Datacard I50i Card Personalization System Maintenance Manual

Datacard I50i
Card Personalization System
Maintenance Manual
June 2001
Part No. 539110-001 Rev. B

Liability Statement
This product has been built to the high standards of Datacard Group. Please do not
attempt to operate or repair this equipment without adequate training. Any use,
operation, or repair in contravention of this document is at your own risk. By
acceptance of this system you hereby assume all liability consequent to your use or
misuse of this equipment. Datacard assumes no liability for incidental, special, or
consequential damage of any kind. Equipment specifications, applications, and
options are subject to change at the sole discretion of Datacard without notice.
Proprietary Notice
All drawings and information herein are the property of Datacard Corporation. All
unauthorized use and reproduction is prohibited.
Trademark Acknowledgments
Datacard is a registered trademark and LaserGrafix is a trademark of Datacard
Corporation.
Torx is a registered trademark of Textron, Inc. Windows is a registered trademark of

Microsoft Corporation.
All other product names are the property of their respective owners.
Datacard Group
11111 Bren Road West
Minnetonka, MN 55343-9015
952.933.1223
Fax: 952.933.7971
www.datacard.com
© 2001 Datacard Corporation.

All rights reserved. Printed in the United States of America.
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Contents
Chapter 1: System Description ___________________________________________________ 1-1

Audience____________________________________________________________________________ 1-2
Repair Ability ________________________________________________________________________ 1-2
Serial Numbers _______________________________________________________________________ 1-2
Use of this Document _________________________________________________________________ 1-3
Product Specifications _______________________________________________________________ 1-4
Electrical ________________________________________________________________________ 1-4
Environmental ___________________________________________________________________ 1-4
Communications ________________________________________________________________ 1-4
Card Capacities_________________________________________________________________ 1-4
Input Hopper Capacity ______________________________________________________ 1-4
Reject Hopper Capacity _____________________________________________________ 1-4
Output Hopper Capacity ____________________________________________________ 1-4
Topper Cassette Capacity _______________________________________________________ 1-4
Protocols ________________________________________________________________________ 1-4
Physical Specifications ___________________________________________________________ 1-5
Card Specifications ______________________________________________________________ 1-5
Magnetic Stripe Encoding Specifications ______________________________________________ 1-6
Standard Financial Emboss Line Locations _____________________________________________ 1-6
Standard Emboss Character Height ___________________________________________________ 1-7
Standard Emboss Character Spacing _________________________________________________ 1-7
Chapter 2: Installation ___________________________________________________________ 2-1

Preparing the Site ____________________________________________________________________ 2-2
Unpacking/Packing ____________________________________________________________________ 2-3
Functional Tests ______________________________________________________________________ 2-6
Administrator Setup ______________________________________________________________ 2-6
Standard CPX Used__________________________________________________________ 2-6
Baud Rate __________________________________________________________________ 2-9
Parity Bits____________________________________________________________________ 2-9
Bits Size _____________________________________________________________________ 2-9
Monitor _____________________________________________________________________ 2-9
Test Card ___________________________________________________________________ 2-9
Stripe Retrys ________________________________________________________________ 2-10
Write Only Once____________________________________________________________ 2-10
Door Password _____________________________________________________________ 2-10
Save Changes _____________________________________________________________ 2-10
Financial Card Password ____________________________________________________________ 2-10
Chapter 3: Preventive Maintenance ______________________________________________ 3-1

Preventive Maintenance _____________________________________________________________ 3-2
Tools and Material ___________________________________________________________________ 3-3
Preventive Maintenance Procedures __________________________________________________ 3-3
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Cleaning the 150i ________________________________________________________________ 3-4
Cleaning the O-Rings/Drive Rollers ________________________________________________ 3-4
Cleaning the Sensors_____________________________________________________________ 3-5
Cleaning the Magnetic Stripe Head ______________________________________________ 3-6
Verifying Embossing Line Locations and Margins _______________________________________ 3-7
Verify Start Sentinel and Track Locations for Magnetic Stripe ____________________________ 3-9
Verify Even and Uniform Topping _____________________________________________________ 3-11
Verify Throat Gap Adjustment________________________________________________________ 3-12
Chapter 4: Theory of Operation___________________________________________________ 4-1

150i Overview________________________________________________________________________ 4-2
Component Identification ____________________________________________________________ 4-2
Inside View of the 150i ________________________________________________________________ 4-3
Rear View of the 150i _________________________________________________________________ 4-4
Sequence of Operation ______________________________________________________________ 4-5
Memory Map ________________________________________________________________________ 4-7
Electrical Block Diagram______________________________________________________________ 4-8
Microprocessor __________________________________________________________________ 4-9
CPLD____________________________________________________________________________ 4-9
Flash ____________________________________________________________________________ 4-9
DRAM ___________________________________________________________________________ 4-9
FPGA Controller_________________________________________________________________ 4-10
ROM ___________________________________________________________________________ 4-10
EEPROM________________________________________________________________________ 4-10
Power Inlet Module _____________________________________________________________ 4-10
36 Volt Power Supply____________________________________________________________ 4-10
5 Volt Regulator ________________________________________________________________ 4-10
12 Volt Regulator _______________________________________________________________ 4-11
System Interlock ________________________________________________________________ 4-11
RS232 Transceiver _______________________________________________________________ 4-11
LCD Display/Keypad and LEDs___________________________________________________ 4-11
Main Control Board Schematics______________________________________________________ 4-12
Chapter 5: Troubleshooting ______________________________________________________ 5-1

Troubleshooting Tips __________________________________________________________________ 5-3
Prerequisite Skills _____________________________________________________________________ 5-4
Diagnostic Routines __________________________________________________________________ 5-4
Diagnostic Routines Menu ________________________________________________________ 5-5
Sensors _____________________________________________________________________ 5-6
MS Start Sentinel (NTT)________________________________________________________ 5-7
MS Start Sentinel (Standard) __________________________________________________ 5-7
Transport____________________________________________________________________ 5-7
Pick & Stack_________________________________________________________________ 5-7
Pick & Reject ________________________________________________________________ 5-7
Calibration Menu ________________________________________________________________ 5-8
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Test Cards Menu _________________________________________________________________ 5-9
Standard Test Card _________________________________________________________ 5-10
Mag Stripe Test Card _______________________________________________________ 5-10
Indent Test Card____________________________________________________________ 5-10
MagStripe/Emboss Test Card ________________________________________________ 5-10
MagStripe/Emboss/Top Test Card____________________________________________ 5-10
Smart Card Test Card _______________________________________________________ 5-11
Wheel Test Card____________________________________________________________ 5-11
Topper Test Card ___________________________________________________________ 5-12
Run Without Cards__________________________________________________________ 5-12
Preembossed Test Card _____________________________________________________ 5-12
Character Height Test Card _________________________________________________ 5-12
Position Offsets Menu ___________________________________________________________ 5-13
Wheel Parameters Menu ________________________________________________________ 5-15
Topper Parameters Menu _______________________________________________________ 5-16
Configuration Menu ____________________________________________________________ 5-16
Status Request Menu____________________________________________________________ 5-17
Restore MCB Defaults ___________________________________________________________ 5-17
Restore Mfg Settings ____________________________________________________________ 5-17
Save Changes__________________________________________________________________ 5-17
150i Interconnect Diagrams _________________________________________________________ 5-18
Main Control Board Connections ________________________________________________ 5-19
Main Control Board Cable Connections__________________________________________ 5-20
AC Wiring Diagram _____________________________________________________________ 5-21
Pin-Out Tables ______________________________________________________________________ 5-22
Motor Pin-Outs__________________________________________________________________ 5-22
Sensor Pin-Outs _________________________________________________________________ 5-24
Serial Communications Pin-Outs _________________________________________________ 5-26
Identifying Errors Using Error Codes ___________________________________________________ 5-27
Group xx _______________________________________________________________________ 5-27
Group yy _______________________________________________________________________ 5-28
Group zz _______________________________________________________________________ 5-28
Error Codes_____________________________________________________________________ 5-32
Main Control Board LEDs ________________________________________________________ 5-38
Chapter 6: Adjustments __________________________________________________________ 6-1

Introduction _________________________________________________________________________ 6-2
Mechanical Adjustments _____________________________________________________________ 6-2
Magnetic Stripe Head Height Adjustment _________________________________________ 6-2
Rear Indent Drive Belt Adjustment_________________________________________________ 6-4
Interlock Switch Adjustment ______________________________________________________ 6-6
Electrical Adjustment _________________________________________________________________ 6-8
Display Contrast Adjustment ______________________________________________________ 6-8
Software Offsets ____________________________________________________________________ 6-10
Start Diagnostic Routines ________________________________________________________ 6-10
Position Offsets Menu ___________________________________________________________ 6-11
Pick Offset _________________________________________________________________ 6-13
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Smart Card Offset __________________________________________________________ 6-14
MagStripe NTT Offset________________________________________________________ 6-15
MagStripe Standard Offset __________________________________________________ 6-17
MagStripe Variables Offset __________________________________________________ 6-19
Emboss Location Offset _____________________________________________________ 6-20
Topper Offset ______________________________________________________________ 6-21
Topper Noise Offset_________________________________________________________ 6-22
Exit Offset __________________________________________________________________ 6-23
Emboss Height Offset _______________________________________________________ 6-24
Indent Depth Offset ________________________________________________________ 6-25
Throat Gap Offset __________________________________________________________ 6-26
Wheel Home Offset _________________________________________________________ 6-27
Card Bow Offset____________________________________________________________ 6-28
Chapter 7: Removal and Replacement ___________________________________________ 7-1
Introduction _________________________________________________________________________ 7-3
Servicing Guidelines __________________________________________________________________ 7-3
Opening the Top Cover ______________________________________________________________ 7-4
Changing the Password ______________________________________________________________ 7-5
Top Cover ___________________________________________________________________________ 7-6
Front Access Panel_______________________________________________________________ 7-8
Single Card Access Door ________________________________________________________ 7-10
Output Hopper Door ____________________________________________________________ 7-12
Key Lock _______________________________________________________________________ 7-14
Input/Output Hopper________________________________________________________________ 7-16
Output Hopper Drive Belt________________________________________________________ 7-20
Output Hopper Drive O-Ring_____________________________________________________ 7-22
Card Registration Sensor ________________________________________________________ 7-24
Input Hopper Empty Sensor______________________________________________________ 7-26
Input Home Sensor ______________________________________________________________ 7-28
Output Full Sensor_______________________________________________________________ 7-30
Card Picked Sensor _____________________________________________________________ 7-32
Throat Gap Motor ______________________________________________________________ 7-34
Throat Gap Motor Belt __________________________________________________________ 7-36
Throat Gap Sensor ______________________________________________________________ 7-38
Card Transport ______________________________________________________________________ 7-40
X-Transport Drive Belt____________________________________________________________ 7-42
X-Home Sensor _________________________________________________________________ 7-44
Y-Home Sensor _________________________________________________________________ 7-46
Card Transport Flex Cable _______________________________________________________ 7-48
Carriage Transport Motor________________________________________________________ 7-50
Magnetic Stripe Assembly ___________________________________________________________ 7-52
Embosser Assembly__________________________________________________________________ 7-54
Wheel Home Sensor_____________________________________________________________ 7-56
Punch Home Sensor_____________________________________________________________ 7-58
Punch Cam Motor ______________________________________________________________ 7-60
Punch Cam Belt ________________________________________________________________ 7-62
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Die Home Sensor _______________________________________________________________ 7-64
Die Cam Motor _________________________________________________________________ 7-66
Die Cam Belt ___________________________________________________________________ 7-68
Punch and Die _________________________________________________________________ 7-70
Topper Assembly ____________________________________________________________________ 7-72
Topper Foil Motion Sensor _______________________________________________________ 7-74
Topper Platen Sensor____________________________________________________________ 7-76
Topper Motor___________________________________________________________________ 7-78
Main Control Board _________________________________________________________________ 7-80
Power Supply Board _________________________________________________________________ 7-82
Line Filter ___________________________________________________________________________ 7-84
Fuse ___________________________________________________________________________ 7-86
Fan ________________________________________________________________________________ 7-88
Display/Keypad_____________________________________________________________________ 7-90
Solenoid Lock Assembly _____________________________________________________________ 7-92
Reject Full Sensor____________________________________________________________________ 7-94
Front Smart Card Module (Option) __________________________________________________ 7-96
Front Indent Printer Module (Option)_________________________________________________ 7-98
Replacing the Front Indent Ribbon______________________________________________7-100
Rear Indent Printer Module (Option) ________________________________________________7-102
Replacing the Rear Indent Ribbon ______________________________________________7-104
Rear Indent Motor _________________________________________________________________7-106
Rear Indent Drive Belt ______________________________________________________________7-108
Rear Indent Solenoid _______________________________________________________________7-110
Chapter 8: Illustrated Parts Breakdown____________________________________________ 8-1

Introduction _________________________________________________________________________ 8-2
General _____________________________________________________________________________ 8-2
Cabinet Parts____________________________________________________________________ 8-3
Input/Output Hopper Assembly ___________________________________________________ 8-4
Card Transport Assembly _________________________________________________________ 8-6
Magnetic Stripe Assembly ________________________________________________________ 8-7
Embosser Assembly ______________________________________________________________ 8-8
Lower Emboss Housing Assembly _________________________________________________ 8-10
Upper Emboss Housing Assembly_________________________________________________ 8-11
Topper Assembly________________________________________________________________ 8-12
Topper Foil _____________________________________________________________________ 8-13
Main Control Board _____________________________________________________________ 8-14
Power Supply ___________________________________________________________________ 8-15
Fan ____________________________________________________________________________ 8-16
Sensor Cable Harness ___________________________________________________________ 8-17
Power Cable Harness ___________________________________________________________ 8-18
Communications Cable_________________________________________________________ 8-19
Cable/Development Cable _____________________________________________________ 8-20
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Display/Keyboard_______________________________________________________________ 8-21
Miscellaneous Spare Parts _______________________________________________________ 8-22
Solenoid Lock Assembly _________________________________________________________ 8-23
Reject Full Photocell ____________________________________________________________ 8-24
Smart Card Assembly ___________________________________________________________ 8-25
Front Indent Print Assembly ______________________________________________________ 8-26
Rear Indent Printer Assembly_____________________________________________________ 8-27
Indent Ribbon __________________________________________________________________ 8-28
Appendix A: Glossary ___________________________________________________________ A-1

Glossary of Terms____________________________________________________________________ A-1
Appendix B: Wheel Table Configurations__________________________________________ B-1

Standard ____________________________________________________________________________ B-3
Tilde N (Ñ) ___________________________________________________________________________ B-4
Visa 'V' ______________________________________________________________________________ B-5
Diners Club __________________________________________________________________________ B-6
Barcelona ___________________________________________________________________________ B-7
Barcelona OCR B1 Special____________________________________________________________ B-8
Large Gothic K_______________________________________________________________________ B-9
Indent-Rear OCR-A1 ________________________________________________________________B-10
Indent-Rear OCR-B1_________________________________________________________________B-11
Indent-Rear MasterCard_____________________________________________________________B-12
Common European _________________________________________________________________B-13
Portugal ____________________________________________________________________________B-14
Japanese Financial _________________________________________________________________B-15
Japanese Financial Special__________________________________________________________B-16
Japanese Healthcare _______________________________________________________________B-17
Japan Credit (Amex/Diners and Others) ___________________________________________B-18
Visa/Master/JCB and Co-Branded ___________________________________________________B-19
Indent-Rear Inverted MasterCard ____________________________________________________B-20
Czech ______________________________________________________________________________B-21
Greece ____________________________________________________________________________B-22
Hungary ____________________________________________________________________________B-23
Iceland_____________________________________________________________________________B-24
Latvian _____________________________________________________________________________B-25
Poland _____________________________________________________________________________B-26
Cyrillic ______________________________________________________________________________B-27
Turkey ______________________________________________________________________________B-28
Yugoslavia__________________________________________________________________________B-29
Ukraine _____________________________________________________________________________B-30
Korea ______________________________________________________________________________B-31
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Front Visa Electron Indent____________________________________________________________B-32
Poland-OCR B1 Indent ______________________________________________________________B-33
Latvian-OCR B1 Indent ______________________________________________________________B-34
Barcelona-OCR B1 Indent ___________________________________________________________B-35
Common European -OCR B1 Indent__________________________________________________B-36
Portugal-OCR B1 Indent _____________________________________________________________B-37
Greece-OCR B1 Indent ______________________________________________________________B-38
Hungary-OCR B1 Indent _____________________________________________________________B-39
Iceland-OCR B1 Indent ______________________________________________________________B-40
Turkey-OCR B1 Indent _______________________________________________________________B-41
Yugoslavia-OCR B1 Indent ___________________________________________________________B-42
Ukraine-OCR B1 Indent ______________________________________________________________B-43
Cyrillic-OCR B1 Indent _______________________________________________________________B-44
Korea Visa Electron _________________________________________________________________B-45
Czech Visa Electron _________________________________________________________________B-46
Common European w/MasterCard Indent____________________________________________B-47
Portugal w/MasterCard Indent_______________________________________________________B-48
Greece w/MasterCard Indent _______________________________________________________B-49
Hungary w/MasterCard Indent_______________________________________________________B-50
Iceland w/MasterCard Indent _______________________________________________________B-51
Latvian w/MasterCard Indent________________________________________________________B-52
Poland w/MasterCard Indent ________________________________________________________B-53
Turkey w/MasterCard Indent _________________________________________________________B-54
Yugoslavia w/MasterCard Indent ____________________________________________________B-55
List of Figures
Figure 2-1: Unpacking/Packing ____________________________________________________________ 2-3
Figure 2-2: Included Packed Materials _____________________________________________________ 2-4
Figure 2-3: Packing Material Removal ______________________________________________________ 2-5
Figure 3-1: Preventive Maintenance Schedule______________________________________________ 3-4
Figure 3-2: Sensor Locations _______________________________________________________________ 3-5
Figure 3-3: Cleaning the Magnetic Stripe Head _____________________________________________ 3-6
Figure 3-4: Embossing Line Locations and Margins Card _____________________________________ 3-8
Figure 3-5: Start Sentinel and Track Locations for Magnetic Stripe ___________________________ 3-10
Figure 3-6: Wheel Test Card ______________________________________________________________ 3-12
Figure 4-1: Component Identification ______________________________________________________ 4-3
Figure 4-2: Inside View of the 150i __________________________________________________________ 4-4
Figure 4-3: Rear View of the 150i ___________________________________________________________ 4-5
Figure 4-4: Sequence of Operation ________________________________________________________ 4-7
Figure 4-5: 150i Embedded System Memory Layout _________________________________________ 4-8
Figure 4-6: 150i Main Control Board Block Diagram _________________________________________ 4-9
Figure 4-7: 150i Main Control Board Schematic (1 of 20) ____________________________________ 4-13
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Figure 4-10: 150i Main Control Board Schematic (4 of 20) ___________________________________ 4-16
Figure 4-16: 150i Main Control Board Schematic (10 of 20)__________________________________ 4-22
Figure 5-1 : Standard Test Card ___________________________________________________________ 5-10
Figure 5-2: Wheel Test Card ______________________________________________________________ 5-11
Figure 5-3: Topper Test Card______________________________________________________________ 5-12
Figure 4: Main Control Input/Output Block Diagram________________________________________ 5-18
Figure 5-5: Main Control Board Connections ______________________________________________ 5-19
Figure 5-6: Main Control Board Cable Connections ________________________________________ 5-20
Figure 5-7: AC Wiring Diagram____________________________________________________________ 5-21
Figure 5-8: Main Control Board LEDs_______________________________________________________ 5-39
Figure 5-9: Sensor Locations ______________________________________________________________ 5-40
Figure 6-1: Magnetic Stripe Head Height Adjustment________________________________________ 6-3
Figure 6-2: Rear Indent Drive Belt Adjustment _______________________________________________ 6-5
Figure 6-3: Interlock Switch Adjustment_____________________________________________________ 6-7
Figure 6-4: Display Contrast Adjustment ____________________________________________________ 6-9
Figure 7-1: Top Cover _____________________________________________________________________ 7-7
Figure 7-2: Front Access Panel _____________________________________________________________ 7-9
Figure 7-3: Single Card Access Door ______________________________________________________ 7-11
Figure 7-4: Output Hopper Door __________________________________________________________ 7-13
Figure 7-5: Key Lock _____________________________________________________________________ 7-15
Figure 7-6: Input/Output Hopper__________________________________________________________ 7-17
Figure 7-7: Output Hopper Drive Belt ______________________________________________________ 7-21
Figure 7-8: Output Hopper Drive O-Ring ___________________________________________________ 7-23
Figure 7-9: Card Registration Sensor_______________________________________________________ 7-25
Figure 7-10: Input Hopper Empty Sensor ___________________________________________________ 7-27
Figure 7-11: Input Home Sensor ___________________________________________________________ 7-29
Figure 7-12: Output Full Sensor ____________________________________________________________ 7-31
Figure 7-13: Card Picked Sensor __________________________________________________________ 7-33
Figure 7-14: Throat Gap Motor____________________________________________________________ 7-35
Figure 7-15: Throat Gap Motor Belt________________________________________________________ 7-37
Figure 7-16: Throat Gap Sensor ___________________________________________________________ 7-39
Figure 7-17: Card Transport _______________________________________________________________ 7-41
Figure 7-18: X-Transport Drive Belt _________________________________________________________ 7-43
Figure 7-19: X-Home Sensor_______________________________________________________________ 7-45
Figure 7-20: Y-Home Sensor_______________________________________________________________ 7-47
Figure 7-21: Card Transport Flex Cable ____________________________________________________ 7-49
Figure 7-22: Carriage Transport Motor _____________________________________________________ 7-51
Figure 7-23: Magnetic Stripe Assembly ____________________________________________________ 7-53
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Figure 7-24: Embosser ____________________________________________________________________ 7-55
Figure 7-25: Wheel Home Sensor __________________________________________________________ 7-57
Figure 7-26: Punch Home Sensor __________________________________________________________ 7-59
Figure 7-27: Punch Cam Motor ___________________________________________________________ 7-61
Figure 7-28: Punch Cam Belt _____________________________________________________________ 7-63
Figure 7-29: Die Home Sensor _____________________________________________________________ 7-65
Figure 7-30: Die Cam Motor ______________________________________________________________ 7-67
Figure 7-31: Die Cam Belt ________________________________________________________________ 7-69
Figure 7-32: Punch and Die_______________________________________________________________ 7-71
Figure 7-33: Topper Assembly _____________________________________________________________ 7-73
Figure 7-34: Topper Foil Motion Sensor_____________________________________________________ 7-75
Figure 7-35: Topper Platen Sensor _________________________________________________________ 7-77
Figure 7-36: Topper Motor ________________________________________________________________ 7-79
Figure 7-37: Main Control Board __________________________________________________________ 7-81
Figure 7-38: Power Supply ________________________________________________________________ 7-83
Figure 7-39: Line Filter ____________________________________________________________________ 7-85
Figure 7-40: Fuse_________________________________________________________________________ 7-87
Figure 7-41: Fan _________________________________________________________________________ 7-89
Figure 7-42: Display/Keypad______________________________________________________________ 7-91
Figure 7-43: Solenoid Lock Assembly ______________________________________________________ 7-93
Figure 7-44: Reject Full Sensor_____________________________________________________________ 7-95
Figure 7-45: Front Smart Card Module _____________________________________________________ 7-97
Figure 7-46: Front Indent Printer Module ___________________________________________________ 7-99
Figure 7-47: Replacing the Front Indent Ribbon ___________________________________________7-101
Figure 7-48: Rear Indent Printer Module __________________________________________________7-103
Figure 7-49: Replacing the Rear Indent Ribbon ___________________________________________7-105
Figure 7-50: Rear Indent Motor __________________________________________________________7-107
Figure 7-51: Rear Indent Drive Belt _______________________________________________________7-109
Figure 7-52: Rear Indent Solenoid ________________________________________________________7-111
List of Tables
Table 1-1: Magnetic Stripe Encoding Specifications_________________________________________ 1-6
Table 2-1: Installation Materials and Special Tools ___________________________________________ 2-2
Table 3-1: Preventive Maintenance Schedule ______________________________________________ 3-2
Table 3-2: Line Location and Margins Checklist _____________________________________________ 3-8
Table 3-3: Even and Uniform Topping Checklist ____________________________________________ 3-11
Table 5-1: Keypad Navigation _____________________________________________________________ 5-5
Table 5-2: Sensor Bit Locations _____________________________________________________________ 5-6
Table 5-3: Test Card Menu ________________________________________________________________ 5-9
Table 5-4 : Smart Card Test Messages _____________________________________________________ 5-11
Table 5-5: Position Offsets Menu __________________________________________________________ 5-14
Table 5-6: Wheel Parameters Menu _______________________________________________________ 5-15
Table 5-7: Spacing and Character Type___________________________________________________ 5-15
Table 5-8: Topper Parameters Menu ______________________________________________________ 5-16
Table 5-9: Configuration Menu ___________________________________________________________ 5-16
Table 5-10: Status Request Menu _________________________________________________________ 5-17
Table 5-11: Motor Pin-Outs for Connector J10______________________________________________ 5-22
Table 5-12: Motor Pin-Outs for Connector J11______________________________________________ 5-23
Table 5-13: Sensor Pin-Outs for Connector J12 _____________________________________________ 5-24
Table 5-14: Sensor Pin-Outs for Connector J13 _____________________________________________ 5-25
xi
Table 5-15: Serial Communications Pin-Outs (J16) __________________________________________ 5-26
Table 5-16: Error Code Troubleshooting Chart______________________________________________ 5-32
Table 5-17: Main Control Board LEDs ______________________________________________________ 5-38
Table 6-1: Keypad Navigation ____________________________________________________________ 6-10
Table 6-2: Position Offsets Menu __________________________________________________________ 6-11
Table 6-3: Pick Offset ____________________________________________________________________ 6-13
Table 6-4: Smart Card Offset _____________________________________________________________ 6-14
Table 6-5: MagStripe NTT Offset ___________________________________________________________ 6-15
Table 6-6: MagStripe Standard Offset _____________________________________________________ 6-17
Table 6-7: MagStripe Variables Offset _____________________________________________________ 6-19
Table 6-8: Emboss Location Offset ________________________________________________________ 6-20
Table 6-9: Topper Offset__________________________________________________________________ 6-21
Table 6-10: Topper Noise Offset ___________________________________________________________ 6-22
Table 6-11: Exit Offset ____________________________________________________________________ 6-23
Table 6-12: Emboss Height Offset _________________________________________________________ 6-24
Table 6-13: Indent Depth Offset __________________________________________________________ 6-25
Table 6-14: Throat Gap Offset ____________________________________________________________ 6-26
Table 6-15: Wheel Home Offset ___________________________________________________________ 6-27
Table 6-16: Card Bow Offset______________________________________________________________ 6-28
xii
Revision Log
150i Card Personalization System Maintenance Manual
Revision Date Affected Description of Changes

Pages
A May 2001 All First release of this document. Information was
originally delivered as an online help file.
B June 2001 Chapter 8 Added Chapter 8, Illustrated Parts Breakdown to his

manual.
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 (CUL)

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.
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.
Notice for Europe

See the Declaration of Conformity on the following page.
xiii
xiv
Safety
All Datacard products are built to strict safety and reliability specifications in
accordance with UL1950 and EN60950, therefore, safety issues pertaining to
operation and repair of Datacard equipment are primarily environmental and
human interface.
The following basic safety tips are given to ensure safe installation, operation and
maintenance of Datacard equipment and are not to be considered as comprehensive
on all matters of safety.
Safe Environment
• Connect equipment to a grounded facility power source. Do not defeat or bypass
the ground lead.
• Place the equipment on a stable surface (table), and ensure floors in work area
are dry and non-slip. Insulated rubber floor mats are preferred.
• Know the location of equipment branch circuit interrupters or circuit breakers
and how to turn them on and off in case of emergency.
• Know the location of fire extinguishers and how to use them. Use only ABC type
extinguishers on electrical fires.
• Know local procedures for first aid and emergency assistance at the customer
facility.
• Use adequate lighting at the equipment.
• Maintain the recommended range of temperature and humidity in equipment
area.
Safe Human Interface

• Use proper lifting techniques when moving or installing the equipment.
• Use standard electrostatic discharge (ESD) precautions when working on or near
electrical circuits.
• Do not defeat or disconnect safety interlocks on covers.
xv
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1
Chapter 1:
System Description
The 150i Card Personalization System operates as a standalone card
embosser. This chapter provides a system description of the 150i
embosser.
Audience 1-2
Repair Ability 1-2
Serial Numbers 1-2
Use of this Document 1-3
Product Specifications 1-4

Electrical 1-4
Environmental 1-4
Communications 1-4
Card Capacities 1-4
Input Hopper Capacity 1-4
Reject Hopper Capacity 1-4
Output Hopper Capacity 1-4
Topper Cassette Capacity 1-4
Protocols 1-4
Physical Specifications 1-5
Card Specifications 1-5
Magnetic Stripe Encoding Specifications 1-6
Standard Financial Emboss Line Locations 1-6
Standard Emboss Character Height 1-7
Standard Emboss Character Spacing 1-7
150i Card Personalization System Maintenance Manual 1-1

Audience
This document is intended for use by authorized representatives of Datacard
Corporation who are responsible for the maintenance, service, and repair of the
Datacard® 150i Card Personalization System, which is also referred to in this
document as the 150i.
Repair Ability
The authorized Datacard representative must possess the following ability:
• Ability to set up the 150i communication parameters.

