and embosser wheel from the shaft.

4-52 Removal and Replacement

 8. Rotate the embosser wheel until the notch in the character return plate lines
up with the rear driver, and carefully pull the wheel off the motor shaft.

9. Continue to unscrew the leadscrew, and remove it from the leadscrew nut.

10. Remove the two screws that secure the leadscrew nut housing to the wheel lift
assembly.

Maxsys Embossing/Indent Module Service Manual 4-53

 11. Raise the wheel lift assembly as far as possible, and remove the leadscrew nut
and nut housing from underneath.

12. Remove the two bearings from the module platform.

Replacement Notes
1. Apply super bond adhesive (414) to the leadscrew nut and thread the
leadscrew nut into the nut housing until there is 0.030-0.040 inch (0.76-0.102
mm) offset between the nut housing and the leadscrew.

2. Make sure the nut housing mounting screws are loose.

3. Lower the wheel lift assembly as low as it will go (the motor mounting plate
will touch the linear rail spacers), and then raise it slightly.

4. Re-tighten the mounting screws on the nut housing.

Follow-up Adjustments

Perform the Wheel Lift Home Offset adjustment as described in chapter 3.

4-54 Removal and Replacement

Wheel Lift Drive Gears

Removal Procedure
1. Shut down the Controller and turn off the power.
2. Remove the module platform assembly from the module as described on page
4-5, and lay it on its side on a work table.
3. Loosen the clamping screw on the encoder gear and motor gear, and remove
the gears.

4. Remove the retaining screw from the leadscrew shaft, loosen the clamping
screw, and remove the gear.

Follow-up Adjustment

Perform the Wheel Lift Home Offset adjustment as described in chapter 3.

Maxsys Embossing/Indent Module Service Manual 4-55

Wheel Lift Linear Rails and Bearing Blocks

Removal Procedure
1. Shut down the Controller and turn off the power.

2. If the linear rails need to be removed, remove the module platform assembly
from the system as described on page 4-5.

3. Remove the tabbed belt drive assembly as described in “Tab Belt Drive
Assembly” on page 4-16.

4. Disconnect the front cam home sensor cable connector.

5. Optional: Disconnect the cam driver motor connectors.

6. Remove the four screws that secure the front driver assembly to the vertical
standoffs, and lift the assembly (including the cam motor) out of the module.

7. While holding the wheel motor shaft stationary with the 5/16-inch wrench,
unscrew the 3/4-inch retaining nut from the shaft, remove the nut, lock
washer, flat washer, and embosser wheel from the shaft.

4-56 Removal and Replacement

 8. Rotate the embosser wheel until the notch in the character return plate lines
up with the rear driver, and carefully pull the wheel off the motor shaft.

9. Remove the two screws that secure the right linear bearing block to the wheel
motor mounting plate, and slide the block up off the rail.
Work on one linear bearing block at a time, so the vertical lift assembly
remains supported.

Maxsys Embossing/Indent Module Service Manual 4-57

 10. Turn the module platform on its side, remove the screw that secures the linear
rail to the module platform, and remove the rail.

11. Reassemble the first slide assembly, and repeat the process for the second
assembly.
Leave the linear block mounting screws loose until the following
alignment procedure is completed.

Replacement Alignment

Before the character wheel is installed, set the alignment of the linear bearing
blocks and the wheel lift leadscrew.

4-58 Removal and Replacement

 1. Loosen the two screws (at least 1/8 inch) that secure the wheel lift leadscrew
nut housing to the wheel carriage.

2. Manually lower the leadscrew until the nut housing no longer touches the
bottom plate of the wheel carriage. The rear wall of the wheel carriage should
be bottomed-out on the spacer plates under the linear rails.

3. Make sure both bearing blocks are also bottomed-out on the spacer plates.

4. Tighten the two screws that secure the right bearing block to the wheel
carriage.

5. While applying force and biasing the left bearing block toward the left,
tighten the two screws that secure it to the wheel carriage.

6. Raise the leadscrew until the wheel carriage lifts off the spacer plates (about
1/8 inch).

7. Tighten the two mounting screws that secure the nut housing to the wheel
carriage.

When replacing the tabbed belt transport platform, release the tabbed
belt tension before tightening the screws that secure the platform. After
the screws are tight, tension the belt.

Follow-up Adjustment

Perform the Wheel Lift Home Offset adjustment as described in chapter 3.

Maxsys Embossing/Indent Module Service Manual 4-59

Isolation Mounts

Removal Procedure
1. Shut down the Controller and turn off the power.

2. Remove the module platform assembly from the system as described and set
it on a work table.

3. Remove the four retaining nuts, lock washers, and washers from the top of
the isolation mounts.

4. To avoid having to remove all of the cables from the underside of the module
platform, operate on a single isolation mount at a time.

5. Lift the main embosser platform (shown in yellow above) off the isolation
mount studs, and shift it to the side to expose one of the isolation mounts.

4-60 Removal and Replacement

 6. Remove the two screws that secure the isolation mount to the cross-bar of the
module platform, and remove the isolation mount.

7. Remove the locknut from the bottom of the isolation mount, and remove the
isolation pad.
During replacement, do not overtighten the locknut. The stud must rotate
with only slight friction during height adjustment.

8. After installing the new isolation mount, shift the main embosser platform to
expose another isolation mount, and repeat the procedure for all four mounts.

Maxsys Embossing/Indent Module Service Manual 4-61

Follow-up Adjustment
1. Reinstall the module platform back in the system.

2. With the retaining nuts loose, slide the main embosser platform forward or
backward until the four alignment pins are centered in the alignment holes.

3. Adjust the height of each stud until the alignment pin is flush with the top of
the platform, and tighten the retaining nuts.

4-62 Removal and Replacement

Electronics
Control Boards
The module control boards are located in the computer enclosure behind the front
panel of the module.

Removal Procedure

ESD! Follow standard ESD procedures whenever you touch a circuit board.

1. Back up (export) the Vital Product Data (VPD) information for the module
using the Diagnostics program. (For instructions, refer to the System and
Controller Service Manual.)

2. Shut down the system and unplug the power cord.

3. Remove the front panel from the module (For instructions, refer to the System
and Controller Service Manual.)

4. Disconnect all the cables from the face of the control board (shown in the
following figure). Start at the bottom of the board and work upward:

• Misc. I/O
• Sensors
• Encoders
• Servo motors
• Stepper motors

Maxsys Embossing/Indent Module Service Manual 4-63

 5. Remove the control board from the computer enclosure:

A. Loosen the retaining screws from the top and bottom of the faceplate. The
screws are captive and will remain with the faceplate.

B. Pull the locking tabs back from both the upper and lower latches.

C. Simultaneously tilt the two retaining latches away from each other. The
latches will pull the circuit board away from the internal connectors.

D. Slide the circuit board out of the enclosure, and place it on an anti-static
mat.

Replacement Procedure
1. Align the edges of the control board with the grooves in the computer
enclosure.

2. Carefully slide the control board into the enclosure. Take care to keep the
board straight. If the board is tilted, it will jam.

3. Make sure both latches are in the open position.

4. The teeth on the latch must be engaged in the slots on the enclosure (see the
picture above).

5. Simultaneously close the two latches, and verify that the locking tabs are
engaged.

6. As a final measure, press firmly against the front of the control board to
ensure it is fully seated.
7. Reinstall the connectors starting from the top and working down.

4-64 Removal and Replacement

Microprocessor Board and Memory Chip
The older microprocessor board contains a DiskOnChip® flash memory chip that
contains the module’s VPD settings; newer boards have a Compact Flash chip. If
the replacement board is the same revision, the current chip needs to be
transferred from the old microprocessor board to the new board. As a safety
precaution, if possible, you should back up the VPD settings before beginning
this procedure.

Removal Procedure

ESD! Follow standard ESD procedures whenever you touch a circuit board.

1. Shut down the Controller and turn off the power.

2. Remove the front panel of the module.

3. Disconnect the cables from the microprocessor board.

4. Remove the board from the enclosure:

A. Loosen the retaining screws from the top and bottom of the faceplate. The
screws are captive and will remain with the faceplate.