• Ability to check 150i configuration against purchase order agreement and, if
necessary, change configuration.
• Ability to run and interpret software diagnostics.
• Ability to remove and replace all FRUs (Field Replaceable Units).
• Ability to diagnose mechanical and electrical failures and correctly adjust all
mechanical components including software adjustments.
Serial Numbers
Information in this document applies to all 150i Card Personalization Systems
beginning with serial number 0350 and higher.
1-2 System Description

Use of this Document
This document contains the following chapters to assist the service representative in
the maintenance, service, and repair of the 150i:
Chapter 1: System Description

Provides general information about this document and service data for the 150i.
Chapter 2: Installation
Provides information for site preparation, unpacking, inspection, setup,
configuration, and initial checkout of a 150i.
Chapter 3: Preventive Maintenance

Provides a preventive maintenance schedule with procedures and tool requirements
for periodic maintenance of the 150i.
Chapter 4: Theory of Operation

Provides basic electrical theory for the 150i.
Chapter 5: Troubleshooting
Provides a troubleshooting guide to determine which FRU needs to be replaced or
what adjustment needs to be performed for proper operation of the 150i.
Chapter 6: Adjustments
Provides detailed procedures for mechanical, electrical, and software adjustments.
Chapter 7: Removal and Replacement

Provides removal and replacement procedures for field replaceable items in the 150i.
Appendix A- Glossary
Provides definitions of terms used throughout the this maintenance manual.
Appendix B – Wheel Table Configurations

Provided wheel table information and configurations of all available character
wheels for the 150i.

Product Specifications
Electrical
• 90-264V AC at 4A, 50/60Hz (Single phase, 3 wire grounded receptacle only)
Environmental
• Noise level: Less than 60dB
• Relative humidity: 20% to 85% non-condensing
• Maximum heat dissipation: 1,195 BTU/Hour
• Operating temperature range: 60° F to 90° F (15° C to 32° C)
• ESD susceptibility: The 150i can withstand an ESD discharge of
15kV, 330pF storage and 1.5K ohm series
resistance in test simulating a human discharge
to the machine’s outer surfaces.
Communications
• RS-232 service port
• RS-232 host port
• Smart card 1 port
• Smart card 2 port
• Diagnostic port
• Development port
Card Capacities
Input Hopper Capacity
• 100 cards (automatic card feed)
Reject Hopper Capacity
• Up to 10 cards
Output Hopper Capacity
• Up to 15 cards
Topper Cassette Capacity

• 1,600 cards (minimum)
Protocols
• Supports CPX

Physical Specifications
• Width: 24 inches (61.0 cm)
• Depth: 15.5 inches (35.6 cm)
• Height: 11 inches (25.4 cm)
• Weight: 70 pounds. (31.8 kg)
Card Specifications
The 150i supports only CR80 plastic cards.
Dimensions: Length: 3.375 inches (85.7 mm)
Height: 2.125 inches (54.0 mm)
Thickness: 0.030 ±0.010 inches (0.76 mm)
Finish: Any gloss or matte finish
Color: Any color except clear
Bow: 0.060 inches maximum from flat
Material: PVC laminated or unlamented
IC (Smart Card): Optional
Magnetic Stripe: Standard coercivity: 300 to 600 Oe. ± 1.0% High
coercivity, reference ISO/IEC 7811 Part 6

Magnetic Stripe Encoding Specifications
The following table gives encoding specifications for magnetic stripe encoding used
on the 150i.
Table 1-1: Magnetic Stripe Encoding Specifications

Track Start Bit Position* Skew Track Location** BPI
Number (inches) (millimeters) Angle (Max Top (Min Bottom in
in inches) inches)
Track 1 (IATA)*** 0.293 ±0.020 (7.44 ±0.51) 0° ±20' 0.223 0.333 210 ±8%
Track 2 (ABA)*** 0.293 ±0.020 (7.44 ±0.51) 0° ±20' 0.353 0.463 75 ±5%
Track 3 (TTS)*** 0.293 ±0.40 (7.44 ±1.02) 0° ±20' 0.493 0.603 210 ±8%
NTT-J1 0.296 ±0.020 (6.00 ±0.51) 0° ±10' 0.236 0.472 210 ±8%
NTT-J2 0.296 ±0.020 (6.00 ±0.51) 0° ±10' 0.236 0.472 210 ±8%
* Start Bit Position is referenced from the right edge of the card as viewed from the
magnetic stripe side.
** Track Location is referenced from the top edge of the card.
*** Track 1 (IATA) = 76 maximum data characters.
*** Track 2 (ABA) = 37 maximum data characters.
*** Track 3 (TTS) = 104 maximum data characters.
Maximum data characters do not include start, end sentinels, and LCR characters.
All magnetic stripe specifications are per ISO 7811-2, 7811-4, and 7811-5.
Standard Financial Emboss Line Locations

L1 = 7CPI V = 0.843 ±0.005 inches OCR
L2 = 10CPI V = 0.646 ±0.005 inches 1st AN
L3 = 10CPI V = 0.488 ±0.005 inches 2nd AN
L4 = 10CPI V = 0.332 ±0.005 inches 3rd AN
L5 = 10CPI V = 0.175 ±0.005 inches 4th AN
All lines have a left margin of 0.401 ±0.010 inch. V is the distance from the bottom of
the card to the center of the character.

Standard Emboss Character Height
OCR Farrington 7B 7 Characters per inch 0.016 to 0.019 inches
AN 10 Characters per inch 0.015 to 0.018 inches
Indent Characters 0.001 to 0.005 inches
Indent Punctuation 0.001 to 0.007 inches
Standard Emboss Character Spacing

OCR Farrington 7B 7 Characters per inch 0.143 ±0.006 inches
AN 10 Characters per inch 0.100 ±0.006 inches
Indent Characters ±0.006 inches
Indent Punctuation ±0.006 inches

Chapter 2: Installation
The 150i Card Personalization System operates as a standalone card embosser. This
chapter provides instructions for installing the 150i at a customer’s site.
Preparing the Site 2-2
Unpacking/Packing 2-3
Functional Tests 2-6
Administrator Setups 2-6

Standard CPX Used 2-6
Baud Rates 2-6
Parity Bits 2-7
Bit Size 2-7
Format Types 2-7
Protocol 2-7
Sweden Stripe 2-7
Auto Retry 2-7
Topper Select 2-8
Monitor 2-8
Test Card 2-8
Stripe Retries 2-8
Write Only Once 2-8
Door Password 2-8
Save Changes 2-8
Baud Rate 2-9
Parity Bits 2-9
Bits Size 2-9
Monitor 2-9
Test Card 2-9
Stripe Retries 2-9
Write Only Once 2-10
Door Password 2-10
Save Changes 2-10
Financial Card Password 2-10

Preparing the Site
The site requirements are as follows:
• The desk or table for the 150i to be placed on must be flat, level, and capable of
supporting 70 pounds (31.8 kg).
• The 150i must have 2 inches of clearance all around the cabinet for ventilation and 18
inches of clearance for the Top Cover to open fully.
• Unpack the delivered equipment and check for any cosmetic damage.
• Connect the cables.
• Power on the 150i.
The following table lists special equipment, materials and special tools required for 150i
installation.
Table 2-1: Installation Materials and Special Tools
Equipment/Material/Tool Note Required for

25 Blank White Cards with Shipped with the 150i Testing general 150i
Magnetic Stripe operation.
Vernier Calipers Standard tool Measuring distances on

card.
Magnetic Stripe Sight Glass Datacard Part No. Checking encoding

594895-001 specifications.
Magnetic Tape Developer Datacard Part No. Checking encoding

TUL001-014 specifications for magnetic
stripe.
Topper Foil Shipped with the 150i Checking Topper operation.
Laptop PC equipped with 150i 150i Setup Utility Running diagnostics,

Setup Utility Part No. 555071-001 uploading Flash memory,
Setting offsets.
OCR Indent Ribbon (option) Shipped with the 150i Checking OCR Indent
(if so equipped) module operation.
2-2 Installation
Unpacking/Packing
Refer to the unpacking illustration in Figure 2-1 for details.
Strapping
Cut
Apart
Cut
Apart
150i001s
Cut Tape
Figure 2-1: Unpacking/Packing

1. Cut the plastic strapping band and remove the top outer container and the protective
plastic bag covering the 150i.
2. Remove the following items from the container:
• Blank cards (25)
• Input Hopper card weight
• Power cord
• Null modem cable (if ordered)
• Administrator’s Guide
• MasterCard™ Insertion tool (if ordered)
• Topper Cassette
• Top Cover access keys
• Datacard 150i Operator Training Video (if ordered)
Input Hopper Power Cord Null Modem

Card Weight Cable
Blank Cards
Insertion Tool
Administrator's Guide
Keys
Datacard Operator
Topper Cassette
Training Video
150i002s
(Located inside the 150i
in the Topper Module)
Figure 2-2: Included Packed Materials
2-4 Installation
3. Cut the tape from all 4 corners of the inner container for easier access in the removal of
the 150i.
4. Unlock and lift open the Top Cover on the 150i using the key provided. Remove two
hold down screws. Remove the shipping cable tie that holds the Topper Cassette to the
Topper module. Remove the shipping foam from the bottom of the transport module. If
Rear Indent was ordered for your 150i, remove the shipping cable tie that holds it to the
horizontal carriage rail. If Front Indent was ordered, remove its shipping cable tie.
The shipping cable ties are removed by pressing the releasing tab located on the head of
the cable tie. Retain all cable ties, shipping foam, the protective plastic bag and the
original container for possible reshipment of the 150i. When reshipping, secure all loose
items to prevent damage to the system. Take special precautions to remove all loose
plastic cards from the Input Hopper along with the Input Hopper Card Weight. Use
appropriate tape for securing the shipping container’s corners and top cover. Datacard is
not responsible for shipping damage due to improperly repackaged systems.
Remove Cable Tie

(Optional Module)
Remove
Cable Tie
Remove Cable Tie

(Optional Module)
Remove
Shipping Foam 150i003s
Figure 2-3: Packing Material Removal
Inspect the 150i and accompanying items for shipping damage. If at any point the
system or packaging appears to be damaged, follow your company policy for reporting
damage.
The 150i weighs about 70 pounds (30 kg). It is advisable to have another person help
you remove the 150i from the container. Use proper lifting techniques when removing
the 150i from the container.
5. Close the Top Cover and lift the 150i from the container and place it at the preferred
location.

Functional Tests
The front panel keypad accesses many functional card tests. Refer to the Test Cards Menu in
order to access these tests.
To access these Setups, power ON the 150i. When “150i/CPX” is displayed, immediately
press the # key.
The # key must be pressed before the machine enters the Ready mode in order to access
the Setup Menu.
Administrator Setups
The following Setups can be changed from the front panel on the 150i:
Baud rate
Parity bits
Bit size
Monitor host stream
Produce a Test Card on power ON
Standard CPX Used

Press the 0 key to select new protocol or the # key to scroll to the next setup. If No was
selected, the following menu items appear:
Baud Rates
Press the 0 key to select one of the following baud rates or press the # key to scroll to the next
setup:
300
1200
2400
4800
9600 (default)
19200
57600
2-6 Installation
Parity Bits
Press the 0 key to select one of the following parity settings or press the # key to scroll to the
next setup.
None (default)
Odd
Even
Bit Size
Press the 0 key to select either 7 bits or 8 bits (default) or press the # key to scroll to the next
setup.
Format Types
Press the 0 key to select one of the following format types or press the # key to scroll to the
next setup.
CPX-## (default)
Open
U5
Sweden1
Sweden2
Protocol
Press the 0 key to select one of the following protocol settings or press the # key to scroll to
the next setup.
CPX-ENQ (default)
Xon/Xoff
RTS=Flow
DTR-Flow
Xoff-ENH
UX
US_EOT
Sweden Stripe
Press the 0 key to select one of the following Sweden Strip settings or press the # key to
scroll to the next setup.
None (default)
Code-00
Auto Retry
Press the 0 key to select either Yes or No (default) for automatic retrying for reading a
magnetic stripe or press the # key to scroll to the next setup.

Topper Select
Press the 0 key to select one of the following topper settings or press the # key to scroll to the
next setup.
On (1) (default)
On (2)
On (3)
On (4)
Off
Monitor
Press the 0 key to select one of the following monitor settings or press the # key to scroll to
the next setup.
Off (default)
Card
Comm.
Stripe
Stats
Test Card
Press the 0 key to select either Yes to produce a sample financial test card every time the 150i
is powered ON or No (default) so test cards will not be produced on power ON or press the #
key to scroll to the next setup. (See Test Cards Menu in Chapter 6 of this manual for details.)
Stripe Retries
Press the 0 key to select the number of magnetic stripe retries from 0 (default) to 9 times or
press the # key to scroll to the next setup.
Write Only Once

Press the 0 key to select either Yes or No (default) for writing to the magnetic stripe only
once or press the # key to scroll to the next setup.
Door Password
Press the 0 key to select to either enable (default) or disable the door password or press the #
key to scroll to the next setup.
Save Changes
Press the 0 key to select either Yes to save the changes made or No (default) to discard all
changes. Press the # key to get out of the Setup Menu and return the 150i to the Ready mode.
2-8 Installation
Baud Rate
Press the 0 key to select one of the following baud rates or press the # key to scroll to the next
setup:
300
1200
2400
4800
9600 (default)
19200
57600
Parity Bits
Press the 0 key to select one of the following parity settings or press the # key to scroll to the
next setup.
None (default)
Odd
Even
Bits Size
Press the 0 key to select either 7 bits or 8 bits (default) or press the # key to scroll to the next
setup.
Monitor
Press the 0 key to select either Yes to output the host computer ‘s data stream or No (default)
so the output will not present the data stream or press the # key to scroll to the next setup. A
terminal emulator must be connected to the 150i Service Port to receive and display this
ASCII data. The speed of the 150i will be reduced when in this mode.
Test Card
Press the 0 key to select either Yes to produce a sample financial test card every time the 150i
is powered ON or No (default) so test cards will not be produced on power ON or press the #
key to scroll to the next setup. (See Test Cards Menu in Chapter 6 of this manual for details.)
Stripe Retries
Press the 0 key to select the number of stripe retries from 0 (default) to 9 times or press the #

Write Only Once
Press the 0 key to select either Yes or No (default) for writing to the magnetic stripe only
once or press the # key to scroll to the next setup.
Door Password
Press the 0 key to select to either enable (default) or disable the door password or press the #
Save Changes
Press the 0 key to select either Yes to save the changes made or No (default) to discard all
changes. Press the # key to get out of the Setup Menu and return the 150i to the Ready mode.
Financial Card Password

To produce major brand financial cards, (i.e., Visa®, MasterCard®, American Express®,
Diners®, JCB®, and Discover®) the 150i must be first given an initializing password to enable
this feature. In the continental US or Canada, this password is obtained by calling the
Datacard Corporation service help desk at: 800.328.3996. All other countries, contact your
local Datacard Service Representative. They will instruct you on how to enter the initializing
password so financial cards can be produced. The format is: *2 (followed by an 8-digit
Financial Card Password).
By entering the 8-digit Financial Card password enable, the Top Cover access will be
reset to the 0000 default password.
2-10 Installation
Chapter 3: Preventive
Maintenance
chapter provides instructions for performing preventive maintenance on the 150i.
Preventive Maintenance 3-2
Tools and Supplies 3-3
Preventive Maintenance Procedures 3-3

Cleaning the 150i 3-4
Cleaning the O-Rings/Drive Rollers 3-4
Cleaning the Sensors 3-5
Cleaning the Magnetic Stripe Head 3-6
Verifying Embossing Line Locations and Margins 3-7
Verifying Start Sentinel and Track Locations for Magnetic Stripe 3-9
Verifying Even and Uniform Topping 3-11
Verifying Throat Gap Adjustment 3-12

Preventive Maintenance
The following table lists the periodic cleaning and adjustment verification requirements for
the 150i. A complete procedure for each item in the table is given in this chapter.
Preventive Maintenance (PM) should be performed at 12-month intervals and after any of the
following activities:
• Any adjustment to a FRU or subassembly.

• Any replacement to a FRU or subassembly.
• Any unscheduled maintenance is performed.
Table 3-1: Preventive Maintenance Schedule
Task FRU/Module Procedure

Clean the 150i 150i Vacuum out the entire inside of the 150i
and clean the outside of the cabinet with
desk cleaner.
Clean the 150i O-Rings/Drive 150i Clean O-rings and rubber drive rollers with
Rollers citrus solvent.
Clean the 150i Sensors 150i Clean sensors with compressed air.
Clean Magnetic Stripe Head Magnetic Stripe Clean head using the Encoder Cleaning
Card.
Verify Adjustment of Card Feed Input/Output Verify throat width: 0.045 ±0.005 inch.
Throat Hopper
Verify Adjustment and Card Transport Verify horizontal margin, character height
Operation of the 150i and vertical line locations on customer
setups.
Verify Start Sentinel and Track Magnetic Stripe Run a Magnetic Stripe Test Card and verify
Locations for Magnetic Stripe start sentinel and track locations.
Verify Even and Uniform Topping Topper Run customer cards and verify cards are
top coated evenly and uniformly.
3-2 Preventive Maintenance

Tools and Supplies
The tools and supplies listed in Table 3-2 are required to perform preventive maintenance as
specified in the PM schedule.
Table 3-2: Tools and Supplies
Item Datacard Part Number

Can of compressed air TUL001-018
Desk cleaner Any type
Encoder cleaning card 597729-001
Lint-free cloth Any type
Magnetic stripe sight gage 594895-001
Magnetic stripe tape developer TUL001-014
Citrus solvent TUL003-007
Vacuum cleaner Any type
Vernier calipers 0.00 to 1.00 inch (0.001-inch increments)
Interlock tool 805957-901
Preventive Maintenance Procedures

The following procedures are performed to complete the requirements of the PM schedule:
• Cleaning the 150i

• Cleaning the O-Rings/Drive Rollers
• Cleaning the Sensors
• Cleaning the Magnetic Stripe Head
• Verifying Embossing Line Locations and Margins
• Verifying Start Sentinel and Track Locations for Magnetic Stripe
• Verifying Even and Uniform Topping
• Verifying Throat Gap Adjustment

Cleaning the 150i
1. Unlock and lift up the Top Cover.
2. Power OFF the 150i and remove the power cord.
3. Vacuum out the inside of the 150i.
4. Clean the outside of the cabinet with either a damp lint-free cloth or desk cleaner.
Cleaning the O-Rings/Drive Rollers

3. Clean the following O-Rings or drive rollers with citrus solvent:
• Magnetic Stripe Encoder roller
• Output Hopper drive rollers (top and bottom)
• Output Hopper drive belt
• Topper Foil Motion roller
Inspect all O-rings and drive rollers for cracks or cuts. Replace if necessary.
Topper
Topper
Foil Motion
Roller
Output Hopper
Magnetic
Drive Roller
Stripe 150i004s
Encoder
Roller
Output Hopper
Magnetic Stripe
Drive Belt Motor
Figure 3-1: Preventive Maintenance for Rollers

Cleaning the Sensors
3. Use a can of compressed air to clean the following sensors (see Figure 3-2).
• Card Picked sensor • Card Registration sensor
• Die Cam Home sensor • Input Home sensor
• Input Hopper Empty sensor • Output Full sensor
• Punch Cam Home sensor • Reject Full sensor
• Throat Gap sensor • Topper Foil Motion sensor
• Topper Platen sensor • Wheel Home sensor
• X-Home sensor (located on 150i base) • Y-Home sensor
• Indent Foil Motion sensor (if so equipped)
Topper Platen
Sensor
Reject Full
Sensor X-Home
Topper Foil Sensor
Motion Sensor Throat Gap
Sensor Y-Home
Sensor
Wheel Home
Sensor
Punch Cam Die Cam
Home Sensor Home Sensor
Card
Registration
Sensor
Card Picked
Sensor
Rear View
Output Full
Sensor Input Hopper Input Home
150i005s Empty Sensor Sensor
Figure 3-2: Sensor Locations

Cleaning the Magnetic Stripe Head
3. Clean the following areas:
• Vacuum card dust from around the magnetic stripe head. Remove remaining dust
with a damp cloth.
• Clean rubber roller with a cloth lightly moistened with citrus solvent.
• Move an Encoder Cleaning Card (see Table 3-2 for part number) back and forth over
the magnetic stripe head.
4. Plug in the power cord and power ON the 150i.
Cleaning Card
150i006s
Figure 3-3: Cleaning the Magnetic Stripe Head

Verifying Embossing Line Locations and Margins
The following procedure will produce a Standard Financial Test Card. The card will be
picked, encoded, embossed, topped and placed in the output tray. Perform the following
steps:
1. Place blank white cards in the Input Hopper.

2. From the READY mode, press *#3253. The message “SELECT EXIT MODE: (1) APP
(2) DIAGNOSE” is displayed.
3. Press 2 on the 150i keypad. The message “BOOT TO SERVICE DIAGS!” is displayed
followed by “150i Diags Rev. X.X Service.”
4. Press the # key. The message “Loading On Board Diags. Please Wait...” is displayed
followed by: “150i On Board Diagnostics Diagnostic Routines.”
5. Press the 8 key twice (2), the message “150i Onboard Diagnostics Test Cards” is
displayed. Press the # key to select.
6. Press the 8 key four (4) times, the message “Mag Stripe/Emboss/Top” is displayed. Press
the # key to select.
7. “Select Encode Format IA” is displayed. Select either IA or NTT by pressing the 8 key.
Press the # key to select.
8. The message “Stop At One Card? (#) YES (1) NO (0) ESC” is displayed. Press the # key
for one card. The message “MS (X10)/Emboss/Top” is displayed as the card is processed.
9. After the card is complete and delivered to the Output Tray, check line locations. (See
Standard Financial Emboss Line Locations in Chapter 1 of this manual.)
10. To exit the Diagnostic Mode and restart the 150i, cycle power to the 150i. To remain in
the Diagnostic Mode, press the 0 key to return to the Diagnostic Menu option.