B. Push down on the locking tab.

C. Tilt the latch cam down. The latch cam will pull the circuit board away
from the internal connectors.

Maxsys Embossing/Indent Module Service Manual 4-65

 D. Slide the board out of the enclosure, and place it on an anti-static mat.

Transfer the DiskOnChip

Use this procedure if the replacement and old boards are both the older revision.

1. Simultaneously pry up from both ends of the chip to remove it from the
socket. Be careful not to bend the pins.

A. Remove the existing (blank) flash memory chip from the new
Microprocessor Board, and label the chip as new. Do not discard the chip.
Even if the chip is not needed at this time, keep it with your spare parts.

B. Remove the original flash memory chip from the old microprocessor
board.

2. Insert the original chip into the new Microprocessor Board. Carefully press
the chip into the first socket on the board.

• Make sure the chip is oriented correctly with the registration indicator
over the registration notch in the socket (see photo inset).
• Make sure all of the pins are lined up before pressing down on the chip.

4-66 Removal and Replacement

Transfer the Compact Flash Chip

Use this procedure if the replacement and previous boards are both the newer
revision.

1. Slide the flash memory chip out the side of the old board.

2. Slide the chip into the side of the replacement board.

Replacement Procedure
1. Align the edges of the board with the grooves in the computer enclosure.

2. Carefully slide the board into the enclosure. Take care to keep the board
straight. If the board is tilted, it will jam.
3. Make sure the latch cam is in the open position.

4. The teeth on the latch must be engaged in the slots on the board enclosure.

5. Tilt the latch cam up into the locked position. Verify that the locking tab is
engaged by gently pressing down on the cam.

6. As a final measure, press firmly against the front of the faceplate to ensure it is
fully seated.

7. Reinstall the Serial Data and High Speed Ethernet cables.

8. Boot up the system and verify that the module is functioning. If the VPD
settings do not appear to be correct or the module is not functioning properly,
refer to the troubleshooting information in the System and Controller Service
Manual.

Maxsys Embossing/Indent Module Service Manual 4-67

I-Button Board
The Embossing module and Indent assemblies each have I-Button boads. This
procedure is for the one on the Embossing module. See page 4-96 for the Indent
procedure.
Unless you already have a replacement I-Button board specifically
pre-programmed for an Embosser module, it will be necessary to install a
temporary, generic board in the module and configure the system to
recognize the correct module type. A Maxsys system can have only one
temporary board installed at a time, so it is important to obtain a
replacement, pre-programmed board as soon as possible.

Removal Procedure

ESD! Follow standard ESD procedures whenever you touch a circuit board.

1. Shut down the Controller and turn off the power.

2. Remove the front panel from the module as described in the System and
Controller Service manual.
3. Disconnect the cable connector from the side of the I-Button board.

4. Remove the two screws that secure the I-Button board to the underside of the
module platform, and remove the board.

4-68 Removal and Replacement

Follow-up Procedure for Generic i-Button

The generic i-Button will have a module type of 99. Before the system can
recognize the temporary i-Button, you must first tell it that a module “99”
represents an Embosser/Indent module. Refer to the Maxsys System and Controller
Service Manual for the procedure to reprogram a generic i-Button.

Notes
• Be sure to order a new i-Button board for the module as soon as possible.

• Only one temporary i-Button board can be used in a system at a time.

• After the permanent i-Button board is installed, you should delete the “99”
directory to avoid confusion in the future.

Maxsys Embossing/Indent Module Service Manual 4-69

300-Volt Driver Board
Lock out the power before beginning as described in “Electrical Power Lockout”
on page 4-3.

Warning: You will be working near the high voltage power. One phase is
always energized unless the main circuit breaker is off.

Removal Procedure

A RoHS-compliant board is being prepared to replace the current board. If you

install the new board (Part No. 568151-00x) in a module, you must also change a
setting in Diagnostics as described at the end of this procedure.

ESD! Follow standard ESD procedures whenever you touch a circuit board.

1. Turn off the Controller and lock out the circuit breaker.
2. Loosen, but do not remove, the two screws that attach the upper rear panel to
the module, and remove the upper rear panel from the module.
3. Loosen, but do not remove, the two screws that attach the lower rear panel to
the module, and remove the lower rear panel from the module.
Support the bottom of the panel while loosening the screws. The lower rear
panel will drop when the screws are loosened.