Table 3-3: Line Location and Margins Checklist
Check Values
Characters All present and flawless.
Tolerances Make sure the left margin is parallel to

the card's left edge and all lines are
parallel to the card's bottom edge.
OCR character height (top line) 0.016 to 0.019 inch.
AN character height (remaining 0.015 to 0.018 inch.

lines)
150i009s
Figure 3-4: Embossing Line Locations and Margins Card

Verifying Start Sentinel and Track Locations for
Magnetic Stripe
The following procedure will cause the 150i to pick a card and transport it to the Magnetic
Stripe module. The card will be written to and read by the module and then transported to the
output tray. No topping or embossing will occur. Perform the following steps:
1. Place blank white cards (with magnetic stripe) in the Input Hopper.
3. Press 2 on the 150i keypad. The message “BOOT TO SERVICE DIAGS!” is displayed
4. Press the # key. The message “Loading On Board Diags. Please Wait...” is displayed
followed by: “150i On Board Diagnostics Diagnostic Routines.”
5. Press the 8 key twice (2); the message “150i Onboard Diagnostics Test Cards” is
displayed. Press the # key to select. The message “150i Test Cards Standard” is
displayed.
6. Press the 8 key once (1); the message “150i Test Cards Mag Stripe” is displayed. Press
the # key to select.
7. The display should read “Select Encode Format.” Select either IA or NTT by pressing the
8 key. Press the # key to select.
8. The message “Stop At One Card?” (#) YES (1) NO (0) ESC” is displayed. Press the #
key for one card.
9. The 150i encodes a test pattern on the magnetic stripe.
10. Develop the magnetic stripe using magnetic tape developer (Datacard PN TUL001-014).
11. Use the magnetic stripe sight gage to ensure proper alignment of the stripe data. Check
the card against Figure 3-5. Also see, Magnetic Stripe Encoding Specifications in Chapter
1 of this manual.

Magnetic Stripe Sight Gage
IATA Track 1 Loc
ABA Track 2 Loc Place card tight to

this corner.
TTS Track 3 Loc
First Bit
0.293 +/-0.020 Inch IATA Track 1
ABA Track 2
TTS Track 3
IATA Track 1
ABA Track 2
TTS Track 3
Card
(Rear)
150i089s
Figure 3-5: Start Sentinel and Track Locations for Magnetic Stripe

Verifying Even and Uniform Topping
The following procedure will cause a Wheel Test Card with topping to be produced. The card
will be picked, embossed with all the embossing wheel characters, topped, and placed in the
output tray. Perform the following steps:
1. Place blank white cards in the Input Hopper.

3. Press 2 on the 150i keypad. The message: “BOOT TO SERVICE DIAGS!” is displayed
4. Press the # key. The message “Loading On Board Diags. Please wait...” is displayed
followed by “150i On Board Diagnostics Diagnostic Routines.”
5. Press the 8 key twice (2); the message “150i On Board Diagnostics Test Cards” is
displayed. Press the # key to select.
6. The message “150i Test Cards Standard” is displayed.
7. Press the 8 key 7 times; the message “Topper” is displayed. Press the # key to select.
8. The message “Stop At One Card?” (#) YES (1) NO (0) ESC” is displayed.
9. Press the # key for one card.
10. The card is embossed and topped at the Topper limits, then delivered to the Output Tray.
11. Inspect the card for even and uniform coating using the following table.
Table 3-4: Even and Uniform Topping Checklist
Check Values
Characters All present and flawless.
Tolerances Make sure the left margin is parallel to the card's

left edge and all lines are parallel to the card's
bottom edge.
OCR character height (top 0.016 to 0.019 inch.

line)
AN character height 0.014 to 0.018 inch.

(remaining lines)

150i013s
Figure 3-6: Wheel Test Card
Verifying Throat Gap Adjustment

To verify the throat gap adjustment, perform the following steps:
1. Insert a stack of pre-embossed cards in the Input Hopper.

2. Cycle the cards through the 150i and observe that only one pre-embossed card at a time
gets picked. If pre-embossed cards are not correctly picked, refer to Throat Gap Offset in
Chapter 6, Adjustments.

4
Chapter 4:
Theory of Operation

embosser. This chapter provides general theory of operation for the 150i.
150i Overview 4-2
Component Identification 4-2
Inside View of the 150i 4-3
Rear View of the 150i 4-4
Sequence of Operation 4-5
Memory Map 4-7
Electrical Block Diagram 4-8

Microprocessor 4-9
CPLD 4-9
Flash 4-9
DRAM 4-9
FPGA Controller 4-10
ROM 4-10
EEPROM 4-10
Power Inlet Module 4-10
36 Volt Power Supply 4-10
5 Volt Regulator 4-10
12 Volt Regulator 4-11
System Interlock 4-11
RS232 Transceiver 4-11
LCD Display/Keypad and LEDs 4-11
Main Control Board Schematics 4-12

150i Overview
The 150i is a full featured single-pass card personalization system. The 150i
embosses, encodes, and tops financial plastic cards. Depending on the options
ordered, the 150i is also capable of indent printing and smart card personalization.
Component Identification
The follow bulleted list identifies the major components of the 150i. See Figure 4-1
for their location.
• Output Hopper Door

• Single Card Access Door
• Keyhole
• Keypad
• Display
• Indicators and icons on display:
• Power Indicator
• Ready Indicator
• Error Indicator
• Service Indicator
• Optional Indicator
• Top Cover
• Power Switch
Indicators
Display
Keypad
Keyhole
Power
Switch
Output
Hopper Door
Single Card
Access Door
Figure 4-1: Component Identification
4-2 Theory of Operation

Inside View of the 150i
The following bulleted list identifies the major modules inside of the 150i. See Figure
4-2 for their location.
• Card Transport Module

• Embosser Module
• Front Indent Printing Module
• Good Card Tray (Output tray)
• Input Hopper
• Magnetic Stripe Encoding Module
• Reject Tray
• Smart Card Personalization (Optional)
• Topper Module
• Front/Rear Indent (Optional)
Top Cover
Reject
Tray
Front Indent
Printing Module
Topper
Module
Card Transport
Module
Embossing
Module
Input
Hopper
SmartCard Personalization Magnetic Stripe Encoding Good Card

Module Module Tray
Figure 4-2: Inside View of the 150i

Rear View of the 150i
The following bulleted list identifies the components on the rear of the 150i. See
Figure 4-3 for their location.
• On/Off Switch
• Communication Ports
• Host
• Service
• Smart Card 1 (Option)
• Smart Card 2 (Option)
• Diagnose (Option)
• Development (Option)
• Power Receptacle
• Fan
Communication Ports
On/Off
Switch Communication Ports
Diagnose
Host
Development
Service
Power
Receptacle
Smart Card 1
Smart Card 2
C ommun ica tion Po rts
D iagno se
De ve lopm ent
Figure 4-3: Rear View of the 150i

Sequence of Operation
When reading the Sequence of Operation, reference Figure 4-4.
1. After the 150i initializes on power up, cards can be produced.
a. Once the system detects that a block of data has been received, the 150i
acknowledges the data and signals the Topper Platen heater to turn on.
2. The 150i senses cards in the Input Hopper by checking the Input Hopper Empty
sensor:
a. The card pick mechanism picks a card and then the Card Picked sensor
detects that a card is present.
b. The card is transported to the Card Registration sensor to index the
position of the card in the 150i.
3. The card is transported to the Magnetic Stripe module:

a. Depending on the magnetic stripe setup, the card makes as many as three
passes to read and write to the card’s magnetic stripe tracks.
b. If the magnetic stripe can not be written to or read from, the card is
transported to the Reject Tray.
4. The Card Transport mechanism moves the card to the Embossing Wheel:
a. The embossing wheel senses the home position (Wheel Home sensor) the
first time a character is requested to print. The embossing wheel will
move either clockwise or counter clockwise depending on how quickly
the embossing character can be moved to be embossed on the card.
b. The card will move in four directions as the punch and dies emboss
characters on the card.
c. The Die Cam Home sensor and the Punch Cam Home sensor detect when
both cams are in their home position. Both the die and the punch cams
work simultaneously to emboss characters on a card.
5. After a card is embossed, it is transported to the Topper assembly where the

bottom half of the card is topped:
a. The Topper Platen sensor detects that the platen is in its home position
and up to temperature and ready to top cards.
b. As a card is moved into the Topper assembly, a solenoid is activated to
apply platen pressure and heat to the topping foil. This topping foil
adheres to the raised embossed characters on the card.
c. After a card is topped and removed from the Topping assembly, the
topping foil is advanced. Movement of the foil is detected by the Topper
Foil Motion sensor and the Topper Platen heater is turned off.

6. After a card is topped, the completed card is transported to the Output Tray for
delivery to the operator.
Card
Registration
Topper Topper Platen Wheel Sensor
Assembly Sensor Home
Sensor
Die Cam
Card Picked
Home
Sensor
Sensor
REAR VIEW Input Home

Topper Foil Sensor
Motion Sensor
Embossing
Wheel
Punch Cam
Home Sensor
Output
Tray Input Hopper
Output Full Empty Sensor
Sensor
Figure 4-4: Sequence of Operation

Memory Map
The following shows a memory map of the 150i system.
BIOS MiniBIOS
ROM-DOS ROM-DOS KERNEL
Drive A: ROM AREA

ROM DISK
COMMAND
Drive B:
FLASH DISK
APPLICATION
DOS
ROM
256K
BIOS RAM
VECTORS
Figure 4-5: 150i Embedded System Memory Layout

Electrical Block Diagram
The following section provides a brief description of the 150i Main Control Board.
Refer to Figure 4-6 for details. The control board provides all the electronics to
control all stepper motor functions, solenoid actions, and monitors all sensor
activity.
Power Inlet 36 Volt Power System

Module Supply Interlock
5 Volt 12 Volt
Regulator Regulator
Microprocessor
CPLD
DRAM Flash
DRAM Controller
RS232 Transceiver
FPGA Controller
LCD Display /
Keypad & LEDs ROM
EEPROM
Figure 4-6: 150i Main Control Board Block Diagram

Microprocessor
The microprocessor is the controlling element for all functions within the 150i
system. It is a 32-bit microprocessor clocked at 50 MHz. The processor power is
supplied by filtered 5.0 volt supply. There are 25 address lines to the processor
which supports 16 MB of memory. The microprocessor supports the address bus A1
– A25. There are two addition signals Byte High Enable (BHE) and Byte Low Enable
(BLE) that are decoded by the CPLD to indicate which address space is desired. The
microprocessor generates six chip selects (CS0 – CS4 and UCS) that are used by the
CPLD and FPGA for device enabling devices. The microprocessor supports four
Interrupts (Int0 – Int3) that are driven by the CPLD, FPGA, and interlock circuitry.
There is one non-maskable interrupt (NMI) that is driven by a power supervisor chip
(DS1231). When voltage drops below a set voltage, a (POWER_FAIL) signal is
asserted to the NMI, which initiates a power-down sequence in the firmware code.
CPLD
This component performs the address decoding, DRAM control, flash control,
additional chip select (CS) generation and microprocessor interface functions. The
global RESETOUT is generated internally by the system RESET input. The display
control signals are generated internally.
Flash
The flash memory chip is 8 MB (512K X 16 ) and contains the firmware code that
controls and operates the 150i system Address line A0 is tied to ground with/BYTE
time high. The flash memory chip is 16-bits wide. This component incorporates a
Boot Block protection jumper (J2) that enables updating of the firmware without
corrupting the boot code. A jumper placed on position 1-2 enables “Protection of the
Boot Block.” A jumper placed on position 2-3 enables “Programming of the Boot
Block.” There are two modes of flash control. J4 enables programming via a JTAG or
invokes normal operation. A jumper placed on position 1-2 enables “Normal
Operation.” A jumper placed on position 2-3 enables JTAG programming of the
firmware.
DRAM
There are two memory DRAMs and are 256K arranged to provide 512K X 16 of main
memory for the microprocessor.

FPGA Controller
The FPGA (Field Programmable Gate Array) performs the controlling functions of
all the mechanical devices. It receives commands from the microprocessor and either
drives the required outputs or sends a block of inputs back to the microprocessor.
All the sensors, stepper motors, the DC motor, solenoids, interlock, and magnetic
stripe functions are controlled by this chip. It is necessary to program this device on
every power cycle. LED D18 is illuminated while the device is being programmed.
D18 will be disabled when programming is complete.
ROM
The ROM (Read Only Memory) is configured in serial for loading of the Field
Programmable Gate Array (FPGA). The device is a one-time programmable (OTP)
device organized as a 262,144 X 1 bit map. The FPGA provides the Clock (CLK) and
Chip Enable (CE) signals. The RESET (RST) is provided by the global reset signal.
EEPROM
The EEPROM (Electrically Erasable Programmable Read Only Memory) can be
written to and changed many times and is used for data storage. This device is
organized as an 8192 X 8 64 K serial device. A 2-Wire communication protocol is tied
to the FPGA. Configurations, offsets, and settings are stored in this chip.
Power Inlet Module

The main system ON/OFF switch is contained on this module. A replaceable 250
volt 6.3 amp fuse is accessible on the rear of the module. A power line filter is
embedded into the inlet module. This reduces the Electro Magnetic Interference
(EMI) measured on the power cord.
36 Volt Power Supply

This switching power supplies 36V DC to the 150i system with a maximum output of
300 watts. The AC input voltage can be anywhere for 90 to 264V AC at 50/60 Hz
5 Volt Regulator
A switching regulator is utilized to create the 5.0-volt supply. An inductor and a
barrier diode are incorporated as part of the regulation circuitry. The 5.0 volts (Vcc)
is supplied to all IC’s via a discrete Vcc plane within the printed circuit board.

12 Volt Regulator
A linear regulator is utilized to create a 12.0-volt regulated supply. A voltage divider
network connected to the Adj Input (pin #1) which controls the output voltage. The
12.0 volts is used to supply to the magnetic stripe driver circuitry.
System Interlock
The 36-volt supply is tied to the input of a safety rated SPST relay. The output
creates a 36-volt interlock voltage plane within the main controller circuit board.
This 36 volts supplies all the stepper motor drivers, solenoids, and the DC Topper
Foil Transport motor. The coil of the relay is connected to the interlock safety switch
on the 150i system.
RS232 Transceiver
The RS232 Transceiver device supports a 3-driver and 5-receiver RS232 transceiver
configuration. The device incorporates an Electro-Static Discharge (ESD) circuit to
withstand +/- 10 K volts shocks. The 150i Host and Debug ports support the modem
control signals found on RS232 Comm lines. The transceivers inputs and outputs are
tied directly to the microprocessor serial Comm ports.
LCD Display/Keypad and LEDs

The display incorporates a 2 X 20 LCD display. LCD control signals and 8-bit data
bus are supplied to the display. Five independently controlled LED’s provide visual
status and control functions. A 10 digit keypad allows user input from the front
panel.

Main Control Board Schematics
The following Main Control Board schematics show the electronic circuitry for
controlling the 150i system.
Figure 4-7: 150i Main Control Board Schematic (1 of 20)




















5
Chapter 5:
Troubleshooting

embosser. This chapter of the manual provides information and
procedures to isolate a fault to the part, and/or component level. It
includes symptoms, fault isolation procedures, use of diagnostic tools,
and error codes.
Troubleshooting Tips 5-3
Prerequisite Skills 5-4
Diagnostic Routines 5-4

Diagnostic Routines Menu 5-5
Sensors 5-6
MS Start Sentinel (NTT) 5-7
MS Start Sentinel (Standard) 5-7
Transport 5-7
Pick & Stack 5-7
Pick & Reject 5-7
Calibration Menu 5-8
Test Cards Menu 5-9
Standard Test Card 5-10
Mag Stripe Test Card 5-10
Indent Test Card 5-10
MagStripe/Emboss Test Card 5-10
MagStripe/Emboss/Top Test Card 5-10
Smart Card Test Card 5-11
Wheel Test Card 5-11
Topper Test Card 5-12
Run Without Cards 5-12
Preembossed Test Card 5-12
Character Height Test Card 5-12
Position Offsets Menu 5-13
Wheel Parameters Menu 5-15
Topper Parameters Menu 5-16
Configuration Menu 5-16
Status Request Menu 5-17

Restore MCB Defaults 5-17
Restore Mfg Settings 5-17
Save Changes 5-17
150i Interconnect Diagrams 5-18

Main Control Board Connections 5-19
Main Control Board Cable Connections 5-20
AC Wiring Diagram 5-21
Pin-Out Tables 5-22

Motor Pin-Outs 5-22
Sensor Pin-Outs 5-24
Serial Communications Pin-Outs 5-26
Identifying Errors Using Error Codes 5-27

Group xx 5-27
Group yy 5-28
Group zz 5-28
Error Codes 5-32
Main Control Board LEDs 5-38
5-2 Troubleshooting
Troubleshooting Tips
When correcting errors, it is a good idea to perform the following:
• Always power OFF the 150i.

• Load the Input Hopper if the card stock is low.
• Clear any rejected cards from the Reject Tray.
• Replace the foil in the Topper Module if it is getting low.
• Replace the Indent Ribbon if it is getting low.
• Make sure the Top Cover is closed and locked.
• Output Hopper door is fully closed.
Use these tips to correct the following general problems.
If A Card Is Loose In The 150i

• Check the inside of the 150i for cards that may have fallen from the Card
Transport module.
• Remove the cards and attempt to resume printing.
If A Card Is Jammed In The Input Hopper

• Remove any jammed cards from the Input Hopper module by pulling cards from
the back of the Input Hopper through the card throat.
• Attempt to resume printing.
If A Card Is Jammed In The Embosser Module

• Remove any jammed cards from the Embosser module.
If A Card Is Jammed In The Topper Module

• Remove any jammed cards from the Topper module.
If A Card Is Jammed In The Front Or Rear Indent Module

• Remove any jammed cards from the front or rear Indent module.
If A Card Is Jammed In The Smart Card Module

• Remove any jammed cards from the Smart Card module.
When removing jammed cards from the 150i, care must be taken not to damage
components.

Prerequisite Skills
Anyone troubleshooting the 150i system should possess the following skills:
• Proficiency in CE communications setup as covered in the Datacard Network
Connectivity Handbook.
Diagnostic Routines
The 150i software offers a number of diagnostic routines that test and exercise
various components in the 150i. These diagnostics can be used to verify proper
operation or to detect a point of failure.
Start Diagnostic Routines

To select the diagnostic programs on the 150i front panel, do the following:
1. Press *#3253 on the front keypad.
2. Press 2 (Diagnose) to select the diagnostic control application.
3. The system will reboot and go into the diagnostics mode.

After a short pause, the 150i front panel will display the following message:
150i Diags Rev X.XX

Service
4. To select the front panel options, press the # (pound) key.
After a short pause, the 150i front panel displays the following message:
Loading Onboard Diags

Please wait...
The main menu appears.
When running diagnostics from the front panel, the 150i system is in the off-line
mode. The keypad is used to navigate through the menus as they are displayed
on the front panel of the 150i system.
5-4 Troubleshooting
Table 5-1: Keypad Navigation
Key Description
# Selects option (Enter key).
0 Aborts menu option or backs-up 1 menu option.
2 Scrolls the menu up or will increment a setting.
3 Offset adjustments range toggle from ±1 times the increment to ±10.
4 Scrolls the menu to the left.
5 Changes offset from (-) negative to (+) positive.
6 Scrolls the menu to the right.
8 Scrolls the menu down or will decrement a setting.
Diagnostic Routines Menu

The Diagnostic Routine menu is used for the selection of various options listed
below:
1. From the Main menu, select Diagnostic Routines.
2. Press the # key to select a one of the menu options below:
• Sensors
• MS Start Sent. (NTT)
• MS Start Sent. (Standard)
• Transport
• Pick & Stack
• Pick & Reject

Sensors
This diagnostic test is used to test all the photocells and switches on the 150i system.
The test returns a status word on the front panel display. This test will indicate if a
photocell or a switch is opened or closed. The test reads a hardware status port.
Some of the signals for open or closed may be inverted. Check whether a photocell
or switch has changed states. The example below shows the sensor value and their
bit location.
Sensor Value: 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 1 0 0 1 1 1 1 0 0
Bit Location: 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Table 5-2: Sensor Bit Locations
Bit Location Description (0=open,1=closed)
1 X Home Sensor
2 Y Home Sensor
3 Wheel Home Sensor
4 Lower Emboss Motor Home Sensor
5 Upper Emboss Motor Home Sensor
6 Unused
7 Input Hopper Empty/Low Sensor
8 Unused
9 Registration Sensor
10 Unused
11 Pick Home Sensor
12 Output Hopper Full Sensor
13 Topper Solenoid Sensor
14 Indent Ribbon Motion Sensor
15 Topper Foil Motion Sensor
16 Card Pick Sensor
17 MCB Type 1=4.0, 0=3.5
18 Reject Full Sensor
19 Unused
20 Unused
20 Unused
22 Unused
23 Top Cover Interlock
24 Throat Gap Home Sensor
2. Press the # key to select Sensors option.
5-6 Troubleshooting
MS Start Sentinel (NTT)
Use this diagnostic to adjust the Magnetic Stripe Start Sentinel position. It will return
an offset back to the display which is used for the stripe head offset. The test will
return an X offset which can be saved as a reference.
2. Press the # key to select MagStripe (NTT) option.
MS Start Sentinel (Standard)

Use this diagnostic to adjust the Magnetic Stripe Start Sentinel position. It will return
an offset back to the display which is used for the stripe head offset. The test will
return an X offset which can be saved as a reference.
2. Press the # key to select MagStripe (Standard) option.
Transport
This diagnostic test exercises the transport. Use this test to exercise the transport
without cards.
2. Press the # key to select the Transport option.
Pick & Stack

This diagnostic test picks a card from the Input Hopper and stacks the card in the
Output Hopper.
2. Press the # key to select the Pick & Stack option.
Pick & Reject

This diagnostic test picks a card from the Input Hopper and stacks the card in the
Reject Tray.
2. Press the # key to select the Pick & Reject option.

Calibration Menu
The Calibration Test moves the card to a fixed stop position. The [X and Y] offsets
are displayed on the front panel for the card stop location. Adjust the offset as
follows:
• All Positions (Pick, Topper, Exit)

• Pick Position
• Topper Position
• Exit Position
• Reject Position
• Throat Gap
• Wheel Offset
• Smart Card XY
Adjust the offsets as follows:
• Select Calibration from the main menu by pressing the # key.

• Press the 4 key to move the card X position to the left, toward the Topper.
• Press the 6 key to move the card X position to the right toward the Input
Hopper X home photocell.
• Press the 8 key to move the card Y position back to the Y home photocell.
• Press the 2 key to move the card Y position away from the Y home photocell.
• Press the # key to select the new offsets. If the 0 key is pressed, the new offset
is ignored.
5-8 Troubleshooting
Test Cards Menu
The Test Cards menu is used for the selection of various test card options.
• When Test Cards appears on the main menu, press # to select.

• Press the # key to select a menu option.
Table 5-3: Test Card Menu
150i Test Cards
Standard
Mag Stripe
Indent
Mag Stripe/Emboss
Mag Stripe/Emboss/Top
Smart Card
Wheel
Topper
Run Without Cards
Preembossed
Character Height
To make any Test Card, do the following:
• Use the 2 key or 8 key to scroll through the Test Cards menu.
• Select the Test Card to be made by pressing the # key.
• If you are making a Mag Stripe test card or a Preembossed test card, do the
following: (For other test cards, skip this step.)
• Press # to select encode format.
• Use the 2 or 8 keys to scroll through options.
• Press # to select an option.
• For “Stop at One Card?”, press # for Yes, 1 for No and 0 to Escape.

Standard Test Card
This option is used to setup emboss line locations and margins. The test will emboss
3 characters on the card with 7 char/inch font using the character 8. The two line
locations (800, 250) are used with a fixed margin of .250 of an inch.
.250 3.000
.800
.250
Standard Test Card

54740-78
Figure 5-1 : Standard Test Card

Mag Stripe Test Card
This option is used to encode 2 tracks of STD bank code data for tracks 1 and 2.
Indent Test Card

This option is used to make an Indent test card if the 150i is so equipped.
MagStripe/Emboss Test Card

This option is used to make a 3-line financial emboss test card with 2 tracks of
encoded data.
MagStripe/Emboss/Top Test Card

This option is used to make a 3-line topped financial emboss test card with 2 tracks
of encoded data.
5-10 Troubleshooting
Smart Card Test Card
If the 150i is so equipped, this option is used to verify the Smart Card option for the
program head location. Use this test to verify the programming of the Smart Card
head in the 150i System and to adjust the Smart Card chip card head offset.
• The test will require a Smart Card placed in the Input Hopper.
• A card will then stop at the Smart Card head location and the program head
solenoid will fire.
• The test will then communicate to the Smart Card board application and reset the
diagnostic. One of the following status messages is returned.
Table 5-4 : Smart Card Test Messages
Smart Card Messages Description
Smart Card Comm Error Comm failure to Smart Card board. Check cables
and see if application is running in the Smart Card
system.
Card OK (Answer to Reset) No errors. Chip card is communicating to the

program head.
Card Not Responding Card time-out error.
Not an ISO 7816 reset The Smart Card chip card is not communicating.
Failure could be the card, not enough pressure on
the head or the card is not aligned correctly to the
program head.
This test will not test the Key Card readers. (Run an online application to test.) A
Smart Card application for the 150i System needs to be loaded.
Wheel Test Card
This option is used to make a card with every character on the wheel, including indent and
special characters.
9/-FWJYBDMSONARELIT
HCUGKPVZQX.,'&
54740d75
Wheel Test Card
Figure 5-2: Wheel Test Card

Topper Test Card
This option is used to verify the topper platen squareness.
.301 3.074
.843
.172 Topper Test Card

54740-77
Figure 5-3: Topper Test Card

Run Without Cards
This option is used to exercise the 150i without using cards in the system.
Preembossed Test Card

This option is used to verify the throat gap adjustment for preembossed cards.
Character Height Test Card

This option is used to verify character height on a standard wheel.
Position Offsets Menu
This option menu is used to control the X and Y position offsets used in the 150i
System.
• Select the # key to change an offset value or to view offset values.

• When there are more than one editable offset, press the 4 or the 6 key to move
between offsets.
• Press the 2 key to increment the offset or the 8 key to decrement the offset.
• Press the 3 key to toggle the increment constant between one and ten. The [x1] is
used to display the times 1 or times 10 increment range.
• Once an offset has been changed, the display will show a <c>. This is a reminder
that the new offset has been detected and should be saved.
• Press the 0 key to Exit.
• Increasing the offset moves the carriage away from the home position.
Decreasing the offset moves the carriage towards the home position.