4. Disconnect the three cables from the 300-volt driver board.

5. Loosen the two screws that secure the driver enclosure to the module, and
slide the enclosure out just far enough to reach the fan cable.

6. Tilt the enclosure down to access the fan cable, and disconnect the cable.

7. Remove the ten screws that secure the shield (cover) on the enclosure, and
remove the shield.

4-70 Removal and Replacement

 8. Remove the four screws that secure the 300-volt driver board to the enclosure,
and remove the board.

Follow-up Adjustment

After replacing the 300-volt driver board, perform the Wheel VKPO Offset
adjustment described in chapter 3.
If the new driver board is Part No. 568151-00x, change the Wheel Motor
Revision in Diagnostics to Rev_B. See “Setting the Wheel Motor Revision” on
page 2-23 for instructions.

Maxsys Embossing/Indent Module Service Manual 4-71

48-Volt Driver Board
Lock out the power before beginning as described in “Electrical Power Lockout”
on page 4-3.
Warning: The 48-volt Driver Board may not be fully discharged, and could
pose a shock hazard.

Removal Procedure

ESD! Follow standard ESD procedures whenever you touch a circuit board.

1. Shut down the Controller and turn off the power.

2. Disconnect the cables on the front of the 48-volt driver board. (Motor 1 is the
front cam motor, and Motor 2 is the rear cam motor.)

3. Loosen the two mounting screws that secure the 48-volt driver board
mounting bracket to the module computer.

4. To remove the bracket:

A. Lift the bracket up and off the mounting screws.

B. Lower the bracket down until the lower mounting tab clears the module
computer power cable.
5. Remove the retaining nuts and screws to remove the circuit board shield
(cover), and the circuit board from the mounting bracket.

4-72 Removal and Replacement

Maxsys Embossing/Indent Module Service Manual 4-73
AC Distribution Board
Lock out the power before beginning as described in “Electrical Power Lockout”
on page 4-3.

Removal Procedure

ESD! Follow standard ESD procedures whenever you touch a circuit board.

1. Shut down the Controller and turn off the power.

2. Remove the rear panel or panels as described in the System and Controller
Service Manual.

3. Disconnect all cables from the face of the AC distribution board.

4. Remove the four screws that secure the AC distribution board to the frame.

4-74 Removal and Replacement

Embosser Resolver Board

Removal Procedure
1. Shut down the Controller and turn off the power.
2. Remove the front panel from the module.

3. Disconnect the cables on the front of the embosser resolver board. (See
“Resolver Board” on page 1-13 for connections.)

4. Loosen the three retaining screws from the faceplate. The screws are captive
and will remain with the faceplate.

Maxsys Embossing/Indent Module Service Manual 4-75

 5. Remove the embosser resolver board from the computer enclosure:

A. Pull the locking tab back on the lower latch, and tilt the latch cam down.

B. Slide the circuit board out of the enclosure, and place it on an anti-static
mat.

Follow-up Adjustment
• Perform the Driver Cam Detent Position adjustment described in chapter 3.

• Perform the Wheel Home Offset adjustment described in chapter 3.

4-76 Removal and Replacement

Power Supply
The power supply is located on the back of the module.
Warning: You will be working near the main power distribution. Make
sure the circuit breakers are locked out as described in “Electrical Power
Lockout” on page 4-3.

Removal Procedure
1. Shut down the Controller and lock out the circuit breakers.
2. Remove the rear panel(s) as described in the System and Controller Service
Manual.
3. Remove the 300V AC cable, the motor thermocouple cable and the wheel
motor cable from their connectors on the 300V power supply.
4. Disconnect the LED cable at the cable interconnect.

5. Disconnect the interlock cable on the AC distribution board.

6. Remove the folding hood, and disconnect the AC power cable from J4, and
7. Loosen the retaining screws from the top and bottom of the power supply
mounting bracket.
8. Lift up on and support the power supply while rotating it out of the module.

Do not allow the power supply to hang by the attached wires.

9. While supporting the power supply, disconnect the power connectors (Line 1,
Line 2, and Ground) from the bottom of the power supply.

Maxsys Embossing/Indent Module Service Manual 4-77

 10. Disconnect the wires from the top of the power supply, and remove it from
the module.

Channels A and B are bridged. Both A and B terminals are installed on the
shared post.

4-78 Removal and Replacement

Module Computer Enclosure
This is also called the board enclosure and card cage.

Removal Procedure
1. Shut down the Controller and turn off the power.
2. Remove the front panel from the module.

3. Disconnect the cables on the front of the 48-volt driver board. (Motor 1 is the
front cam motor, and motor 2 is the rear cam motor.)

4. Disconnect the main power, data, and cooling fan connectors from the bottom
of the computer enclosure.

5. Loosen the two mounting screws that secure the driver board mounting
bracket to the enclosure.

6. To remove the bracket, lift it up and off the mounting screws, then lower the
bracket down until the lower mounting tab clears the module computer
power cable connector.

Maxsys Embossing/Indent Module Service Manual 4-79

 7. Disconnect all cable connectors from the front of the module computer. (See
the connections in “Communication Boards” on page 1-9.)

4-80 Removal and Replacement

 8. Loosen the remaining screw (3 total) that secures the module computer to the
module frame, and lift the enclosure off the mounting screws.

Upper Mounting
Screw

Lower Mounting
Screws (2)

Card_Cage2

Maxsys Embossing/Indent Module Service Manual 4-81

Indent Module Assemblies
Prior to working on the Indent module, remove the assembly from the
Embossing module to prevent small parts from falling into the module.

Indent Assembly
If the Indent Assembly cannot be lowered to the indent position due to a loss of
power or motor failure, use the “Indent Assembly (Without Power)” procedure
on page 4-84.

Removal Procedure
1. With the system powered up, start Diagnostics and lower the Indent
assembly to the tilt home position. This procedure cannot be accomplished
manually without the system powered.

2. Shut down the Controller and turn off the power.

3. Disconnect the four cable connectors (two harnesses) that link the Indent
assembly to the Embossing module.
4. Remove the two screws that secure the Indent assembly to the top of the
Embossing module.
5. Lift the Indent assembly up to remove it.

4-82 Removal and Replacement

Follow-up Adjustment

If the Indent assembly is not replaced, the change in weight to the module will
change the vertical height of the module platform so you need to adjust the Card
Guide Alignment as described in chapter 3. (The same is true if a new Indent
module is added to a module not previously equipped with one.)

Maxsys Embossing/Indent Module Service Manual 4-83

Indent Assembly (Without Power)
Use this procedure if the Indent assembly cannot be lowered to the tilt home
position, such as in the case of loss of power or motor failure. If the assembly can
be lowered to the home position, use the “Indent Assembly” removal procedure
on page 4-82.

Removal Procedure
1. Shut down the Controller and turn off the power.

2. Disconnect the four cable connectors (two harnesses) that link the Indent
module to the Embossing module.

3. Remove the retaining ring from the leadscrew clevis pin.

• If the pin is difficult to reach, use the hook on a spring removal tool to grip
the ring and pull it away from the pin.

• Place your fingertip over the ring as it comes loose to prevent it from
flying loose.

• Be very careful not to lose the retaining ring or the clevis pin inside the
embossing module.

4. Slide the clevis pin out of the yoke and clevis.

4-84 Removal and Replacement

 5. Lower the assembly to the home position.

6. Remove the two screws that secure the assembly to the top of the Embossing
module, and lift the assembly up to remove it.

Maxsys Embossing/Indent Module Service Manual 4-85

Replacement Preparation

Before replacing the Indent assembly, return the leadscrew to the tilt home
position so the assembly can be replaced normally.

1. Rotate the saddle bracket away from the leadscrew clevis. If necessary,
remove the two wiring harnesses from the saddle.
2. Unscrew the leadscrew from the motor until the distance between the motor
and clevis is between 1.4 and 1.5 inches (3.56 and 3.81 cm).

3. Replace the clevis in the yoke and secure it with the clevis pin and retaining
ring.

Follow-up Adjustment

If the Indent module is not replaced, the change in weight to the module will
change the vertical height of the module platform so you will need to adjust the
Card Guide Alignment as described in chapter 3. (The same is true if a new
Indent module is added to a module not previously equipped with the indent
option.)