Table 5-5: Position Offsets Menu
Position Offsets # Key Pressed Example
Pick Pick [x1]

X or Y Offset [ 0]
Smart Card Smart Card [x1]

X, Y Offsets [ 0]
MagStripe NTT Magstripe Front [x1]

X, Y, Coercivity Offsets [ 0]
MagStripe Standard Magstripe Rear [x1]

MagStripe Variables Magstripe variables [x1]

LTJ, BBJ Subinterval,
Start Sent Var [ 0]
Emboss Location Emboss [x1]

X or Y Offsets [ 0]
Topper Topper [x1]

X or Y Offset [ 0]
Topper Noise Topper Noise

Offset [ 0]
Exit Exit [x1]

X or Y Offset [ 0]
Reject Reject [x1]

X Offset [ 0]
Emboss Height Emboss Offsets [x1]

Lower or Upper [ 0]
Indent Depth Indent Offsets [x1]

Lower or Upper [ 0]
Throat Gap Throat Gap [x1]

Offset [ 0]
Wheel Home Wheel Home [x1]

Offset [ 0]
Card Bow Card Bow [x1]

Offset [ 0]
Wheel Parameters Menu
This option menu is used to change the individual wheel finger parameters on the
150i System. This option also is used to move (remap) a character on the wheel,
increase or decrease emboss pressure and dwell, adjust spacing of a character, and
define the character type.
• Select the 2 key or 8 key to select the finger number menu. Valid wheel finger
positions are from 1 to 75.
• Press the # key to select the correct finger to change.
• Keys 4 and 6 are used to scroll through the wheel mapping parameters.
The example below is for the 1st finger position.
Table 5-6: Wheel Parameters Menu
Wheel Parameters # Key Next Screen Example
Remap Finger 1 [x1]

Remap [ 0]
Dwell Finger 1 [x1]

Dwell [ 0]
Lower Pos Finger 1 [x1]

(Motor steps) Lower Pos [ 460]
Upper Pos Finger 1 [x1]

(Motor steps) Upper Pos [ 460]
Spacing Finger 1 [x1]

Spacing [ 38]
Char Type Finger 1 [x1]

Char Type [ 2]
For Spacing and Char Type, the following choices are available:
Table 5-7: Spacing and Character Type
Char Type Char Type Value Spacing Value Characters/Inch
Std Gothic 0 27 10
Indent 1 27 10
Indent 1 19 14
OCR 7B 2 38 7

Topper Parameters Menu
This option menu is used to change each Topper table parameter on the 150i System.
• When Topper Parameters appears on the main menu, press the # key.
• Select the 2 key or the 8 key to select the Topper table number menu. Valid tables
are from 1 to 8.
• Press the # key to select the specific table.
• Keys 4 and 6 are used to scroll through the topper parameters.
The example below is for table one position.
Table 5-8: Topper Parameters Menu
Topper Parameters # Key Next Screen Example
Temperature Table 1 [x1]

Temperature [ 235]
Dwell Table 1 [x1]

Dwell [ 850]
Configuration Menu
This option is used to configure the 150i System hardware options. The configuration
menu is used for selecting the options below:
• When Configuration appears on the main menu, press the # key to select it.
• Press the 2 key or 8 key to scroll through Configuration menu selections.
• Press the # key to select the Configuration menu option.
Table 5-9: Configuration Menu
150i Configuration Description
Configure Indent Press the 2 or 8 key to scroll through Indent

options. Press # to select an option.
Configure Stripe Press the 2 or 8 key to scroll through Mag

Stripe options. Press # to select an option.
Configure Smart Card Press the 2 or 8 key to scroll through Smart

card options. Press # to select an option.
Configure Topper Press the 2 or 8 key to scroll through Topper

options. Press # to select an option.
Status Request Menu
This option menu is used to display status information.
• When Status Request appears on the main menu, press the # key to select it.
• Press the 2 key or 8 key to scroll through Status menu options.
• Press the # key to select a menu option.
Table 5-10: Status Request Menu
150i Status Request Description
Last Reported Status Press # to display last reported

status message.
Card Counts Press # to display the card counts in

the 150i System for total, good, and
rejects.
Hardware Configuration Press # to display 150i hardware

options configured. Press the 2 or 8
keys to scroll.
Restore MCB Defaults

This will restore all MCB offsets to pre-factory defaults. Press # when Restore MCB
Defaults appears on the main menu. Press # again to confirm MCB settings.
Restore Mfg Settings

This will restore all offsets to manufacturing defaults. Press # when Restore Mfg
Settings appears on the main menu. Press # again to confirm manufacturing settings.
Save Changes
When changes in offsets are detected, the display shows <c> on the top line. This is a
reminder to save the new offset values. Press # when Save Changes appears on the
main menu.

150i Interconnect Diagrams
The following diagrams show the 150i system cable connections.
36 Volt
Power Supply
Interlock Interlock 5 Volt 12 Volt

Switch Circuitry Regulator Regulator
U15 Stepper X Axis

556008-000 L298 Driver Motor 1.0 Amp
150i Main
Control U14 Stepper Wheel
L298 Driver Motor 1.0 Amp
U13 Stepper Punch

U17 Stepper Die

U27
XL5210 U28 Stepper Y Axis
Sensors I/O Controller L6219 Driver Motor 0.56 Amp
X-Axis U31 Stepper IH

Home L6219 Driver Motor 0.56 Amp
Y-Axis U30 Stepper OCR

Home L6219 Driver Motor 0.56 Amp
A Encoder U29 Stepper Throat Gap

B Encoder LU6219 Driver Motor 0.56 Amp
Wheel U12 Solenoid OCR Sol.

Home L298 Driver Lock Sol.
Punch
Home
Die U59 Mag Stripe Mag Stripe

Home L6219 Driver Head
Registration
Hopper Q6 Heater
Heater
Empty FET + Output
Output Q2 Topper Topper +

Full FET Solenoid Solenoid
Hopper Q5 Foil Foil +

Home Transistor DC Motor DC Motor
OCR Q4 SC SC
Motion FET Solenoid Solenoid
Platten
Home
Foil
Motion
Reject
Full
Throat
Gap
Cord
Picked
Figure 4: Main Control Input/Output Block Diagram
Main Control Board Connections
Punch 36 Volt Die
Motor Supply Motor
Door Input Indent
Wheel Lock
Motor Motor Motor
Sel Rear Throat
X axis Topper
Motor Indent Gap
Sel Motor Sel
J10 J9 J11
J3
Flash
J tag
Serial
Comm
Front J16
Panel
J7
J14 J12 J13

Jumper Position
1-2 Normal Op
2-3 Program J tag
Display Sensors Sensors

Pot Magnetic Stripe
Adjustment Interlock
Figure 5-5: Main Control Board Connections

Main Control Board Cable Connections
555961-001
Cable Assy, DC Power
556008-001
150i PWA
555037-002
Cable Assy,
Comm I/O
555039-001
Cable Assy,
Display
555962-001
Cable Assy, Sensor
Figure 5-6: Main Control Board Cable Connections
AC Wiring Diagram
804960-024
FUSE
594032-001 555033-001
596679-001 36V Switching
Cable Assy. Power Supply
Main ON/OFF JP2
Switch +
_ ++
EMI Power
Line Filter
Chassis Ground
J9
556008-001
Main Control
150i
Figure 5-7: AC Wiring Diagram

Pin-Out Tables
Motor Pin-Outs
Table 5-11: Motor Pin-Outs for Connector J10
Pin # Signal Name Signal Description

1 OCR_Sol- Rear Indent Solenoid - Output
2 Lock_Sol+ Lock Solenoid + Output
3 PB- Punch Motor B phase -
4 PA+ Punch Motor A phase +
5 YB- Y Axis Motor B phase -
6 YA+ Y Axis Motor A phase +
7 WB- Wheel Motor B phase -
8 WA+ Wheel Motor A phase +
9 XB- X Axis Motor B phase -
10 XA+ X Axis Motor A phase +
11 N/C
12 GND Ground
13 OCR_Sol+ Rear Indent Solenoid + Output
14 Lock_Sol- Lock Solenoid - Output
15 PB+ Punch Motor B phase +
16 PA- Punch Motor A phase -
17 YB+ Y Axis Motor B phase +
18 YA- Y Axis Motor A phase -
19 WB+ Wheel Motor B phase +
20 WA- Wheel Motor A phase -
21 XB+ X Axis Motor B phase +
22 XA- X Axis Motor A phase -
23 N/C
24 36V_NINV 36 volt non-interlock
Table 5-12: Motor Pin-Outs for Connector J11
Pin # Signal Name Signal Description

1 Top_Sol- Topper Solenoid - Output
2 SC_Sol+ Smart Card Solenoid + Output
3 SCM_B- Smart Card Motor B phase -
4 SCM_A+ Smart Card Motor A phase +
5 OCR_B- Rear Indent Motor B phase -
6 OCR_A+ Rear Indent Motor A phase +
7 IHB- Input Hopper B phase -
8 IHA+ Input Hopper Motor A phase +
9 DB- Die Motor B phase -
10 DA+ Die Motor A phase +
11 Heater+ Heater + Output
12 GND Ground
13 Top_Sol+ Topper Solenoid + Output
14 SC_Sol- Smart Card Solenoid - Output
15 SMC_B+ Smart Card B phase +
16 SMC_A- Smart Card A phase -
17 OCR_B+ Rear Indent Motor B phase +
18 OCR_A- Rear Indent Motor A phase -
19 IHB+ Input Hopper Motor B phase +
20 IHA- Input Hopper Motor A phase -
21 DB+ Die Motor B phase +
22 DA- Die Motor A phase -
23 FOILMTR+ Foil Motor + Output
24 GND Ground

Sensor Pin-Outs
Table 5-13: Sensor Pin-Outs for Connector J12
Pin # Signal Name Sensor Name Pin # Signal Name Sensor Name
1 Pullup 26 N/C
2 Sensor 15 Encoder B 27 Sensor 3 Punch Home
3 Sensor 0 X Axis Home 28 N/C
4 Vcc 29 GND
5 GND 30 N/C
6 Sensor 14 Encoder A 31 GND
7 GND 32 N/C
8 GND 33 Pullup
9 Pullup 34 Vcc
10 HD1- 35 Sensor 4 Die Home
11 Sensor 1 Y Axis Home 36 GND
12 HD1+ 37 GND
13 GND 38 GND
14 HD0- 39 GND
15 GND 40 Sensor 6 Registration
16 HD0+ 41 Pullup
17 Pullup 42 Pullup
18 Inter- 43 Sensor 5 Hopper Empty
19 Sensor 2 Wheel Home 44 N/C
20 Inter+ 45 GND
21 GND 46 N/C
22 N/C 47 GND
23 GND 48 N/C
24 N/C 49 N/C
25 Pullup 50 N/C
Table 5-14: Sensor Pin-Outs for Connector J13
Pin # Signal Name Sensor Name Pin # Signal Name Sensor Name
1 GND 21 Sensor 11 Foil Motion
2 Pullup 22 GND
3 GND 23 Pullup
4 Sensor 8 Output Full 24 GND
5 Sensor 7 Hopper Home 25 GND

6 GND 26 Pullup
7 Pullup 27 GND
8 GND 28 Sensor 13 Reject Full

9 GND 29 Sensor 16 Throat Gap
10 Pullup 30 GND
11 GND 31 Pullup
12 Sensor 10 OCR Motion 32 GND
13 Sensor 9 Platen Home 33 N/C

14 GND 34 N/C
15 Pullup 35 N/C
16 GND 6 N/C
17 GND 37 N/C
18 Pullup 38 N/C
19 GND 39 RTD2
20 Sensor 12 Card Picked 40 RTD1

Serial Communications Pin-Outs
Table 5-15: Serial Communications Pin-Outs (J16)
Pin # IC Pin Signal Connector/Pin #
1 RX2 A DCD Host – 1
2 RX3 A DSR Host – 6
3 RX1 A RXD Host – 2
4 TX2 A RTS Host - 7
5 TX1 A TXD Host - 3
6 RX4 A CTS Host - 8
7 TX3 A DTR Host - 4
8 RX5 A RI Host - 9
9 GND GND Host - 5
10 N/C N/C Host - N/C
11 RX2 B DCD Debug - 1
12 RX3 B DSR Debug - 6
13 RX1 B RXD Debug - 2
14 TX2 B RTS Debug - 7
15 TX1 B TXD Debug - 3
16 RX4 B CTS Debug - 8
17 TX3 B DTR Debug - 4
18 RX5 B RI Debug - 9
19 GND GND Debug - 5
20 N/C N/C Debug - N/C
Identifying Errors Using Error Codes
When the Error indicator is illuminated, an Administrator Recoverable Error has
occurred. An Error Code is displayed on the 150i display. Use the following Error
Code list to identify and repair the error.
Errors detected by the 150i firmware are reported as 16-bit values. These values
consist of three basic parts:
1. Which module reported the error.

2. When was the error reported, and
3. Which device reported the error and why.
For clarity, the error codes are grouped as xx-yy-zz. Once an error coded is
displayed, it can be deciphered to give the operator and service personal a clear
understanding on exactly what happened, when it happened, and the offending
module.
For example: the 150i displays the error PK 0826:
• PK (xx) tells the operator that an error occurred while the pick mechanism was
being accessed.
• 08 (yy) tells the operator that the interlock was detected.
• 26 (zz) tells the operator that the interlock was opened unexpectedly
So, PK 0826 tells the operator that while the 150i was attempting to pick a card, the
interlock was opened.
Group xx
This group identifies which module reported the error, but not necessarily which
module was at fault.
Function Value Description
Picking PK yy zz 150i is accessing the Pick mechanism.
Transport XP yy zz 150i is accessing the Transport mechanism.
Mag Stripe MS yy zz 150i is accessing the Mag Stripe mechanism.
Embosser EM yy zz 150i is accessing the Emboss mechanism.
Stacker STyy zz 150i is accessing the Stacker mechanism.
Interlock IN yy zz 150i is accessing the Interlock.

Group yy
This group identifies during which process did the error occur.
Homing xx 01zz 150i is homing mechanisms.
Pick xx 02 zz 150i is picking a card.
Embossing xx 03 zz 150i is embossing (and topping) a card.
Stacking xx 04 zz 150i is stacking a card.
Moving xx 05 zz 150i is moving a card.
Registration xx 06 zz 150i is defining the card origin.
Verify Reg xx 07 zz 150i is verifying that the card/mechanism has slipped.
Interlock xx 08 zz 150i detected interlock.
Encode xx 09 zz 150i is encoding a card.
SCInit xx 0A zz 150i is initializing a Smart Card.
Group zz
This group identifies which device caused the error and why.
X Sensor Hit xx yy 01 X-Sensor was seen.
X Sensor Miss xx yy 02 X-Sensor was not seen.
X Sensor Early xx yy 03 X-Sensor was seen early.
X Sensor Late xx yy 04 X-Sensor was seen late.
Y Sensor Hit xx yy 05 Y-Sensor was seen.
Y Sensor Miss xx yy 06 Y-Sensor was not seen.
Y Sensor Early xx yy 07 Y-Sensor was seen early.
Y Sensor Late xx yy 08 Y-Sensor was seen late.
Pick Sensor Hit xx yy 09 Pick home Sensor was seen.
Pick Sensor Miss xx yy 0A Pick home Sensor was not seen.
Wheel Sensor Miss xx yy 0B Wheel home Sensor not seen.
Wheel Sensor Early xx yy 0C Wheel home Sensor seen unexpectedly.
Upper Emboss xx yy 0D Upper Emboss Home Sensor seen.

Sensor Hit
Upr Emboss Sensor xx yy 0E Upper Emboss Home Sensor missed.

Miss
Upr Emboss Sensor xx yy 0F Upper Emboss Home Sensor seen early.

Early
Upper Sensor Late xx yy 10 Upper Emboss Home Sensor seen late.
Lower Emboss xx yy 11 Lower Emboss Home Sensor seen.

Sensor Hit
Lwr Emboss Sensor xx yy 12 Lower Emboss Home Sensor missed.

Miss
Lwr Emboss Sensor xx yy 13 Lower Emboss Home Sensor seen early.

Early
Lwr Emboss Sensor xx yy 14 Lower Emboss Home Sensor seen late.

Late
Coord. Err xx yy 15 Illegal position requested (card or transport).
Cmd Seq Err xx yy 16 150i Command out of sequence (e.g. emboss

before pick).
No Cards xx yy 17 No cards in card stack.
Card Not Picked xx yy 18 Card was not seen a card exit Sensor.
Card Not Taken xx yy 19 Card was not gripped.
Motor On xx yy 1A Requested motor is on.
User Stop xx yy 1B User requested motor stop.
Illegal Emb Char xx yy 1C Illegal wheel position requested.
Illegal Cmd xx yy 1D Illegal device command.
X Reg Hit xx yy 1E X-Registration Sensor was seen.
X Reg Miss xx yy 1F X-Registration Sensor was not seen.
X Reg Early xx yy 20 X-Registration Sensor was seen early.
X Reg Late xx yy 21 X-Registration Sensor was seen late.
Y Reg Hit xx yy 22 Y-Registration Sensor was seen.
Y Reg Miss xx yy 23 Y-Registration Sensor was not seen.
Y Reg Early xx yy 24 Y-Registration Sensor was seen early.
Y Reg Late xx yy 25 Y-Registration Sensor was seen late.
Interlock xx yy 26 Interlock was broken.

Interlock Missed xx yy 27 Interlock should have been broken before

continuing.
Out Door Open xx yy 28 Output stacker door is open. Output stacker is full.
Platen Stuck Home xx yy 29 Topper platen did not drop.
Platen Stuck Out xx yy 2A Topper platen did not return home.
Card Not Stacked xx yy 2B Card was not placed in output after verifying
registration.
Topper Foil Out xx yy 2C Topping foil is empty.
Reject Tray Full xx yy 2D Reject tray is full.
Topper Temp High xx yy 2E Topper temperature is too high.
Topper Temp Low xx yy 2F Topper temperature is too low.
Topper Temp xx yy 30 Topper temperature is not in control.
Indent Rib. Out xx yy 31 Indent ribbon is empty.
Indent Stuck In xx yy 32 Indent (solenoid) is stuck in.
Indent Stuck Out xx yy 33 Indent (solenoid) is stuck out.
SC Not Present xx yy 34 Smart Card application is not responding.
Encode errors are handled separately as follows:
MS Error Value Description
CARD_POSITION_ERROR MS0901 Error positioning card.
TRACK_TABLE_NOT_FOUND MS0902 Requested track table not found. (Possible

financial password violation.)
INVALID_START_CODE MS0910 Bad start code given.
INVALID_START_SENTINEL MS0911 Invalid start sentinel.
INVALID_END_SENTINEL MS0912 Bad end sentinel given.
INVALID_CHARACTER MS0913 Bad character to encode.
INVALID_DATA_LENGTH MS0914 Data is too long.
READ_OVERRUN_ERROR MS0915 Overrun while reading stripe data from

card.
NO_TRANSITIONS_FOUND MS0916 No transitions seen on stripe.
NO_START_FOUND MS0917 No start sentinel found.
START_POSITION_ERROR MS0918 Start code was in wrong position.
LTJ_ERROR MS0919 Long term jitter.
BBJ_ERROR MS091A Short term jitter.
PARITY_ERROR MS091B Parity error.
LRC_ERROR MS091C Checksum error.
COMPARE_ERROR MS091D Data read did not match data written.

Error Codes
Error codes and messages are displayed on the display located to the left of the
keypad on the front of the 150i. The error codes are structured to tell the operator not
only what the failure is but where the failure occurred in the system. Use the
following table to identify and correct these errors:
Table 5-16: Error Code Troubleshooting Chart
Error Code Error Message Possible Cause Corrective Action

EM0301 Transport Error The card carriage could Open the top cover and verify no
not verify its position. obstructions to prevent moving
Transport to the right or left.
not verify its position. obstructions to prevent moving
transport in or out.
not verify its position. obstructions preventing Transport from
moving backward.
not verify its position. obstructions preventing Transport from
moving backward.
EM030B Emboss Wheel Error The embossing wheel Check Embosser Wheel Home sensor.
could not verify its
position.
EM030C Wheel Error The embossing wheel Check Embosser Wheel Home sensor.
could not verify its
position.
EM030E Embossing Error The emboss mechanism Check Input Hopper mechanism..
jammed. Two cards may
have been picked.
EM030F Embossing Error The emboss mechanism Check Input Hopper mechanism..
have been picked.
EM0310 Emboss Char Err The emboss mechanism Check Input Hopper mechanism..
have been picked.
EM0312 Embossing Error The emboss mechanism Check Input Hopper mechanism..
have been picked.
have been picked.
have been picked.
EM0315 Coordinate Out Of Range The 150i could not make Redo card layout..
the card due to physical
limits of the card. Either
too many emboss
characters on the card
or they are in the wrong
position on the card.
EM0326 Interlock Seen The top cover was Close the Top Cover.
opened during card
processing.
EM0329 Topping Platen Error The topper platen did not Open the top cover and verify no
come down correctly. obstructions around or in Topper or
platen photocell. Check Topping foil for
correct routing.
EM032A Topping Platen Error The topper platen did not Open the top cover and verify no
come down correctly. obstructions around or in Topper or
platen photocell. Check Topping foil for
correct routing.
EM032C Foil Advance Error The 150i did not detect Verify no obstructions around or in
topper foil motion. Topping foil. Is there foil and is it loaded
correctly?
EM032E Top Temperature Error The 150i detected the Topper temperature too hot. Shut down
topper temperature is out 150i and allow to cool at least 5 minutes
of its limits. then send card data again.
EM0330 Top Temperature Error The 150i detected the Allow Topper to warm up. Check heater
topper temperature is not platen.
hot enough.
EM0331 Indent Ribbon Error The 150i did not detect Broken ribbon, out of ribbon or not
indent ribbon motion. installed correctly.
IN0826 Interlock Seen The top cover was Close the Top Cover.
opened during card
processing
MS 0902 TRACK_TABLE_NOT_FOUND The 150i could not verify Reload table magnetic stripe table and
the information that it send card data again (unique table).
encoded on the (Possible financial password violation.)
magnetic stripe.
MS0910 INVALID_START_CODE The 150i could not verify Examine data for correct start sentinel.
the information that it Send card data again.
encoded on the
magnetic stripe.
MS0911 INVALID_START_SENTINEL The 150i could not verify Examine data for correct start sentinel.
encoded on the
magnetic stripe.
MS0912 INVALID_END_SENTINEL The 150i could not verify Examine data for correct end sentinel.
encoded on the
magnetic stripe.
MS0913 INVALID_CHARACTER The 150i could not verify Examine data for correct information.
encoded on the
magnetic stripe.

MS0914 INVALID_DATA_LENGTH The 150i could not verify Examine the data sent. Send card data
the information that it again.
encoded on the
magnetic stripe.
MS0915 READ_OVERRUN_ERROR The 150i could not verify Check cards in the Input Hopper.
the information that it Check coercivity (refer to CPX Manual).
encoded on the Send card data again.
magnetic stripe.
MS0916 NO_TRANSITIONS_FOUND The 150i could not verify Check coercivity (refer to CPX Manual).
the information that it Verify the card has a magnetic stripe
encoded on the and cards are stacked in the Input
magnetic stripe. Hopper correctly.
MS0917 NO_START_FOUND The 150i could not verify Clean Magnetic Strip head.
the information that it
encoded on the
magnetic stripe.
MS0918 START_POSITIION_ERROR The 150i could not verify Check for obstructions in the magnetic
the information that it stripe encoding area. Send card data
encoded on the again.
magnetic stripe.
MS0919 LTJ_ERROR The 150i could not verify Check for bad card stock. Send card
the information that it data again.
encoded on the
magnetic stripe.
MS091A BBJ_ERROR The 150i could not verify Check for bad card stock. Send card
encoded on the
magnetic stripe.
MS091B PARITY_ERROR The 150i could not verify Check for bad card stock. Send card
encoded on the
magnetic stripe.
MS091C LRC ERROR The 150i could not verify Check for bad card stock. Send card
encoded on the
magnetic stripe.
MS091D COMPARE_ERROR The 150i could not verify Check for bad card stock.
the information that it
encoded on the
magnetic stripe.
MS0926 Interlock Open The top cover was Close the Top Cover.
opened during card
processing.
PK0102 Transport Error The card carriage could Verify no obstructions are between
not verify its position. Transport and the right side of the 150i.
PK0105 Transport Error The card carriage could Verify no obstructions between Card
not verify its position. Carriage and back of the Transport.
PK0106 Transport Error The card carriage could Verify no obstructions between Card
not verify its position. Carriage and back of the Transport.
PK010A Transport Error The card carriage could Verify no obstructions between
not verify its position. Transport and Input Hopper. Remove all
cards and reload Input Hopper.
PK010B Emboss Wheel Error The emboss mechanism Verify no obstructions preventing the
jammed. Two cards may Emboss wheel from turning.
have been picked.
PK010E Embossing Error The emboss mechanism Verify no obstructions preventing the
jammed. Two cards may Die mechanism from returning to home.
have been picked.
PK0112 Embossing Error The emboss mechanism Verify no obstructions around punch.
have been picked.
PK0119 Card Feed Error 150i failed to pick a card. Open the top cover and remove all
cards from the Input Hopper and
reload.
PK0126 Interlock Seen The top cover was Close Top Cover and send card data
opened during card again.
processing.
PK0128 Check Output Tray Output door is opened Close Output Door or empty Output
during card processing or Stacker.
output tray is full.
PK012B Card Not Stacked Card did not make it to Open Output Supply door and remove
the output stacker. card from rollers.
PK012D Reject Stack Full Reject Stacker full. Open Top Cover and empty Reject
Stacker.
PK0135 Card Feed Error Throat home sensor not Reload cards and send card data
found during homing. again.
PK0201 Transport Error The card carriage could Verify that there are no obstructions
not verify its position. preventing Transport from moving to
the left.
PK0202 Transport Error The card carriage could Verify that there are no obstructions
not verify its position. preventing Transport from moving to
the right or left.
PK0205 Transport Error The card carriage could Verify no obstructions preventing
not verify its position. Transport Carriage from moving forward
or backwards.
PK0206 Transport Error The card carriage could Verify no obstructions preventing
not verify its position. Transport Carriage from moving
backward or forward.
PK0209 Transport Error i+ The card carriage could Verify no obstructions around Card
not verify its position. Supply Stack preventing stack from
moving. Two cards may have be
picked, remove and reload cards.
PK020A Transport Error i+ The card carriage could Verify no obstructions around Card
not verify its position. Supply Stack preventing stack from
moving. If two cards were picked,
remove and reload cards.
PK0217 Card Supply Empty No cards in the input Place cards in card Input Hopper.
hopper.
PK0218 Card Feed Error 150i failed to pick a card. Remove all cards, reload and retry.
Verify cards are in Input Hopper.

PK0219 Card Feed Error 150i failed to pick a card. Remove all cards, reload and retry.
Verify no obstructions around Input
Hopper card throat and cards are in
Input Hopper.
PK0226 Interlock Seen The top cover was Close Top Cover and send card data
opened during card again.
processing
PK0228 Check Output tray Output door is opened Empty Output Tray and/or close door.
during card processing or
output tray is full.
PK022D Reject Stack Full Reject Tray is full Open the top cover and remove cards
from the Reject Tray.
PK0235 Card Feed Error 150i failed to pick a card. Turn off 150i, remove all cards, reload
cards and send card data again.
SC0A34 Smart Card Comm Error The 150i failed to Reload Smart Card application.
communicate with the
Smart Card logic board.
ST0401 Transport Error The card carriage could Verify no obstructions around Transport
not verify its position. and Output Stacker.
ST040A Transport Error The card carriage could Verify no obstructions around Output
not verify its position. Stacker. Card jammed.
ST0426 Interlock Open The top cover was Close the Top Cover.
opened during card
processing.
ST042B Card Not Stacked Cards not stacked Remove card from Output Stack rollers.
properly in Input Hopper. Verify no obstructions around Output
Stacker that would prevent card from
exiting.
XP0501 Transport Error The card carriage could Verify no obstructions in X transport
not verify its position. direction.
XP0505 Transport error The card carriage could Verify no obstructions around Y- Sensor.
not verify its position.
XP061E Card Registration Error The 150i could not verify Verify no obstructions around
the correct card position. Registration photocell or Transport.
XP061F Card Registration Error The 150i could not verify Verify no obstructions around
XP0622 Card Registration Error The 150i could not verify Send card data again.
the correct card position.
XP0623 Card Registration Error The 150i could not verify Verify no obstructions around
XP0626 Interlock Open The top cover was Close the Top Cover.
opened during card
processing.
XP071F Verify Regist. Error This error is due to Verify that the embossing on the card is
possible card slippage correct. Send card data again if
during processing. necessary.
XP0720 Verify Regist. Error This error is due to Verify that the embossing on the card is
possible card slippage correct. Send the card data again if
during processing. necessary
XP0726 Interlock Open The top cover was Close the Top Cover.
opened during card
processing.

Main Control Board LEDs
The following describes the LED functions for the Main Control Board of the 150i.
These LEDs serve as a quick visual indication that the LED, sensor and the
associated wiring harness to that LED is functional. See Figure 5-8 for LED locations.
See Figure 5-9 for the physical location of the sensor.
Table 5-17: Main Control Board LEDs
LED ID Description LED is ON LED is OFF

D17 Throat Gap Sensor Indicates the Throat Gap Indicates the Throat Gap
sensor is fully open. sensor is closed.
D18 Xilinx Done Indicates the Xilinx Indicates the Xilinx

processor is busy. processor is not busy.
D19 Reject Full Sensor Indicates the Reject Indicates the Reject
Hopper if filled with Hopper is not
cards. completely filled with
cards
D20 Topper Foil Motion Sensor Indicates the Topper Foil is moving.
D21 Card Picked Sensor Indicates that a card Indicates that no card is
has been picked. blocking the sensor.
D22 Topper Platen Home Sensor Indicates the Topper Indicates the Topper
Platen is at home Platen is not at home
position. position.
D23 OCR Motion Sensor Indicates the OCR ribbon is moving.
D24 Input Home Sensor Indicates the Input Indicates the Input
Home Picker is at home Home Picker is not at
position.. home position.
D25 Output Full Sensor Indicates the Output Indicates the Output
Input Hopper is filled with Input Hopper is not
cards. completely filled with
cards.
D26 Card Registration Sensor Indicates a card is Indicates that nothing is

blocking the Card blocking the Card
Registration sensor. Registration sensor.
D27 Input Hopper Empty Sensor Indicates there are no Indicates there is at least
cards in the Input one card in the Input
Hopper. Hopper.
D28 Upper Emboss Home Sensor Indicates the Upper Indicates the Upper
Emboss cam is in the Emboss cam is not in the
home position. home position.
D29 Lower Emboss Home Sensor Indicates the Lower Indicates the Lower
Emboss cam is in the Emboss cam is not in the
home position. home position.
D30 Wheel Home Sensor Indicates the Embosser Indicates the Embosser
Wheel is in the home Wheel is not in the home
position. position.
LED ID Description LED is ON LED is OFF
D31 Y-Home Sensor Indicates the Y Carriage Indicates the Y Carriage
is in the home position. is not in the home
position.
D32 ENC B Indicates the B section of the Magnetic Stripe

Encoder Wheel is moving.
D33 X-Home Sensor Indicates the X Carriage Indicates the X Carriage

is in the home position. is not in the home
position.
D34 ENC A Indicates the A section of the Magnetic Stripe

Encoder Wheel is moving.
D35 +12V2 Indicates the +12 VDC Indicates the +12 VDC
V2 Power Supply is on. V2 Power Supply is off.
D36 +12V1 Indicates the +12 VDC Indicates the +12 VDC
V1 Power Supply is on. V1 Power Supply is off.
D37 +5V Indicates the +5 VDC Indicates the +5 VDC

Power Supply is on. Power Supply is off.
D17 D19 D21 D23 D25 D27 D29 D31 D33 D35 D37
D18 D20 D22 D24 D26 D28 D30 D32 D34 D36
150i015s
Figure 5-8: Main Control Board LEDs

Topper Platen
Sensor
Reject Full
Sensor X-Home
Topper Foil Sensor
Motion Sensor Throat Gap
Sensor
Y-Home
Sensor
Wheel Home
Sensor
Punch Cam Die Cam

Home Sensor Home Sensor
Card
Registration
Sensor
Card Picked
Sensor
REAR VIEW
Output Full
Input Hopper Input Home
Sensor
Empty Sensor Sensor
Figure 5-9: Sensor Locations
Chapter 6:
Adjustments
chapter provides information for adjusting the 150i.
Introduction 6-2
Mechanical Adjustments 6-2

Magnetic Stripe Head Height Adjustment 6-2
Rear Indent Drive Belt Adjustment 6-4
Interlock Switch Adjustment 6-6
Electrical Adjustment 6-8

Display Contrast Adjustment 6-8
Software Offsets 6-10

Start Diagnostic Routines 6-10
Position Offsets Menu 6-11
Pick Offset 6-13
Smart Card Offset 6-14
MagStripe NTT Offset 6-15
MagStripe Standard Offset 6-16
MagStripe Variables Offset 6-18
Emboss Location Offset 6-19
Topper Offset 6-20
Topper Noise Offset 6-21
Exit Offset 6-22
Emboss Height Offset 6-23
Indent Depth Offset 6-24
Throat Gap Offset 6-25
Wheel Home Offset 6-26
Card Bow Offset 6-27

Introduction
This chapter presents mechanical, electrical, and software adjustment procedures for the 150i.
These procedures are not part of preventive maintenance and are performed only as
unscheduled maintenance requirements identified during fault isolation.
Mechanical Adjustments
The following pages describe the mechanical adjustments for the 150i. The software offset
adjustments appear after the mechanical adjustments.
Magnetic Stripe Head Height Adjustment

The purpose of this adjustment is to insure proper pressure and contact of the encoding head
with card stripe.
Symptoms
If this adjustment is not correct, the magnetic head will not come in contact with the magnetic
stripe and read/write errors will occur. If the magnetic head is too high, card jamming may
occur.
Tools
• Hex key set
Procedure
1. Unlock and lift up the Top Cover (see Opening the Top Cover in Chapter 7, Removal
and Replacement).
3. Loosen one Magnetic Stripe height holding screw on the side of the Magnetic Stripe
module.
4. Manually rotate the Card Transport carriage lead screw so the Card Transport carriage is
in front of the Magnetic Stripe module.
5. Manually insert a card with the magnetic stripe up in the Card Transport carriage
grippers.
6. Position the card over the Magnetic Stripe head.
6-2 Adjustments
7. Adjust the Magnetic Stripe head height so as a card enters the nip of the roller, minimum
deflection of the card occurs, while still making good contact with the Magnetic Stripe
head.
8. Tighten the Magnetic Stripe height holding screw.
Head Height Adjustment Wheel
Height Holding Screw
Figure 6-1: Magnetic Stripe Head Height Adjustment

Rear Indent Drive Belt Adjustment
The purpose of this adjustment is to ensure the Rear Indent Drive Belt engages with the
motor and drive pulleys.
Symptoms
If this adjustment is not correct, the Indent ribbon will not advance.
Tools
• #10 Torx driver
Procedure
1. Unlock and lift up the Top Cover (see Rear Indent Drive Belt Adjustment in Chapter 7,
Removal and Replacement).
3. Loosen two Rear Indent Motor adjustment screws.
4. Adjust the bracket so the Rear Indent Drive belt has enough tension so it will not slip
when driven.
5. Tighten the two Rear Indent Motor adjustment screws.
6-4 Adjustments
Adjustment
Screws
Drive Belt
Rear Indent Motor
Figure 6-2: Rear Indent Drive Belt Adjustment

Interlock Switch Adjustment
This adjustment is to ensure power will be OFF to the 150i when the Top Cover is opened.
Symptoms
If this adjustment is not correct, the 150i will not operate.
Tools
• #20 Torx driver
Procedure
and Replacement).
3. Loosen two bracket adjustment screws.
4. Adjust the bracket so when the Top Cover is fully closed and seated, the Interlock switch
is activated.
5. Tighten the two bracket adjustment screws.
Test the Key Lock using a key and the password control to open the Top Cover.
6-6 Adjustments
Bracket
Adjustment
Screws
Figure 6-3: Interlock Switch Adjustment

Electrical Adjustment
The following pages describe the electrical adjustment for the 150i.
Display Contrast Adjustment

This adjustment sets the viewing brightness of the 150i display for optimum viewing.
Symptoms
If this adjustment is not correct, the display will be too faint or too bright to read.
Tools
• Pot adjustment tool
Procedure
and Replacement).
2. Power ON the 150i and adjust the contrast control (R212) for the best readability for an
operator.
3. Power OFF the 150i and replace Front Access Panel.
6-8 Adjustments
Display Contrast
Adjustment Pot
Figure 6-4: Display Contrast Adjustment

Software Offsets
The following software adjustments are used to set up, calibrate, and define the operating
parameters for the 150i.
Start Diagnostic Routines

To select the diagnostic programs from the 150i front panel, perform the following steps:

2. Press 2 (Diagnose) to select the diagnostic control application.
3. The system will reboot and go into the diagnostics mode.
4. After a short pause, the 150i front panel will display the following message:
150i Diags Rev X.XX
Service
5. To select the front panel options, the user must first press the # (pound) key.
6. After a short pause, the 150i front panel will display the following message:
Please wait...
The main menu appears.
When running diagnostics from the front panel, the 150i System is in the off-line mode.
The keypad is used to navigate through the menus as they are displayed on the front panel of
the 150i System.
Table 6-1: Keypad Navigation
Key Description
# Selects option (Enter key).
0 Aborts menu option or backs-up 1 menu option.
2 Scrolls the menu UP or will increment a setting.
3 Offset adjustments range toggle from ±1 times the increment to ±10.
4 Scrolls the menu LEFT.
5 Changes offset from (-) negative to (+) positive
6 Scrolls the menu RIGHT.
8 Scrolls the menu DOWN or will decrement a setting.
6-10 Adjustments
Position Offsets Menu
This option menu is used to control the X and Y position offsets used in the 150i System.
1. Select the # key to change an offset value or to view offset values.

2. When there are more than one editable offset, press the 4 or the 6 key to move between
offsets.
3. Press the 2 key to increment the offset or the 8 key to decrement the offset.
4. Increasing the offset moves the carriage away from the home position. Decreasing the
offset moves the carriage towards the home position.
5. Press the 3 key to toggle the increment constant between one and ten. The [x1] is used to
display the times 1 or times 10 increment range.
6. After changing the offset, press the # key to save the setting.
Once an offset has been changed, the display will show a <c>. This is a reminder
that the new offset has been detected and should be saved.
7. Press the 0 key and the message “Save Changes?” appears. Press the # key for Yes, the 1
key for No or the 0 key to Escape.
Table 6-2: Position Offsets Menu

Pick Pick [x1]
X or Y Offset [ 0]
Smart Card Smart Card [x1]

X, Y Offsets [ 0]
MagStripe NTT Magstripe Front [x1]

MagStripe Standard Magstripe Rear [x1]

MagStripe Variables Magstripe variables [x1]

LTJ, BBJ Subinterval,
Start Sent Var [ 0]
Emboss Location Emboss [x1]

X or Y Offsets [ 0]
Topper Topper [x1]

X or Y Offset [ 0]
Topper Noise Topper Noise

Offset [ 0]
Exit Exit [x1]

X or Y Offset [ 0]

Reject Reject [x1]
X Offset [ 0]
Emboss Height Emboss Offsets [x1]

Lower or Upper [ 0]
Indent Depth Indent Offsets [x1]

Lower or Upper [ 0]
Throat Gap Throat Gap [x1]

Offset [ 0]
Wheel Home Wheel Home [x1]

Offset [ 0]
Card Bow Card Bow [x1]

Offset [ 0]
6-12 Adjustments
Pick Offset
The purpose of this offset is to adjust the position of the card grips so they are flush and
centered on the card being picked.
Table 6-3: Pick Offset
Reference Pick X-Offset Pick Y-Offset

Point
Default value 0 0
Increase offset Moves the grip position to the Moves the grip position
left-hand sided of a card. closer to a card.
Decrease offset Moves the grip position to the Moves the grip position
right-hand sided of a card. away from a card.
Symptoms
If this offset is not correct, a card will not be properly gripped and may hit obstructions as it
moves through the 150i.
Procedure
2. Press the 2 key to select the diagnostic control application.
3. The system will reboot and go into the diagnostics mode. After a short pause, the 150i
front panel will display the following message:
150i Diags Rev X.XX
Service
4. To select the front panel options, you must first press the # (pound) key. After a short
pause, the 150i front panel will display the following message:
Please wait...
5. The main menu will appear. Press the 8 key until Position Offsets appears.
6. Press the # key to enter the Position Offsets menu. Scroll down to Pick, and then press
the # key.
When there is more than one editable offset, press the 4 or the 6 key to move between
offsets.
9. After changing the offset, press the # key to store the setting.

Smart Card Offset
The purpose of this offset is to set the Smart Card Offset position to position a smart card
accurately over the programming pins.
Table 6-4: Smart Card Offset
Reference Smart Card X-Offset Smart Card Y-Offset

Point
Default value 0 0
Increase offset Moves a card to the left-hand Move a card closer to the
side of the programming pins. programming pins.
Decrease offset Moves a card to the right-hand Moves a card away from
side of the programming pins. the programming pins.
Symptoms
If this offset is not correct, a smart card will not make proper contact with the smart card
programming pins.
Procedure
150i Diags Rev X.XX
Service
Please wait...
6. Press the # key to enter the Position Offsets menu. Scroll down to Smart Card, and then
press the # key.
offsets.
10. Press the 0 key and follow the prompts to save the new setting.
6-14 Adjustments
MagStripe NTT Offset
The purpose of this offset is to set the front MagStripe NTT Offset position and select the
coercivity.
Table 6-5: MagStripe NTT Offset
Reference Point MagStripe NTT MagStripe NTT MagStripe NTT

X-Offset Y-Offset Coercivity
Default value 0 0 2
Increase offset Moves a card to the Raises the track 1 = 25 ma (Loco)

left-hand side of the position on the card. 2 = 50 ma
Magnetic Stripe Head. 3 = 75 ma
4 = 100 ma
Decrease offset Move a card to the Lowers the track 5 = 150 ma (Hico)
right-hand side of the position on the card.
Magnetic Stripe Head.
Symptoms
If this offset is not correct, the track data may be positioned too high or too low on the
magnetic stripe. No data or data errors will occur if not positioned correctly.
Procedure
150i Diags Rev X.XX
Service
Please wait...
6. Press the # key to enter the Position Offsets menu. Scroll down to MagStripe NTT, and
then press the # key.
offsets.

MagStripe Standard Offset

The purpose of this offset is to set the rear MagStripe Standard Offset position and select the
coercivity.
Table 6-6: MagStripe Standard Offset
Reference MagStripe X- MagStripe Y- MagStripe

Point Offset Offset Coercivity
Default value 0 0 1
Increase offset Moves a card to Raises the track 1 = 25 ma (Loco)

the left-hand side position on the 2 = 50 ma
of the Magnetic card. 3 = 75 ma
Stripe Head. 4 = 100 ma
5 = 150 ma (Hico)
Decrease offset Move a card to the Lowers the track
right-hand side of position on the
the Magnetic Stripe card.
Head.
Symptoms
If this offset is not correct, the track data may be positioned too high or too low on the
magnetic stripe. No data or data errors will occur if not positioned correctly.
Procedure
150i Diags Rev X.XX
Service
Please wait...
6. Press the # key to enter the Position Offsets menu. Scroll down to MagStripe Standard,
and then press the # key.
offsets.
6-16 Adjustments

MagStripe Variables Offset
The purpose of this offset is to set the MagStripe Variables Offset percentages.
Table 6-7: MagStripe Variables Offset
Reference MagStripe MagStripe MagStripe

Point Variables LTJ Offset Variables BBJ Variables Start Sent
Subinterval Var
Default value 12 15 0
Offset Value 10 to 20% 10 to 25% 8 to 100%
Symptoms
If this offset is not correct, offset errors will occur.
Procedure
150i Diags Rev X.XX
Service
Please wait...
6. Press the # key to enter the Position Offsets menu. Scroll down to MagStripe
Variables, and then press the # key.
offsets.
6-18 Adjustments
Emboss Location Offset
The purpose of this offset is to set the Emboss Location Offset position so characters can be
embossed in the proper location on a card.
Table 6-8: Emboss Location Offset
Reference Emboss Location X- Emboss Location Y-

Point Offset Offset
Default value -10 -10
Increase offset Moves embossing to the Raises the embossing on a

right-hand side on a card. card.
Decrease offset Moves embossing to the Lowers the embossing on

left-hand side on a card. a card.
Symptoms
If this offset is not correct, embossed characters may not be properly located on a card.
Procedure
150i Diags Rev X.XX
Service
Please wait...
6. Press the # key to enter the Position Offsets menu. Scroll down to Emboss Location,
and then press the # key.
offsets.

Topper Offset
The purpose of this offset is to adjust the position of a card in the Topper.
Table 6-9: Topper Offset
Reference Point Topper X-Offset Topper Y-Offset

Default value 0 0
Increase offset Moves the card position to Moves the card position
the left of the Topper. closer to the Topper.
Decrease offset Moves the card-position to Moves the card position

the right of the Topper. away from the Topper.
Symptoms
If this offset is not correct, topping quality will be bad or missing on the bottom of a topped
card.
Procedure
150i Diags Rev X.XX
Service
Please wait...
6. Press the # key to enter the Position Offsets menu. Scroll down to Topper Offset, and
offsets.
6-20 Adjustments
Topper Noise Offset
The purpose of this offset is to set the Topper Noise Offset attempts to lessen the noise made
by the topping solenoid.
Table 6-10: Topper Noise Offset
Reference Point Topper Noise Offset

Default value 0
Increase offset Makes the solenoid louder.
Decrease offset Makes the solenoid quieter.
Symptoms
If this offset is not correct, excessive noise may be generated by the topping solenoid.
Procedure
150i Diags Rev X.XX
Service
Please wait...
6. Press the # key to enter the Position Offsets menu. Scroll down to Topper Noise, and
offsets.

Exit Offset
The purpose of this offset is assure cards are placed accurately in the Output Hopper.
Table 6-11: Exit Offset
Reference Point Exit X-Offset Exit Y-Offset

Default value -100 -100
Increase offset Moves a card to the left-hand Moves a card closer to the
side of the Output Hopper. Output Hopper.
Decrease offset Moves a card to the right-hand Moves a card away from
side of the Output Hopper. the Output Hopper.
Symptoms
If this offset is not correct, cards will not be placed in the Output Hopper and/or not released
from the card pick mechanism.
Procedure
150i Diags Rev X.XX
Service
Please wait...
6. Press the # key to enter the Position Offsets menu. Scroll down to Exit, and then press
the # key.
offsets.
6-22 Adjustments
Emboss Height Offset
The purpose of this offset is to set the Emboss Height Offset position.
Table 6-12: Emboss Height Offset
Reference Emboss Height Lower Emboss Height Upper

Point Offset Offset
Default value 0 0
Increase offset Increases the distance the Increases the distance the
lower stepper drive moves. upper stepper drive moves.
Decrease offset Decreases the distance the Decreases the distance the
Symptoms
If this offset is not correct, may become bowed. Characters may experience excessive height
when the card is embossed or too little height.
Procedure
150i Diags Rev X.XX
Service
Please wait...
6. Press the # key to enter the Position Offsets menu. Scroll down to Emboss Height, and
offsets.

Indent Depth Offset
The purpose of this offset is to set the Indent Depth Offset position.
Table 6-13: Indent Depth Offset
Reference Indent Depth Lower Offset Indent Depth Upper

Point Offset
Default value 0 0
Increase offset Increases the distance the Increases the distance the
Decrease offset Decreases the distance the Decreases the distance the
Symptoms
If this offset is not correct, cards may become bowed. Wheel characters may experience
excessive pressure when the card is indented or not enough pressure to properly intent a card.
Procedure
150i Diags Rev X.XX
Service
Please wait...
6. Press the # key to enter the Position Offsets menu. Scroll down to Indent Depth, and
offsets.
6-24 Adjustments
Throat Gap Offset
The purpose of this offset is to set the Throat Gap Offset position in order to process pre-
embossed cards.
Table 6-14: Throat Gap Offset
Reference Point Throat Gap Offset

Default value 0
Increase offset Widens the throat gap.
Decrease offset Narrows the throat gap.
Symptoms
If this offset is not correct, the 150i may jam cards in the Input Hopper.
Procedure
150i Diags Rev X.XX
Service
Please wait...
6. Press the # key to enter the Position Offsets menu. Scroll down to Throat Gap, and then
press the # key.
offsets.
7. Press the 2 key to increment the offset or the 8 key to decrement the offset. The throat
gap should be approximately 0.015 inch between the card and the pick plate.

Wheel Home Offset
The purpose of this offset is to properly align the print wheel for embossing characters on
cards.
Table 6-15: Wheel Home Offset
Reference Wheel Home Offset

Point
Default value 0
Increase offset Moves the wheel further clockwise from the home position.
Decrease offset Moves the wheel further counter clockwise from the home position.
Symptoms
If this offset is not correct, characters will be not be registered on the card correctly. Damage
could also be incurred to the punches and dies on the print wheel or emboss errors from the
lower emboss and upper emboss motors will occur.
Procedure
150i Diags Rev X.XX
Service
Please wait...
6. Press the # key to enter the Position Offsets menu. Scroll down to Wheel Home, and
offsets.
6-26 Adjustments
Card Bow Offset
The purpose of this offset is to set the Card Bow Offset position to minimize card bowing.
Table 6-16: Card Bow Offset
Reference Point Card Bow Offset

Default value 0
Increase offset Affects card bowing in one direction.
Decrease offset Affects card bowing in the opposite

direction.
Symptoms
If this offset is not correct, cards may be bowed when they exit the 150i.
Procedure
150i Diags Rev X.XX
Service
Please wait...
6. Press the # key to enter the Position Offsets menu. Scroll down to Card Bow, and then
press the # key.
offsets.

6-28 Adjustments
Chapter 7:
Removal and Replacement
The 150i Card Personalization System operates as a standalone card embosser.

This chapter provides instructions for removal and replacement of assemblies and
parts.
Introduction 7-3
Servicing Guidelines 7-3
Opening the Top Cover 7-4
Changing the Password 7-5
Top Cover 7-6

Front Access Panel 7-8
Single Card Access Door 7-10
Output Hopper Door 7-12
Key Lock 7-14
Input/Output Hopper 7-16

Output Hopper Drive Belt 7-20
Output Hopper Drive O-Ring 7-22
Card Registration Sensor 7-24
Input Hopper Empty Sensor 7-26
Input Home Sensor 7-28
Output Full Sensor 7-30
Card Picked Sensor 7-32
Throat Gap Motor 7-34
Throat Gap Motor Belt 7-36
Throat Gap Sensor 7-38
Card Transport 7-40

X-Transport Drive Belt 7-42
X-Home Sensor 7-44
Y-Home Sensor 7-46
Card Transport Flex Cable 7-48
Carriage Transport Motor 7-50

Magnetic Stripe Assembly 7-52
Embosser Assembly 7-54

Wheel Home Sensor 7-56
Punch Home Sensor 7-58
Punch Cam Motor 7-60
Punch Cam Belt 7-62
Die Home Sensor 7-64
Die Cam Motor 7-66
Die Cam Belt 7-68
Punch and Die 7-70
Topper Assembly 7-72

Topper Foil Motion Sensor 7-74
Topper Platen Sensor 7-76
Topper Motor 7-78
Main Control Board 7-80
Power Supply Board 7-82
Line Filter 7-84

Fuse 7-86
Fan 7-88
Display/Keypad 7-90
Solenoid Lock Assembly 7-92
Reject Full Sensor 7-94
Front Smart Card Module (Option) 7-96
Front Indent Printer Module (Option) 7-98

Replacing the Front Indent Ribbon 7-100
Rear Indent Printer Module (Option) 7-102

Replacing the Rear Indent Ribbon 7-104
Rear Indent Motor 7-106
Rear Indent Drive Belt 7-108
Rear Indent Solenoid 7-110
7-2 Removal and Replacement

Introduction
This section gives procedures for the removal and replacement of the 150i Card
Personalization System Field Replaceable Units (FRUs) and sub-assemblies.
Some FRU replacements may require self-tapping screws to be used.
Servicing Guidelines
Use the following guidelines when servicing the 150i:
• Observe warning and caution labels affixed to various areas of the equipment.
• Use only the recommended tools as specified to perform service.
• Replacement of certain assemblies and parts requires follow-up adjustments. Make
sure these adjustments are performed after replacement.
• Always perform preventive maintenance as described in Chapter 3, Preventive
Maintenance, of this manual after replacement procedures.
• Verify the 150i functions after replacement by performing and/or observing a limited
customer production run.
• DO NOT defeat the safety interlock.