4-86 Removal and Replacement

Ribbon Diameter Encoders and Loading Springs

Removal Procedure
1. Lower the Indent assembly to the tilt home position.
2. Shut down the Controller and turn off the power.

3. Remove the Indent Assembly as described on page 4-82.

4. Remove one of the two screws that secure the high-flex grounding wire
between the driver board mounting bracket and the saddle bracket.

5. Remove the four screws that secure the encoder serial data board to the back
of the assembly. This provides additional clearance for removing the encoder
bodies.

6. Disconnect the encoder cable from the back of the encoder.

Maxsys Embossing/Indent Module Service Manual 4-87

 7. Loosen the setscrew that secures the encoder arm to the encoder shaft, and
remove the arm and return spring.

Before removing the encoder arm, note the position of the return spring to
make replacement easier.
8. Remove the retaining nut from the encoder shaft, and remove the encoder.

Replacement Notes
• When replacing the encoder body, make sure the anti-rotation bracket is in
place to prevent the encoder body from rotating.

• When tightening the encoder arm setscrew, make sure it is clamping on the
flat of the encoder shaft.

4-88 Removal and Replacement

Ribbon Encoder

Removal Procedure
1. Lower the indent assembly to the tilt home position.
2. Shut down the Controller and turn off the power.

3. Remove the Indent Assembly as described on page 4-82.

4. Remove the indent ribbon.

5. Remove the four screws that secure the front cover plate to the Indent
module, and slide the cover straight out horizontally to remove it.

Maxsys Embossing/Indent Module Service Manual 4-89

 6. Using a small screwdriver to release the connector latch, disconnect the
encoder cable connector from the encoder.

7. Loosen the setscrew on the encoder roller, and remove the roller.
8. Remove the retaining nut and lock washer from the encoder, and remove the
encoder.

Replacement Notes
• When replacing the encoder, make sure the anti-rotation bracket is in place to
prevent the encoder from rotating.

• When tightening the encoder arm setscrew, make sure it is clamping on the
flat of the encoder shaft.

4-90 Removal and Replacement

Ribbon Replacement Procedure

Removal Procedure
1. Lower the indent assembly to the tilt home position.
2. Shut down the Controller and turn off the power.

3. Remove the Indent Assembly as described on page 4-82.

4. Remove the indent ribbon. (Rethread it as indicated below.)

Maxsys Embossing/Indent Module Service Manual 4-91

Tilt Up and Tilt Home Sensors

Removal Procedure
1. Lower the indent assembly to the tilt home position.

2. Shut down the Controller and turn off the power.

3. Remove the Indent Assembly as described on page 4-82.

4. Remove the indent ribbon.

5. Remove the four screws that secure the front cover plate to the Indent
module, and slide the cover straight out horizontally to remove it.

4-92 Removal and Replacement

 6. Turn the indent assembly over, and disconnect the sensor cable connector.

7. Remove the screw that secures the sensor, and remove the sensor.

Maxsys Embossing/Indent Module Service Manual 4-93

Encoder Driver Board

Removal Procedure
1. With Maxsys powered on, start Diagnostics and lower the Indent module to
the tilt home position.

2. Shut down the Controller and turn off the power.

3. Disconnect the four cable connectors (two harnesses) that link the Indent
assembly to the Embossing module.

4. Remove the two screws that secure the wire harness cable clamps to the
saddle bracket.

5. Remove the four screws that secure the driver board mounting bracket to the
assembly.

6. Remove one of the two screws that secure the high-flex grounding wire
between the driver board mounting bracket and the saddle bracket.

4-94 Removal and Replacement

 7. Without straining the wires, turn the encoder driver board and mounting
bracket over to expose the connectors and mounting screws.

8. Disconnect the two encoder inputs from the board.

9. Remove the two screws that secure the outbound data connector to the board,
and disconnect the cable.

10. Remove the four screws that secure the board to the mounting bracket, and
remove the board.

Maxsys Embossing/Indent Module Service Manual 4-95

Indent I-Button Board
The majority of this procedure is focused on freeing up wiring to provide easier
access to the I-Button board. For minimal disassembly, use the “Encoder Driver
Board” removal procedure on page 4-94, and return to this procedure at step 10.