Opening the Top Cover
The Top Cover can be opened with either a four-digit password or a key. The default
password shipped from the factory for the 150i is *00000. This password should be changed
upon receipt of the machine (see Changing the Password).
• To open the Top Cover using a password, using the keypad, enter *0 (unlock code)
followed by your 4 digit password (XXXX). The solenoid to open the Top Cover
will be energized for 5 seconds.
• The Message “OPEN COVER!” is displayed. If the password is entered incorrectly,
“ACCESS DENIED!” is displayed. To reenter the correct password, press *0
followed by the correct password.
• To open the Top Cover using a key, insert the key in the keyhole and turn it
clockwise ¼ turn.
150i
R

Changing the Password
The default password shipped from the factory for the 150i is *00000. The password can be
changed by doing the following:
Change Password Code
*1[0000][5555]
Old Password New Password
Enter *1 (change password code) followed by the current password and then the new
password. For example, to change the default password 0000 to 5555, enter *100005555. In
this example, the keystrokes to open the Top Cover again using the new password would be
*05555.
If you do not remember your current password, use the key or contact your Datacard
Service Representative for information on how to reset it.
By entering the 8 digit Financial Card Password enable, the Top Cover access will be
reset to the 0000 default password.

Top Cover
The Top Cover can be locked to protect unauthorized access to the inside of the 150i. Use the
following procedure to remove and replace the Top Cover.
Tools
• Phillips screwdriver
• #10 Torx driver
• 11/32 inch nut driver
Remove
1. Unlock and lift up the Top Cover (see Opening the Top Cover).
2. Power OFF the 150i and remove the power cord from the wall outlet.
3. Remove four nuts (1 in Figure 7-1) holding the two ribbon cable straps (2)
4. Disconnect Display Cable connector P4 (3) and place the cable inside the 150i.
5. Remove one nut (4) holding the cover grounding strap and place inside the 150i.
6. Loosen two screws (5) retaining the cover holding pins (left-hand side of the 150i).
7. Manually rotate the Card Transport carriage lead screw to the left-hand side of the 150i.
8. Loosen one screw (6) that retain the cover holding pins.
9. Remove four Phillips screws (7)holding the right Top Cover bracket and the Input
Hopper shield (8). Fold the hinge out of the way.
10. Remove three Phillips screws (9) holding the left Top Cover bracket. Fold the hinge out
of the way.
11. Close the Top Cover and remove the three cover holding pins (10).
12. Remove the Top Cover.
Replace
1. Transfer the Display/Keyboard, Key Lock and the Alignment Pin bracket for the old Top
Cover over to the new Top Cover (see Display/Keypad and Key Lock).
2. Place the Top Cover on the 150i. Insert and center the cover holding pins so the screws
align with the cover holding pin groves. Tighten all three screws to retain the cover
holding pins.
3. Lift up the Top cover and place the left Top Cover bracket in place, securing it with three
screws.

4. Place the right Top Cover bracket and the Input Hopper shield in place and attach with
four screws.
5. Place the grounding strap in position and attach with one nut.
6. Reconnect the Display Cable to P4.
7. Replace the ribbon cable straps and attach with four screws.
8. Ensure that the Top Cover opens and closes properly with no binding.
9. Run a Standard Test Card to confirm proper operation of the 150i. If successful, run a
limited number of customer produced cards for a final quality verification.
4
2 (2x)
1 (4x)
9 (3x)
5 (2x)
6 8
7 (4x)
10 (3x)
Figure 7-1: Top Cover

Front Access Panel
The Front Access Panel is used to restrict access to the Main Control Board. Use the
following procedure to remove and replace the Front Access Panel.
Tools
• #20 Torx driver
Remove
The Topper Platen May Be Very Hot.
3. Lift up on the Topper Solenoid Ring and remove the Topping Foil Cassette.
4. Loosen two screws (1 in Figure 7-2) but do not remove, then remove the Front Access
Panel (2).
Replace
1. Place the Front Access Panel in position and tighten two screws.

1 (2x)
Figure 7-2: Front Access Panel

Single Card Access Door
The Single Card Access Door is used to insert one plastic card at a time for embossing. Use
the following procedure to remove and replace the Single Card Access Door.
Tools
• #20 Torx driver
Remove
3. Open the Single Card Access Door (1 in Figure 7-3) and remove two screws (2) securing
the door to the base of the cabinet.
4. Lift the access door so the door arms (3) are in a vertical position. Squeeze the access
door arms together to remove them from the access door guides (4).
Replace
1. Place the new Single Card Access Door in position and attach with two screws.
Check the door for proper movement and alignment.


3
4 3
4
2 (2x)
Figure 7-3: Single Card Access Door

Output Hopper Door
The Output Hopper Door holds cards that have been produced by the 150i. Use the following
procedure to remove and replace the Output Hopper Door.
Tools
• #10 Torx driver
• #20 Torx driver
Remove
3. Remove two screws (1 in Figure 7-4) attaching the Output Hopper Door (2) to the base of
the 150i.
4. Remove two screws (3) from the pivot arm block (4) and remove Output Hopper Door.
Replace
1. Place the new pivot arm block in position and attach with two screws.
2. Position the Output Hopper Door in place and attach with two screws.
Check the door for proper movement and alignment.


Inside View Of Output Door
3
4
Figure 7-4: Output Hopper Door

Key Lock
The Key Lock is designed to secure the top cover preventing unauthorized access to the
inside of the cabinet Use the following procedure to remove and replace the Key Lock.
Tools
• Adjustable crescent wrench
Remove
3. Remove the Paddle Nut (1 in Figure 7-5) and the Paddle (2) from the Key Lock.
4. Remove the Key Lock Securing Nut (3) and remove the Key Lock (4) from the Top
Cover.
Replace
1. Place the new Key Lock on the Top Cover and screw on the Securing Nut.
2. Place the Paddle on the Key Lock and screw on the Paddle Nut.
4. Test the Key Lock using a key and also by using the password control to open the Top
Cover. (see Opening the Top Cover.)

1
2
Figure 7-5: Key Lock

Input/Output Hopper
The Input/Output Hopper is a main assembly used for stacking cards (or a single card) to be
embossed and as an output receptacle for completed cards. Use the following procedure to
remove and replace the Input/Output Hopper.
Tools
• ¼ inch box wrench
• #20 Torx driver
Remove
3. Manually rotate the Card Transport carriage lead screw to the center of the 150i.
4. Remove the Input Hopper card weight and all cards from the 150i.
5. Remove the Single Card Access Door.
6. Remove two screws (1 in Figure 7-6) and remove the Input/Output Hopper holding plate
(2).
7. Open the Output Hopper Door.
8. Loosen the rear mounting screw (3) and rotate the hold down plate (4) 180 degrees and
partially remove the Input/Output Hopper from the base to gain access to the cable
connectors.
Remove cable ties as necessary.

9. Disconnect the following cable connectors:
• Motor Cable (5)
• Input Empty Sensor (6)
• Input Home Sensor (7)
• Card Picked Sensor (8)
• Card Registration Sensor (9)
• Output Full Sensor (10)
• Throat Gap Motor (11)
• Throat Gap Sensor (12)
10. Lift the Input/Output Hopper from the 150i.

12
11
10
7
1 (2x)
2
6
Figure 7-6: Input/Output Hopper

Replace
1. Partially place the new Input/Output Hopper in position.
2. Reconnect the following inline connectors:

• Motor Cable (5)
• Input Empty Sensor (6)
• Input Home Sensor (7)
• Card Picked Sensor (8)
• Card Registration Sensor (9)
• Output Full Sensor (10)
• Throat Gap Motor (11)
• Throat Gap Sensor (12)
3. After connecting the inline connectors, place the new Input/Output Hopper in position
and rotate the hold down back into place, then tighten the rear mounting screw.
4. Place the Input/Output Hopper holding plate in position and attach with two screws.
5. Replace the Single Card Access Door.
6. Replace any cable ties that were removed.
Make sure wires are not pinched. Secure wires with tie wraps. Make sure connectors and
wires will not interfere with any mechanical movement inside the 150i.

12
11
10
7
1 (2x)
2
6

Output Hopper Drive Belt
The Output Hopper Drive Belt provides movement to transport an embossed card into the
Output Hopper. Use the following procedure to remove and replace the Output Hopper Drive
Belt.
Tools
• #10 Torx driver
Remove
4. Remove one screw (1 in Figure 7-7) holding the upper Output Guide Card Transport
Drive Roller (2) and remove the roller.
5. Slip the Output Hopper Drive Belt (3) off the Output Hopper drive motor pulley and
remove the belt from the assembly.
Replace
1. Place the new Output Hopper Drive Belt in position.
2. Replace the upper output guide Card Transport drive roller in position and hold in place
with one screw.

2
Input/Output Hopper
Figure 7-7: Output Hopper Drive Belt

Output Hopper Drive O-Ring
The Output Hopper Drive O-Rings provide traction for moving an embossed card into the
Output Hopper. Use the following procedure to remove and replace the Output Hopper Drive
O-Ring.
Tools
• #10 Torx driver
Remove
4. Remove one screw (1 in Figure 7-8) holding the upper Output Guide Card Transport
Drive Roller (2). This will allow better access for the removal of the Output Hopper
Drive O-Rings (3).
5. Roll all four Output Hopper Drive O-Rings off from the upper and lower Output Hopper
drive rollers.
Replace
1. Place all new Output Hopper Drive O-Rings on the upper and lower Output Hopper drive
rollers.
2. Place the upper output guide Card Transport drive roller in position and hold in place
with one screw.

2
1
Input/Output Hopper
Figure 7-8: Output Hopper Drive O-Ring

Card Registration Sensor
The Card Registration Sensor detects when a card first enters the 150i. Use the following
procedure to remove and replace the Card Registration Sensor.
Tools
• #10 Torx driver
Remove
3. Open the Output Hopper Door for better access.
4. Remove the Output Hopper Drive Belt (1 in Figure 7-9) from the drive motor pulley.
5. Disconnect the Output Full Sensor cable connector (2) and the Card Registration Sensor
cable connector (3).
Cut cable ties as necessary.

6. Remove four screws (4) holding the Card Transport Drive assembly.
7. Remove two screws (5) holding the Card Registration Sensor (6) and remove the sensor
from the Card Transport assembly.
Replace
1. Place the new Card Registration Sensor in position with emitter pointing down and attach
with two screws.
2. Place the Card Transport Drive assembly in place and attach with four screws.
3. Place the Output Hopper Drive Belt back on the drive motor pulley.
4. Connect the Output Full Sensor and the Card Registration Sensor cable connectors.
Make sure wires are not pinched. Make sure connectors and wires will not interfere with
any mechanical movement inside the 150i.

6 5 (2x)
2
3
4 (4x)
Figure 7-9: Card Registration Sensor

Input Hopper Empty Sensor
The Input Hopper Empty Sensor detects when the Input Hopper has no more cards. Use the
following procedure to remove and replace the Input Hopper Empty Sensor.
Tools
• #10 Torx driver
Remove
3. Open both input and output doors for better accessibility.
4. Disconnect the Input Hopper Empty Sensor cable connector (1 in Figure 7-10).
Cut cable ties as necessary.

5. Remove one screw (2) holding the Input Hopper Empty Sensor (3) to the Input/Output
Hopper assembly and remove the sensor.
Replace
1. Place the new Input Hopper Empty Sensor in position and attach with one screw.
2. Reconnect the Input Hopper Empty Sensor connector.

1
Figure 7-10: Input Hopper Empty Sensor

Input Home Sensor
The Input Home Sensor detects when the card picking mechanism is at its home position. Use
the following procedure to remove and replace the Input Home Sensor.
Tools
• #10 Torx driver
Remove
5. Disconnect the Input Home Sensor cable connector (1 in Figure 7-11).

6. Remove one screw (2) holding the Input Home Sensor (3) to the Input/Output Hopper
assembly.
Replace
1. Place the new Input Home Sensor in position and attach with one screw.
2. Reconnect the Input Home Sensor connector.

3
2
1
Figure 7-11: Input Home Sensor

Output Full Sensor
The Output Full Sensor detects when the Output Hopper is full of embossed cards and should
be emptied. Use the following procedure to remove and replace the Output Full Sensor.
Tools
• #10 Torx driver
Remove
4. Disconnect the Output Full Sensor cable connector (1 in Figure 7-12).

5. Remove one screw (2) holding the Output Full Sensor (3) to the Input/Output Hopper
assembly.
Replace
1. Place the new Output Full Sensor in position and attach with one screw.
2. Reconnect the Output Full Sensor connector.

1
3
2
Figure 7-12: Output Full Sensor

Card Picked Sensor
The Card Picked Sensor detects when a card has been selected by the card picking
mechanism. Use the following procedure to remove and replace the Card Picked Sensor.
Tools
• #10 Torx driver
Remove
3. Disconnect the Card Picked Sensor cable connector (1 in Figure 7-13).

4. Remove one screw (2) holding the Card Picked Sensor (3) to the Input/Output Hopper
assembly and remove the sensor from the 150i.
Replace
1. Place the new Card Picked Sensor in position and attach with one screw.
2. Reconnect the Card Picked Sensor connector.

3 2
Figure 7-13: Card Picked Sensor

Throat Gap Motor
The Throat Gap Motor provides movement to the throat gap mechanism to accommodate pre-
embossed card. Use the following procedure to remove and replace the Throat Gap Motor.
Tools
• #10 Torx driver
Remove
3. Disconnect the TG Motor cable connector (1 in Figure 7-14).

4. Remove two screws (2) holding the Throat Gap Motor (3) and the ground wire (4) to the
Input/Output Hopper assembly.
5. Move the Throat Gap Motor away from the Throat Gap Motor drive belt (5) to allow
removal of the motor.
Replace
1. Place the new Throat Gap Motor in place and attach with two screws. Make sure to attach
the ground wire. Make sure the Throat Gap Motor drive belt is positioned properly on the
motor shaft and pulley.
2. Reconnect the TG Motor connector.

2
4
5
1
Figure 7-14: Throat Gap Motor

Throat Gap Motor Belt
The Throat Gap Motor Belt provides a means to move the throat gap mechanism to
accommodate pre-embossed card. Use the following procedure to remove and replace the
Throat Gap Motor Belt.
Tools
• #10 Torx driver
Remove

3. Remove two screws (1 in Figure 7-15) holding the Throat Gap Motor (2) and the ground
wire (3) to the Input/Output Hopper assembly.
4. Move the Throat Gap Motor (3) away from the Throat Gap Motor Belt (4) to allow
removal of the motor.
5. Remove the Throat Gap Motor Belt.
Replace
1. Position the new belt over the motor shaft and pulley, then attach the Throat Gap Motor
with two screws. Make sure to attach the ground wire. Make sure the Throat Gap Motor
drive belt is positioned properly on the more shaft and pulley.

1
3
Figure 7-15: Throat Gap Motor Belt

Throat Gap Sensor
The Throat Gap Sensor detects when the throat gap mechanism has reached its home
position. Use the following procedure to remove and replace the Throat Gap Sensor.
Tools
• #10 Torx driver
Remove
3. Manually move the Card Transport carriage to the left-hand side of the 150i.
4. Disconnect the Throat Gap Sensor cable connector (1 in Figure 7-16).

5. Remove one screw (2) holding the Throat Gap Sensor (3) to the Input/Output Hopper
assembly.
Replace
1. Place the new Throat Gap Sensor in position and attach with one screw.

1
Figure 7-16: Throat Gap Sensor

Card Transport
The Card Transport consists of a screw mechanism for moving a card through different stages
of production to produce a final card. Use the following procedure to remove and replace the
Card Transport.
Tools
• #10 Torx driver
• #20 Torx driver
Remove
6. Manually rotate the Card Transport carriage lead screw so the Y-Transport is centered
between the Embosser Wheel and the Magnetic Stripe Head.
Make sure not to crimp or damage the Card Transport Flex Cable.
7. Remove two screws (1 in Figure 7-17) holding the Card Transport Flex Cable retaining
clamp (2).

• Card Transport Flex Cable (3)
• Transport Lead Screw Motor (4)
9. Remove two screws (5) holding the Card Transport (6).
10. Lift up and move the Card Transport to the right. Tilt the Card Transport towards the
front of the 150i, then lift the Card Transport up to remove.
Replace
11. Place the new Card Transport on the locating pins on the base of the 150i and attach with
two screws. Make sure to include one grounding wire when attaching the left-hand screw.
12. Reconnect the following cable connectors.

• Card Transport Flex Cable (3)
• Transport Lead Screw Motor (4)
13. Place the new Cable Transport Flex Cable retaining clamp in position and attach with two
screws.

Figure 7-17: Card Transport

X-Transport Drive Belt
The X-Transport Drive Belt drives the transport screw mechanism for moving cards through
the 150i. Use the following procedure to remove and replace the X-Transport Drive Belt.
Tools
• #20 Torx driver
Remove
3. Manually rotate the Card Transport carriage lead screw so the Y-Transport is on the left-
hand side of the 150i.
4. Remove two screws (1 in Figure 7-18) holding the X-Transport Drive Motor (2).
5. Remove the X Transport Drive Belt (3) from the Card Transport (4) assembly.
Replace
1. Place the new X-Transport Drive Belt in position and attach the X-Transport Drive Motor
with two screws. Make sure belt tension is sufficient to ensure that no slippage will
occur.

1
Figure 7-18: X-Transport Drive Belt

X-Home Sensor
The X-Home Sensor detects when the X card transport mechanism is at its home position.
Use the following procedure to remove and replace the X-Home Sensor.
Tools
• #10 Torx driver
Remove
4. Disconnect the X-Home Sensor cable connector (1 in Figure 7-19).
5. Remove one screw (2) holding the X-Home Sensor (3) to the base of the 150i.
Replace
1. Place the new X-Home Sensor in position and attach with one screw.
2. Reconnect the X-Home Sensor connector.
Make sure wires are not pinched. Make sure connector and wires will not interfere with
any mechanical movement inside the 150i. Make sure the sensor is correctly positioned
so the sensing flag will not hit it.

Figure 7-19: X-Home Sensor

Y-Home Sensor
The Y-Home Sensor detects when the Y card transport mechanism is at its home position.
Use the following procedure to remove and replace the Y-Home Sensor.
Tools
• #10 Torx driver
Remove

4. Disconnect Y-Home Sensor cable connector (1 in Figure 7-20).
5. Remove one screw (2) holding the Y-Home Sensor (3).
Replace
1. Place the new Y-Home Sensor in position and attach with one screw.
Make sure wires are not pinched. Make sure the connector and wires will not interfere
with any mechanical movement inside the 150i. Make sure the sensor is correctly
positioned so the sensing flag will not hit it.

Figure 7-20: Y-Home Sensor

Card Transport Flex Cable
The Card Transport Flex Cable provides a means to power the Y-Transport Motor and
communication with the Y-Home Sensor. Use the following procedure to remove and replace
the Card Transport Flex Cable.
Tools
• Hex key set
• #10 Torx driver
• #20 Torx driver
Remove
3. Remove two screws (1 in Figure 7-21) and remove the Cable Plate (2) from the 150i
base.
4. Remove one screw (3) and remove the Flex Cable Holding Plate (4).

5. Remove two screws (5) and remove the Cable Holding Clamp (6).
6. Remove one screw (7), one nut (8) and the Top Cover Grounding Wire (9) on the left-
hand side of the Inner Fan Guard (10).
7. Manually rotate the Card Transport lead screw to the left-hand side of the 150i.
8. Remove one screw (11) from the right-hand side of the Inner Fan Guard, then lift the
Inner Fan Guard out.
9. Disconnect the Card Transport Flex Cable (12) at both ends.
10. Peel the flex cable from the back panel, then completely remove it from the 150i.
Replace
1. Place the new Card Transport Flex Cable in place making sure it adheres to the back
panel of the 150i.
2. Reconnect both ends of the flex cable to their connectors.
3. Make sure the Cable Back Plate is against the back panel of the 150 and attach it with one
screw.
4. Placed the Cable Holding Clamp in position and attach with two screws.

5. Place the Inner Fan Guard in position and attach with one screw and one nut on the left-
hand side. Make sure to attach the Top Cover Grounding Wire. On the right-hand side,
attach with one screw.
6. Place the Cable Plate in position and attach with two screws.
Figure 7-21: Card Transport Flex Cable

Carriage Transport Motor
The Carriage Transport consists of a screw mechanism for moving cards in the Y-axis
through different stages of production to produce a final card. Use the following procedure to
remove and replace the Carriage Transport Motor.
Tools
• #10 Torx driver
• #20 Torx driver
Remove
3. Manually rotate the Card Transport carriage lead screw so the Y-Transport is centered
between the Embosser Wheel and the Magnetic Stripe Head.
Make sure not to crimp or damage the Card Transport Flex Cable.
4. Remove two screws (1 in Figure 7-22) holding the Card Transport (2).

5. Disconnect the Carriage Transport Motor connector (3).
6. Carefully lift up and tilt the Card Transport towards the front of the 150i, but do not
remove.
7. Remove two screws (4) holding the Carriage Transport Motor (5).
8. Remove the Carriage Transport Motor Belt (6) from the motor pulley, and then remove
the Carriage Transport Motor.
Replace
1. Place the new Carriage Transport Motor in place making sure the Carriage Transport
Motor Belt is in position, and then tighten the two mounting screws.
2. Place the Card Transport on the locating pins on the base of the 150i and attach with two
screws. Make sure to include one grounding wire when attaching the left-hand screw.
3. Reconnect the Carriage Transport Motor connector.

Figure 7-22: Carriage Transport Motor

Magnetic Stripe Assembly
The Magnetic Stripe Assembly head reads and writes data on the magnetic stripe on a card.
Use the following procedure to remove and replace the Magnetic Stripe Assembly.
Tools
• Hex key set
Remove
3. Open up the Output Tray for better access to the connectors.

• Magnetic Stripe Head Cable (1 in Figure 7-23)
• Encoder Cable (2)
5. Remove one screw (3) and the ground wire (4) attaching the Magnetic Stripe Assembly
(5) to the 150i base.
Replace
1. Place the new Magnetic Stripe Assembly in position and attach with one screw. Make
sure to ground wire is also attached.
2. Reconnect the following cable connectors:

• Magnetic Stripe Head Cable (1)
• Encoder Cable (2)
any mechanical movement inside the 150i. Make sure the Magnetic Stripe module is
aligned parallel to the 150i base casting.

Follow-up Adjustments
This remove and replace procedure affects the following adjustments which must be
performed after this procedure.
• Magnetic Stripe Start Sentinel Offset

• Magnetic Stripe Head Height Adjustment
• Magnetic Stripe Track Location Offset
Figure 7-23: Magnetic Stripe Assembly

Embosser Assembly
The Embosser Assembly, comprised of two rotating disks of punches and dies, provides a
means to make embossed characters on a plastic card. Use the following procedure to remove
and replace the Embosser Assembly.
Tools
• #20 Torx driver
Remove
3. Open up the Output Tray for better access to the connectors.

• Wheel Home Sensor (1 Figure 7-24)
• Die Home Sensor (2)
• Die Motor (3)
• Wheel Motor (4)
• Punch Motor (5)
• Punch Home Sensor (6)
6. Remove three mounting screws (7) attaching the Embosser to the 150i base. The front
Embosser mounting screw can be removed by spreading unused emboss wheel fingers.
7. Lift and remove the Embosser.
Replace
1. Place the new Embosser in position and attach with three screws.
2. Reconnect the following cable connectors:

• Wheel Home Sensor (1)
• Die Home Sensor (2)
• Die Motor (3)
• Wheel Motor (4)
• Punch Motor (5)
• Punch Home Sensor (6)

When a new Embosser is installed, verify that all special punches and dies are installed
on the new Embossing Wheel.
7
5
1
Figure 7-24: Embosser

Wheel Home Sensor
The Wheel Home Sensor detects when the embossing wheel is at its home position. Use the
following procedure to remove and replace the Wheel Home Sensor.
Tools
• #10 Torx driver
Remove

3. Disconnect the Wheel Home Sensor cable connector (1 in Figure 7-25).
4. Remove one screw (2) and remove the Wheel Home Sensor (3).
Replace
1. Place the new Wheel Home Sensor in position and attach with one screw.
2. Reconnect the Wheel Home Sensor cable connector.
• Wheel Offset

2 1 3
Figure 7-25: Wheel Home Sensor

Punch Home Sensor
The Punch Home Sensor detects when the punch cam has returned to its home position. Use
the following procedure to remove and replace the Punch Home Sensor.
Tools
• #10 Torx driver
Remove

3. Remove the Embosser Assembly far enough to gain access to the Punch Home Sensor.
4. Disconnect the Punch Home Sensor (1 in Figure 7-26) cable connector:
5. Remove one screw (2) and remove the Punch Home Sensor (3).
Replace
1. Place the new Punch Home Sensor in position and attach with one screw.
2. Reconnect the Punch Home Sensor cable connector.
3. Replace the Embosser assembly and attach with three screws.

2
Figure 7-26: Punch Home Sensor

Punch Cam Motor
The Punch Cam Motor applies pressure to the embossing punch on the character wheel to
form a character on plastic cards. Use the following procedure to remove and replace the
Punch Cam Motor.
Tools
• #20 Torx driver
Remove

3. Remove the Embosser Assembly.
4. Remove two screws (1 in Figure 7-27) and one nut (2), then remove the Punch Cam
Motor (3) from the Embosser Assembly.
Replace
1. Place the new Punch Cam Motor in position and attach with two screws and one nut, but
do not fully tighten.
2. Tension the Punch Cam Motor against the Punch Cam Belt, then completely tighten the
screws.
3. Replace the Embosser Assembly.
4. Make sure all connectors are firmly connected.

1 (2x)
2
Figure 7-27: Punch Cam Motor

Punch Cam Belt
The Punch Cam Belt transfers motion from the Punch Cam Motor to the cam, which in turn
applies pressure to the embossing punch on the character wheel. Use the following procedure
to remove and replace the Punch Cam Belt.
Tools
• #10 Torx driver
• #20 Torx driver
Remove

3. Remove the Embosser Assembly.
4. Remove two screws (1 in Figure 7-28) and one nut (2), then remove the Punch Cam
Motor (3) from the Embosser Assembly.
5. Remove one screw (4) holding the Punch Cam Home Sensor (5) to the Embossing
Assembly and remove the sensor.
6. Remove the Punch Cam Belt (6).
Replace
1. Place the new Punch Cam Belt in position around the idler pulley.
2. Place the Punch Cam Home Sensor in position and attach with one screw.
3. Place the Punch Cam Motor in position and attach with two screws and one nut, but do
not fully tighten.
4. Tension the Punch Cam Motor against the Punch Cam Belt, then completely tighten the
screws.
5. Replace the Embosser Assembly.
6. Make sure all connectors are firmly connected.

4
5
(2x) 1
3
2
3 6
Figure 7-28: Punch Cam Belt

Die Home Sensor
The Die Home Sensor detects when the embossing die cam has reached its home position.
Use the following procedure to remove and replace the Die Home Sensor.
Tools
• #10 Torx driver
Remove

3. Disconnect the Die Home Sensor cable connector (1 in Figure 7-29).
4. Remove one screw (2) and remove the Die Home Sensor (3).
Replace
1. Place the new Die Home Sensor in position and attach with one screw.
2. Reconnect the Die Home Sensor cable connector.

3
2
Figure 7-29: Die Home Sensor

Die Cam Motor
The Die Cam Motor applies pressure to the embossing die on the character wheel to form a
character on plastic cards. Use the following procedure to remove and replace the Die Cam
Motor.
Tools
• #10 Torx driver
Remove
3. Disconnect the Die Cam Motor connector.
4. Remove two screws (1 in Figure 7-30) and one nut (2), then remove the Die Cam Motor
(3) from the Embosser Assembly.
Replace
1. Place the new Die Cam Motor in position and attach with two screws and one nut, but do
not fully tighten.
2. Tension the Die Cam Motor against the Die Cam Belt, then completely tighten the
screws.
3. Reconnect the Die Cam Motor connector.

3
1 (2x)
2
Figure 7-30: Die Cam Motor

Die Cam Belt
The Die Cam Belt transfers motion form the Die Cam Motor to the cam, which in turn,
applies pressure to the embossing die on the character wheel. Use the following procedure to
remove and replace the Die Cam Belt.
Tools
• #10 Torx driver
Remove
3. Disconnect the Die Cam Motor connector.
4. Remove two screws (1 in Figure 7-31) and one nut (2), then remove the Die Cam Motor
(3) from the Embosser Assembly.
5. Remove one screw (4) holding the Die Cam Home Sensor (5) to the Embossing
Assembly and remove the sensor.
6. Remove the Die Cam Belt (6).
Replace
1. Place the new Die Cam Belt in position around the idler pulley.
2. Place the Die Cam Home Sensor in position and attach with one screw.
3. Place the Die Cam Motor in position and attach with two screws and one nut, but do not
fully tighten.
4. Tension the Die Cam Motor against the Die Cam Belt, then completely tighten the
screws.
5. Reconnect the Die Cam Motor connector.

6
3
3
1 (2x)
2
5
4
Figure 7-31: Die Cam Belt

Punch and Die
The punches and dies are used in conjunction with each other to emboss individual characters
and letters on a plastic card. Use the following procedure to remove and replace individual
punches and dies.
Tools
• Insertion tool (PN 556335-001)
Remove
3. To remove a punch (1) or die (2), clip one side of the wheel fingers of the punch or die to
be removed.
Replace
1. To replace a punch or die, select an unused wheel finger and press the punch or die in
using the special insertion tool.
The dot on the punch or die must face out from the center of the Embosser Wheel.
Do not deform the punch or die or the wheel fingers.
• Wheel Parameters Menu (Remap)

2
Dot
Figure 7-32: Punch and Die

Topper Assembly
The Topper Assembly places a colored layer on the top of embossed characters on a plastic
card. Heat is used to affix this layer to the plastic card. Use the following procedure to
remove and replace the Topper Assembly.
Tools
• #27 Torx driver
Remove

• Topper Motor (1 in Figure 7-33)
• RTD (2)
• Topper Heat (3)
• Topper Sol (4)
• Platen Sensor (5)
• Foil Motion Sensor (6)
5. Remove four screws (7) lift up the Topper Assembly (8) of the 150i.
Replace
1. Place the new Topper Assembly in position and attach with four screws.
2. Connect the following connectors:

• Topper Motor (1)
• RTD (2)
• Topper Heat (3)
• Topper Sol (4)
• Platen Sensor (5)
• Foil Motion Sensor (6)

4. Replace the Topping Foil Cassette.
8
5
1
2
7 (4x)
Figure 7-33: Topper Assembly

Topper Foil Motion Sensor
The Toper Foil Motion Sensor detects physical motion of a slotted wheel insuring that the
topper foil has advanced. Use the following procedure to remove and replace the Topper Foil
Motion Sensor.
Tools
• Hex key set
• #10 Torx driver
Remove

4. Disconnect the Topper Foil Motion Sensor (1 in Figure 7-34) cable connector.
5. Loosen the Topper Foil Motion Sensor pivot bolt (2). This allows the assembly to move
forward past the stop peg (3).
6. Remove one screw (4) from the Topper Foil Motion Sensor (5) and sensor.
Replace
1. Place the new Topper Foil Motion Sensor in position and attach with one screw.
2. Move the Topper Foil Motion Sensor back into position and tighten down the pivot hex
bolt. Make sure there is spring tension on the pivoting assembly.
3. Connect the Topper Foil Motion Sensor cable connector.

4
3
2
Figure 7-34: Topper Foil Motion Sensor

Topper Platen Sensor
The Toper Platen Sensor detects when the Topper Platen is in its home position. Use the
following procedure to remove and replace the Topper Platen Sensor.
Tools
• #10 Torx driver
Remove

4. Disconnect the Topper Platen Sensor (1 in Figure 7-35)cable connector.
5. Remove one screw (2) from the Topper Platen Sensor (3) and remove sensor.
Replace
1. Place the new Topper Platen Sensor in position and attach with one screw.
2. Connect the Topper Platen Sensor cable connector.

3
2
Figure 7-35: Topper Platen Sensor

Topper Motor
The Topper Motor is a DC motor used to advance the topping foil in the Topper Foil
Cassette. Use the following procedure to remove and replace the Topper Motor.
Tools
• #10 Torx driver
• Hex key set
Remove

4. Disconnect the Topper Motor connector (1 in Figure 7-36).
5. Remove two screws (2) and two star washers (3), then remove the Topper Motor (4).
Replace
1. Transfer the Topper Motor Coupler (5) from the old motor to the new motor. Make sure
the coupler is flush with the top of the motor shaft.
2. Place the new Topper Motor in place and secure with two screws and two star washers.
3. Reconnect the Topper Motor connector.

3 (2x) 4
2 (2x)
Flush
Figure 7-36: Topper Motor

Main Control Board
The Main Control Board is the main processor board of the 150i. Use the following
procedure to remove and replace the Main Control Board (MCB).
Tools
• PC (minimum requirements: Windows 95/66 MHz/32K of RAM)
• Disk Assy, Diag Install Utility (PN 555071-001)
• J-TAG Cable (PN 557028-001) (Required when reformatting the Main Logic Board
memory.)
Remove
Before replacing the Main Control Board, backup all stored setting using the 150i
Diagnostic Install Utility. This program will give you step by step instructions for
backing up the Main Control Board.
3. Remove the Front Access Panel (see Front Access Panel).
Use proper anti-static grounding techniques when handling the Main Control Board.
Remove any shipping cable ties if present.
4. Unlatch the Main Control Board (1 in Figure 7-37) and pull forward far enough to
disconnect the following connectors:
• J12 (2)
• J13 (3)
5. Continue to pull the Main Control Board out further and disconnect the following
connectors:
• J7 (4)
• J16 (5)
6. Pull the Main Control Board out completely from the 150i.
Replace
Use proper anti-static grounding techniques when handling the new Main Control Board.
1. Slide the new Main Control Board in the board guides and reconnect all cables that were
previously disconnected.

Make sure wires are not pinched and are placed in the casting slot provided. Make sure
all cables connectors and the Main Control Board are firmly seated.
2. Reload the saved configurations into the 150i.
3. Replace the Front Access Panel.
3
4
Pin 1
Pin 1 •
• J12
J16
J7 J13
150i061s
1
Figure 7-37: Main Control Board

Power Supply Board
The Power Supply Board delivers DC power to the stepper motors, LEDs and powers the
Main Control Board. Use the following procedure to remove and replace the Power Supply.
Tools
• Phillips screwdriver
• #20 Torx driver
Remove
3. Remove the Input Hopper card weight and all cards from the 150i.
4. With the Top Cover closed and locked, place the 150i in an upright position on the rear of
the machine.
5. Remove four long screws (1 in Figure 7-38), six short screws (2), and one rubber foot (3).
6. Tilt down the Power Supply mounting plate (4) and disconnect connector JP2 (5) from
the Power Supply Board (6).
7. Lay the Power Supply mounting plate down and remove two red wires from the + (plus)
side of JP1.
8. Remove two black wires from the - (minus) side of JP1.
9. Remove seven screws (7) attaching the Power Supply Board to the mounting plate.
Replace
1. Position the new Power Supply Board on the mounting plate and attach with five screws.
2. Attach two black wires to the - (minus) side of JP1.
3. Attach two red wires to the + (plus) side of JP1.
4. Connect JP2 on the Power Supply Board.
5. Attach the Power Supply mounting plate with four long screws, six short screws, and one
rubber foot.

6. Return the 150i to its normal resting position.
7 (2x)
4
2 (6x) 5
JP 2
4
1 (4x)
6 7(5x)
Black Wires
Red Wires
JP 1
150i062s
Figure 7-38: Power Supply

Line Filter
The Line Filter is used to remove transient spikes of power from the power line and acts as a
surge protector. Use the following procedure to remove and replace the Line Filter.
Tools
• Small flat blade screwdriver
• #20 Torx driver
Remove
4. Remove one screw (1 in Figure 7-39), one nut (2) and the Top Cover Grounding Wire (3)
on the left-hand side of the Inner Fan Guard (4).
5. Remove one screw (5) from the right-hand side of the Inner Fan Guard, then lift out.
6. Remove one screw (6) and one star washer (7) attaching the grounding wire to the 150i
base.
7. Disconnect both fast-on connectors (8) from the Line Filter (9).
8. Compress the locking tabs on the Line Filter to clear the mounting hole opening and
remove.
Replace
1. Place the new Line filter in position and make sure the locking tabs secure the Line Filter
in the mounting hole.
2. Connect the fast-on connector marked “L” (red wire) to the “L” connector on the Line
Filter.
3. Connect the fast-on connector marked “N” (blue wire) to the “N” connector on the Line
Filter.
4. Attach the grounding wire using one screw and one star washer to the 150i base.
When replacing the Inner Fan Guard, insure the Card Transport Flex Cable is correctly
positioned or the Card Transport movement may be obstructed.
5. Place the Inner Fan Guard in position and attach with one screw on the right-hand side of
the 150i.

6. Attach the left-hand side of the Inner Fan Guard with one screw and one nut. Make sure
to attach the Top Cover Grounding Wire.
3
5 ref
1 ref 4 ref
8
L
7
Figure 7-39: Line Filter

Fuse
The Fuse protects the electronic components inside the 150i. Use the following procedure to
remove and replace the Fuse.
Tools
• Flat blade screwdriver
Remove
2. Use a flat blade screwdriver to pry out the Fuse Holder as shown.
Replace
1. Place the new fuse in the Fuse Holder and press the Fuse Holder back in place.

1
Figure 7-40: Fuse

Fan
The Fan removes excess heat generated by the stepper motors and the power supply from the
150i cabinet. Use the following procedure to remove and replace the Fan.
Tools
• Nut driver set
• #20 Torx driver
Remove
4. Remove one screw (1 in Figure 7-41), one nut (2) and the Top Cover Grounding Wire (3)
on the left-hand side of the Inner Fan Guard (4).
5. Remove one screw (5) from the right-hand side of the Inner Fan Guard, then lift out.
6. Disconnect the Fan connector (6).
7. Remove four nuts (7) attaching the Fan (8) to the 150i cabinet and remove the Fan.
Replace
1. Place the new Fan in position and attach using four nuts.
2. Connect the Fan connector.
When replacing the Inner Fan Guard, insure the Card Transport Flex Cable is correctly
positioned or the Card Transport movement may be obstructed.
3. Place the Inner Fan Guard in position and attach with one screw on the right-hand side of
the 150i.
4. Attach the left-hand side of the Inner Fan Guard with one screw and one nut. Make sure
to attach the Top Cover Grounding Wire.
any mechanical movement inside the 150i. Make sure grounding strap is replaced.

3
2
1 ref
5 ref
4 ref
7 (4x)
Figure 7-41: Fan

Display/Keypad
The Display/Keypad allows 150i information to be displayed on a two line LCD display. The
keypad provides a means to access the 150i’s operating menu. Use the following procedure to
remove and replace the Display/Keypad.
Tools
Remove
3. Disconnect the Display/Keypad cable connector P4 (1 in Figure 7-42).
4. Remove four nuts (2) and one grounding wire (3), then remove the Display/Keypad from
the top cover.
Replace
1. Place the new Display/Keypad in position and attach with four nuts. Make sure to attach
the ground wire.
2. Connect the Display/Keypad cable connector P4.

4
3
2 (4x)
Figure 7-42: Display/Keypad

Solenoid Lock Assembly
The Solenoid Lock Assembly prevents unauthorized access to the 150i without entering a
correct password or using a key. The Top Cover interlock switch is also incorporated in this
assembly Use the following procedure to remove and replace the Solenoid Lock Assembly.
Tools
• #20 Torx driver
Remove
3. Remove three screws on the Embosser so the Embosser can be partially removed. The
front Embosser mounting screw can be removed by spreading unused embossing fingers
(see Embosser Assembly).
4. Move the Embosser out of the way to allow access for the removal of the Solenoid Lock
Assembly.
5. Disconnect two fast-on connects (1 in Figure 7-43) from the Lock Solenoid (2) and two
fast-on connectors (3) from the Interlock Switch (4).
6. Remove three screws (5) holding the Solenoid Lock mounting bracket (6) and remove the
assembly.
Replace
1. Place the new Solenoid Lock Assembly in position and attach with three screws.
2. Connect the fast-on connectors to both the Interlock Switch and the Lock Solenoid.
3. Place the Embosser in position and attach with three screws.
• Interlock Switch Adjustment

2
1 (2x)
5 (3x)
6
3 (2x)
Figure 7-43: Solenoid Lock Assembly

Reject Full Sensor
The Reject Full Sensor detects when the reject hopper is filled with cards. Use the following
procedure to remove and replace the Reject Full Sensor.
Tools
• #10 Torx driver
Remove
3. Disconnect the Reject Full Sensor connector (1 in Figure 7-44).
4. Remove one screw (2) from the Reject Full Sensor (3) and remove.
Replace
1. Place the new Reject Full Sensor in position and attach with one screw.
2. Reconnect the Reject Full Sensor connector.

3
2
Figure 7-44: Reject Full Sensor

Front Smart Card Module (Option)
The Front Smart Card Module allows plastic cards with Smart Card chips (on the front side)
to be programmed. Use the following procedure to remove and replace the Front Smart Card
Module.
Tools
• #10 Torx driver
Remove
3. Remove the Indent module if so equipped. See Front Indent Printer Module (Option) or
the Replacing the Front Indent Ribbon.
4. Remove three screws (1 in Figure 7-45) holding the Smart Card Pin Block/solenoid (2)
and the Smart Card Logic board bracket (3) to the Front Smart Card bracket (4).
5. Disconnect the SC Sol cable connector (5) and cable connector J5 (6) from the Smart
Card Logic board (7).
6. Disconnect the communication cable J4 (8) and the power connector J1 (9) from the
Smart Card Logic board.
Replace
1. Reconnect the SC Sol cable and cable connectors J1, J4, and J5 to the Smart Card Logic
board.
2. Place the Smart Card Logic board in position along with the Smart Card Pin
Block/solenoid and attach them with three screws to the Front Smart Card bracket.
• Front Smart Card Stop Adjustment (see Front Smart Card Stop Adjustment in Chapter 6)

7
J10
J4 J1
J5
9
6
8
1 (3x)
5
Figure 7-45: Front Smart Card Module

Front Indent Printer Module (Option)
The Front Indent Printer Module provide a means to indent characters (using a colored
ribbon) to the front side of a plastic card. Use the following procedure to remove and replace
the Front Indent Printer Module.
Tools
• #10 Torx driver
Remove
3. Remove the Front Indent Print Ribbon (see Replacing the Front Indent Ribbon)
4. Remove the following cable connectors:

• OCR Motor (1 in Figure 7-46)
• OCR Sol (2)
• OCR Motion (3)
5. Remove four screws (4) attaching the module to the 150i and remove the indent module.
Replace
1. Place the Front Indent Printer module in position and secure with four screws.
2. Reconnect the following connectors:

• OCR Motor (1 in Figure 7-46)
• OCR Sol (2)
• OCR Motion (3)
3. Replace the Front Indent Ribbon.
4. Run a Standard Test Card with front indent printing to confirm proper operation of the
150i. If successful, run a limited number of customer produced cards for a final quality
verification.

4 (4x)
150i114s
1
Figure 7-46: Front Indent Printer Module

Replacing the Front Indent Ribbon
To change the Rear Indent Ribbon, perform the following steps:
Remove
2. Power OFF the 150i.
3. Remove the used indent ribbon from the Take Up Spool (1 in Figure 7-47) by sliding the
Take Up Retainer (2) off the Take Up Spool and removing the ribbon and core from the
Take Up Spool.
4. Set the Take Up Retainer aside.
5. Remove the Supply Retainer (3) from the Supply Spool (4) as shown in, then remove the
core from the Supply Spool and set it aside.
Replace
1. Place the new indent ribbon roll on the Supply Spool as shown.
2. Slide the Supply Retainer onto the Supply Spool until it clicks in place.
3. Wrap the indent ribbon around the Ribbon Guide Rollers and Ribbon Foil Motion Wheel
(5) as shown.
4. Tape the edge of the ribbon, dull side out, to the core, as shown.
5. Place the core on the Take Up Spool, as shown below, and slide the Take up Retainer on
the Take Up Spool until it clicks in place.
6. Close the Top Cover.

Ribbon Guide
Rollers (Typical)
Dull Side
Core
Core
Figure 7-47: Replacing the Front Indent Ribbon

Rear Indent Printer Module (Option)
The Rear Indent Printer Module provides a means to indent characters (using a colored
ribbon) to the rear side of a plastic card. Use the following procedure to remove and replace
the Rear Indent Printer Module.
Tools
• Hex key set
Remove
3. Remove the Rear Indent Ribbon from the Rear Indent Printer Module (see Replacing the
Rear Indent Ribbon).
4. Disconnect the OCR Motion sensor cable connector (1 in Figure 7-48).
5. Remove the module return spring (2) from the holding post (3).
6. Loosen the set screw (4) on the Ribbon Take Up Spool shaft and remove the Ribbon
Take Up Spool Holding disk.
7. Remove the Rear Indent Printer module (5) from the 150i.
Replace
1. Place the new the new Rear Indent Printer module in position.
2. Tighten the set screw on the Ribbon Take Up Spool shaft. Make sure to tighten the set
screw on the flat portion of the shaft and check for binding of the Ribbon Take Up Spool
on the Rear Indent Printer module.
3. Reconnect the OCR Motion sensor cable connector.
Make sure wires are not pinched. Make sure the connector and wires will not interfere
with any mechanical movement inside the 150i.
4. Replace the Rear Indent Ribbon (refer to Replacing the Rear Indent Ribbon).
5. Run a Standard Test Card with rear indent printing to confirm proper operation of the
verification.

1
OCR
Motion
Rear Indent Printer
5 2
Flat
Figure 7-48: Rear Indent Printer Module

Replacing the Rear Indent Ribbon
To change the Rear Indent Ribbon, perform the following steps:
Remove
2. Remove the used indent ribbon from the Take Up Spool (1 in Figure 7-49) by sliding the
Take Up Retainer (2)off the Take Up Spool and removing the ribbon and core from the
Take Up Spool.
3. Set the Take Up Retainer aside.
4. Remove the Supply Retainer (3) from the Supply Spool (4) as shown, then remove the
core from the Supply Spool and set it aside.
Replace
1. Place the new indent ribbon roll on the Supply Spool as shown.
2. Slide the Supply Retainer on the Supply Spool until it clicks in place.
3. Wrap the indent ribbon around the Ribbon Guide Rollers and Ribbon Foil Motion Wheel
(5) as shown.
4. Tape the edge of the ribbon, dull side out, to the core.
5. Place the core on the Take Up Spool, as shown below, and slide the Take up Retainer on
the Take Up Spool until it clicks in place.
6. Close the Top Cover.

Dull Side
5
Shiny Side
1
2
Figure 7-49: Replacing the Rear Indent Ribbon

Rear Indent Motor
The Rear Indent Motor advances the indent ribbon. Use the following procedure to remove
and replace the Rear Indent Motor.
Tools
• #10 Torx driver
Remove
3. Disconnect the OCR Motor connector (1 in Figure 7-50).
4. Remove two adjustment screws (2) from the Rear Indent Motor bracket (3).
5. Remove the drive belt (4) from the motor pulley (5) and remove the Rear Indent motor
(6).
Replace
1. Place the Rear Indent motor in position and secure with two adjustment screws, but do
not tighten.
2. Install the drive belt and then tension the belt. Tighten the two adjustment screws.
3. Reconnect the OCR Motor connector.
any mechanical movement inside the 150i. Refer to Replacing the Rear Indent Ribbon if
ribbon replacement is needed.
verification.
• Rear Indent Drive Belt Adjustment (see Rear Indent Drive Belt Adjustment in Chapter 6)

2
6 1
OCR Motor
150i111s
Figure 7-50: Rear Indent Motor

Rear Indent Drive Belt
The Rear Indent Drive Belt transfers movement from the Read Indent Motor to move the
indent ribbon. Use the following procedure to remove and replace the Rear Indent Drive Belt.
Tools
• #20 Torx driver
Remove
3. Remove of the Rear Indent Print Module from the 150i. (See Rear Indent Printer Module
(Option) removal.
4. Loosen two adjustment screws (1 in Figure 7-51) on the Rear Indent Motor (2) and
remove the drive belt (3).
Replace
1. Place the new drive belt in position, then tension the Rear Indent motor and tighten down
the two adjustment screws.
2. Install the Rear Indent Print Module.
verification.
• Rear Indent Drive Belt Adjustment (see Rear Indent Drive Belt Adjustment in Chapter 6)

1
150i110s
Figure 7-51: Rear Indent Drive Belt

Rear Indent Solenoid
The Rear Indent Solenoid is used to move the Rear Indent Ribbon in position so printing can
occur. Use the following procedure to remove and replace the Rear Indent Solenoid.
Tools
• 7/8 inch box wrench
Remove
3. Disconnect the OCR Sol cable connector (1 in Figure 7-52).
4. Remove one solenoid retraction spring (2) and move the Rear Indent module out of the
way.
5. Remove one solenoid retaining nut (3) on the Rear Indent solenoid (4) and remove.
Replace
1. Place the new the Rear Indent Solenoid in position and secure with one retaining nut.
2. Replace the solenoid retraction spring.
3. Reconnect the OCR Sol cable connector.
4. Run a Indent Test Card with rear indent printing to confirm proper operation of the 150i.
If successful, run a limited number of customer produced cards for a final quality
verification.