Removal Procedure
1. With Maxsys powered on, enter Diagnostics and lower the Indent assembly
to the tilt home position.

2. Shut down the Controller and turn off the power.

3. Remove the Indent assembly from the Embossing module.

4. Remove the four screws that secure the front cover plate to the assembly, and
slide the cover straight out horizontally to remove it.

4-96 Removal and Replacement

 5. Using a small screwdriver to release the connector latch, disconnect the
ribbon encoder able connector from the encoder.

6. Disconnect the tilt down and tilt up sensor connectors, and free all three
cables (including the encoder cable) from the cable retainers. Freeing the
cables permits the encoder board mounting bracket to be further out of the
way of the I-Button board.

Maxsys Embossing/Indent Module Service Manual 4-97

 7. Remove the two screws that secure the wire harness cable clamps to the
saddle bracket.

8. Remove the four screws that secure the encoder driver board mounting
bracket to the module.

9. Remove one of the two screws that secure the high-flex grounding wire
between the encoder driver board mounting bracket and the saddle bracket.

4-98 Removal and Replacement

 10. Disconnect the two encoder inputs from the board.

11. Remove the two screws that secure the outbound data connector to the board,
and disconnect the cable.

12. Disconnect the VPD cable from the I-Button board.

13. Remove the two mounting screws that secure the I-Button board to the
assembly, and remove the board.

Maxsys Embossing/Indent Module Service Manual 4-99

4-100 Removal and Replacement
Chapter 5: Preventive
Maintenance
This chapter describes the processes for performing preventive
maintenance on the Maxsys Embossing/Indent module.

Service Engineer Maintenance Schedule ______________________________ 5-2

Checking Cam Driver Guide Bearing Clearance _______________________ 5-3

Maxsys Embossing/Indent Module Service Manual 5-1

Service Engineer Maintenance Schedule
See the list of supplies and materials for preventive maintenance using the option
on the Service Library menu.
Caution: Vacuum the dust from these parts because blowing the dust might
cause it to lodge in other module components such as the power supply and
eventually cause the component to malfunction.

Procedure Frequency Comments

Inspect wheel Once a month or • There should be a slight amount of grease on

characters for every 300,000 the sides of the characters.
sufficient grease cards • If the grease is contaminated with debris,
remove the characters, clean them and re-
apply grease.
• Using compressed air, blow out any dust from
the wheel.

Inspect the vertical Once a month or • The shafts should have a slight layer of Delron
lift linear rails every 300,000 dust from the bearings. Do not wipe the shafts
cards clean.
• If the shafts have excessive dirt build up and the
module experiences vertical lift errors, wipe the
shafts.
• Do not lubricate the shafts.

Clean the cam Once a month or Dust will build up on the fan impellers and the motor
motors and fans every 300,000 body
cards

Inspect the cam Once a month or Check the clearance between the bearing and
driver guide every 300,000 the guide block. Refer to the following figure.
bearings cards

Inspect the driver Once a month or Look for rounded edges on the tips of the drivers.
tips every 300,000 This indicates that the drivers are not striking the
cards characters squarely. If found, replace the driver
assembly and adjust the wheel home offset.

Clean the cams Once a month or Wipe the surface of the cams with a cloth
every 300,000 dampened in isopropyl alcohol.
cards

Inspect the Once a month or • Verify that the isolation mounts are not jammed
isolation mounts every 300,000 by rocking the module.
cards • Check the isolation mount alignment. Refer to
“Card Guide Alignment” in chapter 3.

Inspect indent Every 500,000

ribbon guides cards

5-2 Preventive Maintenance

 Procedure Frequency Comments

Clean indent Every 500,000

ribbon advance cards
roller

Replace Tab Belt Every 3 million

cards

Inspect front/rear Every 5 million

emboss assembly cards
bearings

Checking Cam Driver Guide Bearing Clearance

The gap between the cam driver guide bearing and the guide block should be less
than 0.005 inch (0.127 mm).

If the gap is larger, remove the two screws that secure the guide block to the top
of the driver assembly, and lift the guide block from the guide bearing.

Maxsys Embossing/Indent Module Service Manual 5-3

5-4 Preventive Maintenance