3
1
150i117s To OCR Solenoid
Figure 7-52: Rear Indent Solenoid


8
Chapter 8:
Illustrated Parts Breakdown

embosser. This chapter provides information on assembly and sub-
assembly part numbers for the 150i.
Introduction 8-2
General 8-2
Cabinet Parts 8-3
Input/Output Hopper Assembly 8-4
Card Transport Assembly 8-6
Embosser Assembly 8-8
Lower Emboss Housing Assembly 8-10
Upper Emboss Housing Assembly 8-11
Topper Foil 8-13
Power Supply 8-15
Fan 8-16
Sensor Cable Harness 8-17
Power Cable Harness 8-18
Communications Cable 8-19
Cable/Development Cable 8-20
Display/Keyboard 8-21
Miscellaneous Spare Parts 8-22
Reject Full Photocell 8-24
Smart Card Assembly 8-25
Front Indent Print Assembly 8-26
Rear Indent Printer Assembly 8-27
Indent Ribbon 8-28

Introduction
This chapter provides information on assembly and sub-assembly part numbers for
the 150i.
General
The 150i Series Card Personalization System final assembly may be configured
under different part numbers related to the 150i Series Card Personalization System
defined in the customer order. Verify the final assembly part number before
replacing components.
8-2 Illustrated Parts Breakdown

Cabinet Parts
Description Part Number

Top Cover 555120-002
Front Access Panel 556272-001
Outside Cabinet 596625-001
Single Access Door 556277-001
Output Hopper Door 556278-001
Output Door Assembly 556788-001

Input/Output Hopper Assembly

Input / Output Hopper Assembly 556787-051
Input Hopper Card Weight 596713-001
Output Hopper Drive Belt 803478-018
Card Registration Photocell 590067-003
Input Hopper Empty Photocell 593463-003
Input Home Photocell 593463-003
Output Full Photocell 596463-003
Card Pick Photocell 593463-003
O-Rings 803478-009
Throat Gap Motor 555938-001
Throat Gap Photocell 593463-003
Throat Gap Motor Belt 803129-126
Assembly, IH/OS Base Plate 596695-002
Plate Assembly, Left Side, IH/OS 596697-001
Plate Assembly, Right Side, IH/OS 596698-001
Roller, Cam 596328-001
Gear, Idler 596455-001
Plate, Card Gap 596333-001
Assembly, Plate, Support, Card Gap 556473-001
Wire Assembly, Input Motor Gnd 556307-001
Shaft, Support 596353-001
Motor Assembly, GFX .5a Stepper,280 596104-001
Motor Assembly, IH/OS 555082-001
Plate Assembly, Stacker, Output 596696-001
Cam 596454-001
Plate, Support 555981-001
Block, Leadscrew 556280-001
Pulley, Leadscrew-12 Groove 555986-001
Block, Slide 556281-001
Bracket, Support, Motor 555989-001
Pulley, Leadscrew-20 Groove 555990-001
Leadscrew 555991-001

Card Registration
Photocell
Input Home
O-Rings Photocell
Output Full
Photocell
Card Picked
Photocell
Output Hopper
Drive Belt
Throat Gap Throat Gap

Input/Output Motor Motor Photocell
Hopper
Input Hopper
Empty Photocell
Throat Gap
Motor Belt

Card Transport Assembly

Card Transport (Complete) 556787-050
Transport Flex Cable 555040-001
X Transport Drive Belt 803129-122
Y-Home Photocell 593463-003
X Home Photocell 593463-003
Y Belt 803129-123
Block Assembly, Support, Leadscrew 596690-001
Assembly, Y-Drive Card Carriage 596686-002
Assembly, X-Drive Card Carriage 555921-002
Motor Assembly, X Carriage 596691-001
Pulley, 48 Groove 596446-001
Tube, Support 596312-001
Shaft, Leadscrew, X-Drive 596311-001
Bearing, Guide 596444-001
O-Ring, .114id .06w Buna-N 803478-006
Y-Belt
Y-Home
Photocell
Card Transport
X-Home
Photocell X-Transport
Drive Belt


Magnetic Stripe (IA/IAT) 596663-001
Magnetic Stripe (J) 596663-002
Magnetic Stripe (IAJ) 596663-003

Embosser Assembly

Wheel Home Photocell 593463-003
Driver 596421-001
Arm Assembly, Rocker 596680-001
Shaft, Rocker 596416-001
Emboss Wheel Assembly

150i C. S. EMB-Standard 556787-001
150i C. S. EMB-Japan Fin 73 Char 556787-002
150i C. S. EMB-Japanese HC 63 Char 556787-003
150i C. S. EMB-Swedish 60 Char 556787-004
150i C. S. EMB-Russian 73 Char 556787-005
150i C. S. EMB-Japanese Credit 556787-006
150i C. S. EMB-Visa Elec 37 Char 556787-007
150i C. S. EMB-Std W/Ind OCR-A1 556787-008
150i C. S. EMB-Std W/Ind OCR-B1 556787-009
150i C. S. EMB-Std W/MC 0-9r 556787-012
150i C. S. EMB-Std W/OCRB1 Fine 556787-013
150i C. S. EMB-Std W/Inv MC 0-9 556787-014
150i C. S. EMB-Visa Elec Fine 52 556787-015
150i C. S. EMB-Korean 75 Char 556787-017
150i C. S. EMB-Czech 75 Char 556787-018
150i C. S. EMB-Poland Visa Elec 556787-028

Wheel Home
Photocell
Embosser

Lower Emboss Housing Assembly

Lower Emboss Housing Assembly 596683-002
Pulley, Cam 555051-002
Cam 555044-002
Belt, Htd .118p 5.787l .354w 805727-004
Motor Assembly, Cam 596682-001
Photocell, 1 Ear Pt 593463-003
Spring, Comp 555610-001
Driver 596421-001
Arm Assembly, Rocker 596680-001
Shaft, Rocker 596416-001
Motor Assembly, Wheel 596681-001
Cam
Photocell
Spring
Washer
Driver
Cam Motor
Belt
Cam Pulley
Rocker
Arm Assy
Shaft
Wheel Motor

Upper Emboss Housing Assembly

Upper Emboss Housing Assembly 596684-002
Pulley, Cam 555051-002
Cam 555044-002
Belt, Htd .118p 5.787l .354w 805727-004
Motor Assembly, Cam 596682-001
Photocell, 1 Ear Pt 593463-003
Cam
Photocell
Cam Pulley
Belt
Cam Motor

Topper Assembly

Topper Platen Photocell 593463-003
Foil Cassette 596666-002
Assembly, Foil Motion 555092-001
Motor Assembly, Topper 555096-001
Ring, Lift 597970-001
Block, Back-Up 596393-001
Block, Cassette Mounting 597980-001
Lift Ring
Topper Foil
Motion Photocell
Back-Up Block
Topper Platen Note:
Photocell Chamfer location
Topper Motor
Topper Foil
Motion Assy
Cassette Mounting
Blocks
Foil Cassette

Topper Foil

Silver 597950-013
Gold 597950-003
Black 597950-002
White 597950-004
Dark Blue 597950-001
Process Blue 597950-008
Red 597950-006

Main Control Board

Main Control
Board

Power Supply

Power Supply 555093-001
Line Filter 594032-001
Fuse 804960-024
Line Cord 804517-001
Fuse
Line
Power Filter
Supply
Cord

Fan

Fan 594030-001
Fan

Sensor Cable Harness

Y-Home
OCR
Motion
Platen
Sensor
Foil
Cable
Motion
Harness
Reject
Full Die
Home
RTD
J12 Wheel
Home
Punch
Home MS Front
MS back
Inter
Lock
X-Home
Card
J13 Picker
Registration
IH-Home
IH-Empty
Output
Full
Throat
Gap

Power Cable Harness

POWER
SUPPLY
FAN
Y-MOTOR
MPC
MOTOR
TOPPER
MOTOR
J11
TOPPER
SOL
TOPPER
HEAT
J9 POWER
MOTOR
OCR SOL
INPUT MOTOR
X-MOTOR
J10
TG MOTOR
OCR MOTOR
SC OCR
WHEEL
MOTOR DIE
MOTOR
LOCK
SOL

Communications Cable

J7
J8

Cable/Development Cable

Cable Assembly, SC Application, 150i 556226-001
J4
DEVELOPMENT
DIAGNOSE

Display/Keyboard

Display Assembly 596289-001
Display Cable 555039-001
Display
Assembly
Display
Cable

Miscellaneous Spare Parts

Character Type Insertion Tool (MasterCard™ Only) 556335-001
Administrator’s Guide 526638-001
CPX Protocol/Setup Manual 526637-001
Software Developer’s Manual 526698-001

Key Lock Assembly (With Key) 807100-001
Key
Key Lock
Assembly
Solenoid Lock
150i220s

Reject Full Photocell

Reject Full Photocell 593463-003
Reject Full
Photocell 150i221s

Smart Card Assembly

Smart Card Front IC Assembly 596668-003
Smart Card Assembly

Front Indent Print Assembly

Front Indent Printer Assembly 555110-001
Front Indent
Printer
150i223s

Rear Indent Printer Assembly

Rear Indent Printer Assembly 555111-002
Rear Indent Motor 555122-001
Rear Indent Drive Belt 803129-123
Rear Indent Solenoid 555932-001
Rear Indent
Printer
Rear Indent
Solenoid
Rear Indent
Motor
Rear Indent
150i224s
Drive Belt

Indent Ribbon

Black Infill Ribbon 596805-001

Chapter 8:
Illustrated Parts
embosser. This chapter provides information on assembly and sub-
assembly part numbers for the 150i embosser.
Introduction 8-3
General 8-3
Parts Lists for Base Assembly 8-3
Base System without Topper (596660-102) 8-3
Base Assembly (555099-002) 8-4
Top Cover Assembly (555120-002, FRU is 555120-008) 8-5
Right Door Assembly (556277-001), Rev E 8-5
Back Side Panel Assembly (555098-002) 8-5
Null Modem Cable, DSub,9P-M-F (596813-001) 8-6
Output Door Assembly (556788-001) 8-6
Illustrated Cabinet Parts 8-7
Input/Output Assembly (556787-051), Rev Y 8-8
Input/Output Assembly Parts (596662-002) 8-8
Output Stacker Plate Assembly Parts (596696-001), Rev E 8-9
Illustrated Input/Output Assembly 8-10
Card Transport Assembly 8-11
Card Transport Assembly FRU Parts (556787-050) 8-11
Card Transport Assembly Parts (596661-002) 8-11
X Carriage Motor Assembly FRU Parts (596691-999) 8-11
Y-Drive Card Carriage Assembly Parts (596686-002) 8-11
Right Support Block Assembly FRU Parts (596690-002) 8-12
Illustrated Card Transport Assembly 8-12
IA/IAT, Hico/Loco Parts (596663-001 in Kit 555103-001) 8-13
J, Hico/Loco Parts (596663-002 in Kit 555103-002) 8-13
Back J, Hico/Loco Parts (596663-007 in Kit 555103-007) 8-13
IAJ, Hico/Loco Floating Heads Parts (596663-009 in Kit 555103-009) 8-14
IAJ, Hico/Loco Floating Heads, PR-MBSD (596663-010 in Kit 555103-010) 8-14
Illustrated Magnetic Stripe 8-16
Embosser/Indent Assemblies 8-17
Embosser Assembly Parts (596664-002) 8-17
Daisy Wheel Assembly, 7BSG, 52Char (596678-001) 8-17

Daisy Wheel Assembly, 7BSG, 50Char (596678-002) 8-17
Emboss Module Wheel Assemblies 8-18
Illustrated Embosser Assembly 8-19
Upper Emboss Housing Assembly Parts (596684-002) 8-20
Illustrated Upper Emboss Housing Assembly 8-20
Lower Emboss Housing Assembly Parts (596683-002) 8-21
Illustrated Lower Emboss Housing Assembly 8-22
Front Indent Assembly Parts (555110-001) 8-23
Front Indent Installation Kit Parts (555111-003) 8-23
Illustrated Front Indent Assembly 8-23
Rear Indent Assembly (555121-999) 8-24
Rear Indent Installation Kit Parts (555111-002) 8-24
Illustrated Rear Indent Assembly 8-25
C. S. Topper FRU Parts (556787-052) 8-26
Topper Assembly Parts (596665-002) 8-26
Topper Heater Assembly Parts (555094-001) 8-26
Lower Topper Assembly Parts (596675-001) 8-26
Topper Left Side Plate Assembly Parts (555091-001) 8-26
Topper Right Side Plate Assembly Parts (555090-001) 8-27
Topper Cassette Assembly Parts (596666-002) 8-27
Foil Motion Assembly Parts (555092-001) 8-27
Topper Foil Parts 8-28
Illustrated Topper Assembly 8-28
Power Supply 8-30
Power Supply Assembly Parts (555093-999) 8-30
Power Cords 8-30
Illustration of Power Supply 8-31
Fan 8-32
Smart Card Development Cable 8-35
Display/Keyboard 8-36
Miscellaneous Spare Parts 8-36
Solenoid Lock Assembly Parts (555113-002) 8-37
Key Lock Parts 8-37
Illustrated Solenoid Lock Assembly 8-38
Reject Full Sensor 8-39
Smart Card Assembly 8-40
8-2 Illustrated Parts

Introduction
This chapter provides information on assembly and subassembly part numbers for
the 150i.
General
The 150i Series Card Personalization System final assembly may be configured
under different part numbers related to the 150i Series Card Personalization System
defined in the customer order. Verify the final assembly part number before
replacing components.
Parts Lists for Base Assembly
Base System without Topper (596660-102)

Item Item Description Qty Part Number
1 Base Assembly 1 555099-002
2 Top Cover Assembly 1 555120-998
3 Installation, Transport 1 555101-002
4 Install, In/Output Assembly 1 555102-002
5 Install, Embosser 1 555105-002
6 Washer, Flat, Stl 8x.375 1 800075-004
8 Screw, Hex Washer, Tf 8-32x .750 9 805991-412
10 Right Door Assembly 1 556277-001
11 Output Hopper Door 1 556278-001
12 Pin, Dowel .1252od .50l 1 800257-017
13 Front Bottom Panel 1 556276-001
14 Front Access Panel 1 556272-001
15 Pin, Pivot, Lid 3 596767-001
18 Nut, Hex Loc, Nyl Ins.25-20unc 2 803053-005
19 Washer, Friction 4 555647-001
20 Washer, Belv .500d .258id .035 4 803297-007
22 Screw, Phil, Ph,Tf, 8-18 X 1.0 1 806531-116
23 Container, Shipping, 150i 1 552875-001
24 Disk Assembly, Diag Install Utility 0 555071-001
25 Manual Assembly, Admin Guide,150i 1 526701-001
27 Guard, Output Hopper 1 555735-001
31 Screw, Fh100 Phil 4-40x.250 2 800072-204
33 Checklist, 150i Installation 1 526791-001
37 Inductor, Ferrite Bead, 250ohm 2 805513-007

39 Clip, Ferrite Bead 2 805513-101
41 Pamphlet, Security 1 598713-001
Base Assembly (555099-002)

1 Clamp, Cable, Adhesive 6 803323-006
2 Block, Pivot 1 596720-001
3 Pin, Dowel .1252od .50l 2 800257-017
4 Link, Tray 1 596719-001
5 Screw, Hex Wshr,Tf 4-40x.312 1 805991-205
7 Reject Tray Assembly 1 555114-001
8 Screw, Hex Washer, Tf 8-32x.505 48 805991-408
9 Photocell, 1 Ear Pt 1 593463-003
10 Lock Bracket Assembly 1 555113-002
11 Cable Assembly, Flex Circuit 1 555040-001
12 Washer, Lock, Ext Tooth 8 3 800506-004
13 Strap. Black Abs 4 552002-001
14 Nut, Hex Ext T Keps 6x32 2 506021001
15 Lower Left Support Link Assembly 1 555751-003
16 Lower Right Support Link Assembly 1 555751-004
17 Base, 150i 1 556786-001
19 Screw, Cap Button 8-32x.500 3 803336-408
20 Nut, Hex, Ext T Keps 8x32 1 506022001
21 Strap, Flex Cable Lower 1 596794-001
22 Conn, Pin Shroud, Pnl Mt, 9pos 1 806553-009
23 Access Panel, Fan Housing 1 596758-001
25 Assembly, MCB Plate 1 555112-998
26 Cable Assembly, Sensor 1 555962-001
27 Assembly, Power Supply 1 555096-999
29 Rubber Bumper, No. 8 4 805351-002
31 Cable Assembly, Comm I/O 1 555037-002
32 Cable Assembly, Display 1 555039-001
33 Spacer 1 555068-001
34 Strap, Flex Cable Upper 1 596793-001
35 Angle, Display Cable Clamp 1 555600-001
37 Assembly, MCB Mounting Pan 1 555097-002
41 Cable Assembly, Display Ground 1 555723-001
45 Switch-Intlk,Spst,10a,250v,Vde 1 805957-001
46 Cable Assembly, Pwr, Blockpoint,150i 1 555961-002
50 Screw, Hex Washer, Tf 8-32x .750 7 805991-412
51 Screw, Hex Washer, Tf 8-32x1.00 1 805991-416

Top Cover Assembly (555120-002, FRU is 555120-008)
3 Display Assembly 1 596289-001
5 Lock-Key,Tubular,1w90,Key Diff 1 807100-001
6 Lock, Plate 1 596771-001
8 Lid Guide Bracket Assembly 1 555755-001
9 Guard, Hopper, Input 1 596769-001
10 Upper Left Support Link Assembly 1 555750-003
11 Upper Right Support Link Assembly 1 555750-004
13 Top Cover,150i 1 556270-001
14 Front Panel (Pushes Interlock) 1 556271-001
15 Screw, Phil, Ph,Tf 8-18 X 1/2 16 806531-108
16 Nut, Self-Thd, Washer, .12stud 4 806742-001
17 Strap. Black Abs 2 552002-001
18 Clamp, Cable, Adhesive 3 803323-006
Right Door Assembly (556277-001), Rev E

1 Input Door 1 556275-001
2 Plate, Cover, Input 1 596748-001
4 Right Door Pivot Assembly 1 555753-001
5 Pin, Pivot, Door 2 596766-001
6 Spacer, Door Hinge 2 560008-001
7 Slide Block, Exception Card 2 596718-001
8 Spring, Tor 180lh,.348od X.040w 1 803940-016
9 Screw, Ph, Tf, Torx 6-19 X.375 4 806575-406
Back Side Panel Assembly (555098-002)

1 Filter-Line Assembly, AC 1 594032-001
2 Fuse, Fast-Acting, 6.3a, 250VAC 2 804960-024
3 Outside Cabinet 1 596625-001
4 Cable Assembly, Power Switch 1 596679-001
7 Nut, Hex Ext T Keps 6x32 2 506021001
8 Fan Assembly, 24 VDC 1 594030-002
10 Tape, Double Sided,3/4in X.010 0 803133-005
12 Panel, Right, Front 1 556273-001
13 Screw, Phil, Ph,Tf, 8-18 X .375 4 806531-106
14 Bezel-Dsub, Snap-In, 9 Pos 4 805551-003
15 Screwlock Assembly, Fem, D Conn 2 803986-101

Null Modem Cable, DSub,9P-M-F (596813-001)
1 Cable Assembly, Null Modem, 9PM-F, 10FT 1 806771-001
Output Door Assembly (556788-001)

Ite Item Description Qty Part Number
m
1 Left Door Assembly 1 556278-001
2 Tray Link (from Door to Base) 1 596719-001
3 Pivot Block (on Base) 1 596720-001
4 Pin, Dowel .1252OD .50L 2 800257-017

Illustrated Cabinet Parts

Input/Output Assembly (556787-051), Rev Y
Input/Output Assembly Parts (596662-002)

1 Base Plate Assembly, IH/OS 1 596695-002
2 Left Side Plate Assembly, IH/OS 1 596697-001
3 Right Side Plate Assembly, IH/OS 1 596698-001
4 Roller, Cam 1 596328-001
5 Gear, Idler 1 596455-001
6 Plate, Card Gap 1 596333-001
7 Assembly Plate, Support, Card Gap 1 556473-001
8 Screw, Phil, Fh, Tf 4-24 X .375 2 806582-106
9 Screw, Phil, Ph, Tf, 4-24 X .375 6 806531-006
10 Wire Assembly, Input Motor Ground 1 556307-001
12 Shaft, Support 3 596353-001
19 Throat Gap Motor Assembly (includes motor 596104-001) 1 548992-003
(pulley is item 66, 555986-001)
22 Motor Assembly, IH/OS 1 555082-999
24 Plate Assembly, Stacker, Output (contains PC flag, output 1 596696-001
rollers, o-ring)
26 Cam (with Shaft) (Idler gear is item 5.) 1 596454-001
29 Spacer Washer, Ins .125x.312x.032 1 803223-016
37 Pin, Dowel .0939od .50l 2 800257-002
38 Screw. Hex Washer, Tf 4-40 X.375 6 805991-206
41 Spacer Washer, Uns .127x.250x.015 1 803112-026
43 Ring, Retaining, Ext- .125sd- .094fd 1 803113-034
46 Ball Bearing Mr .13id .38od .16w 4 803128-004
47 Ball Bearing Mr .13id .31od .14w 2 803128-005
48 Input Hopper Card Weight 1 596713-001
49 Screw, Shoulder, .125x.188 4-40 2 803140-001
50 Spacer Washer, Ins .126x.250x.015 2 803223-045
51 Washer-Curved,Spring,No.5 2 805439-002
52 Input Hopper Empty Sensor, Input Home Sensor, Output 5 593463-003
Full Sensor, Card Picked Sensor, Throat Gap Motor
Sensor
53 Card Registration Sensor 1 590067-003
60 Spring, Extension .19OD .88L .020W 1 803111-058
61 Support Plate 1 555981-001
65 Block, Leadscrew 1 556280-001
66 Pulley, Leadscrew-12 Groove 1 555986-001
67 Block, Slide 1 556281-001
69 Bracket, Support, Motor 1 555989-001
70 Pulley, Leadscrew-20 Groove 1 555990-001
71 Leadscrew 1 555991-001
72 Throat Gap Motor Belt 1 803129-126

74 Spacer Washer, Uns .127x.250x.015 3 803112-026
75 Washer, Flat, Stl 6x.267 2 800718-003
Output Stacker Plate Assembly Parts (596696-001), Rev E

1 Roller, Output 2 596458-001
2 Output Hopper Drive Belt 4 803478-009
3 Plate, Support, Stacker 1 596465-001
7 O-Ring, Output Hopper Drive Belt 1 803478-019
8 Pulley, Groove 1 596459-001
10 Spring, Extension .09od 1.00l .010w 1 803111-023
11 Arm, Output Full 1 596457-001
12 Flag, Sensor 1 596478-001

Illustrated Input/Output Assembly

Card Transport Assembly
Card Transport Assembly FRU Parts (556787-050)
1 Transport Assembly, 150i Blockpoint 1 596661-002
2 Transport FRU Shipping Crate 1 556791-001
Card Transport Assembly Parts (596661-002)

1 Block, Support, Leadscrew 2 596658-001
2 Y-Drive Card Carriage Assembly 1 596686-002
3 X-Carriage Assembly 1 596688-002
4 Motor Assembly, 1.0amp,9 Pos Mml 1 598174-002
5 Pulley, 48-Groove 3 596446-001
7 Screw, Set 8-32x.19 3 804020-020
9 Y Transport Drive Belt 1 803129-122
10 Screw, Hex Washer, Tf 4-40 X.375 2 805991-206
11 Y-Carriage Motor Assembly 1 596687-001
12 Bracket, Mount, Flex Circuit 1 596784-001
13 Conn, Pin Shroud, Pnl Mt, 9pos 1 806553-009
15 Y-Home Sensor, X-Home Sensor 1 593463-003
17 Tube, Support 2 596312-001
18 X-Drive Leadscrew Shaft 1 596311-001
19 Bearing, Guide (brown piece around black tube) 1 596444-001
20 X Transport Drive Belt 1 803129-123
21 Brg, Ball R .25id .75od .28w 2 803106-009
24 Screw, Shoulder .187x.250 8-32 3 803140-010
25 O-Ring, .114id .06w Buna-N 3 803478-006
26 Washer, Flat, Stl 8x.375 3 800075-004
28 Pin, Dowel .1877od .50l 2 800257-025
X Carriage Motor Assembly FRU Parts (596691-999)

0 Motor Assembly, X Carriage 1 596691-001
Y-Drive Card Carriage Assembly Parts (596686-002)

1 Y-Carriage Assembly 1 555915-001
2 Cable Assembly, Flex Adapter 1 555041-001
5 Card Pick Cam 2 596437-001
6 Link Plate Hinge 2 596438-001

7 Pin, Dowel .0939od X .25l 2 800257-056
8 Pivot Shaft 2 596471-001
9 Lever Assembly (Pin) 1 596782-001
10 Spring, Comp .36od 1.25l .026w 1 803072-105
11 Shaft, Leadscrew, Y-Drive 1 596307-001
13 Latch Plate (clicks the gripper pens shut) 1 596304-001
14 Spring, Ext .12od .67l .014w 1 803111-076
Right Support Block Assembly FRU Parts (596690-002)

1 Block, Support, Leadscrew 1 596658-001
2 Brg, Ball R .25id .75od .28w 1 803106-009
4 Pin, Dowel .1877od .50l 1 800257-025
Illustrated Card Transport Assembly

IA/IAT, Hico/Loco Parts (596663-001 in Kit 555103-001)

1 Roller Assembly, Drive,M/S 1 596692-001
2 Plate Assembly, Mount, Base 1 596693-001
3 Plate Assembly, Support, Mag Stripe 1 596694-001
8 Screw, Cap Soc 2-56x.250 2 800200-104
13 Screw, Set Silver Tip 4-40x.125 2 805544-202
14 Screw, Set, Cup 10-32x.19 2 804020-025
15 Encoder, Optical, 500cpr,1/4dia 1 805386-001
19 Mag Stripe Head Assembly, IA/IAT 1 555715-003
J, Hico/Loco Parts (596663-002 in Kit 555103-002)

1 Roller Assembly, Drive,J,M/S 1 596692-002
3 Assembly, Mounting Plate,J,M/S,150i 1 555933-001
4 Assembly, Support Plate,J,M/S,150i 1 555934-001
8 Screw, Cap Soc 2-56x.250 2 800200-104
10 Spring, Comp .30od .62l .022w 1 803072-047
14 Screw, Set, Cup 10-32x.19 2 804020-025
19 Mag Stripe Head Assembly, NTT 1 555715-004
20 Clamp, Cable Routing, Adhes,3/8 2 806792-001
22 Tx, Jumper, Static Protection 0 580197-901
Back J, Hico/Loco Parts (596663-007 in Kit 555103-007)

1 Roller Assembly, Drive, J 1 596692-002
3 Plate Assembly, Support, Mag Stripe 1 596694-001
8 Screw, Cap Soc 2-56x.250 2 800200-104
14 Screw, Set, Cup 10-32x.19 2 804020-025

IAJ, Hico/Loco Floating Heads Parts (596663-009 in Kit
555103-009)
1 Plate, Mount, Base 1 556283-001
2 Block, Support, Lower 1 548379-001
4 Nut, Thumb 1 596432-001
5 Pin, Dowel .2502od 1.00l 1 800257-010
6 Block, Support Middle 1 548380-001
7 Brg, Ball Mr .25id .50od .19w 2 803128-013
8 Pin, Dowel .1252od 1.00l 1 800257-020
9 Shaft, Encoder 1 555142-001
12 Bearing, Head, Roller 1 590128-004
13 Roller, Rubber 1 590127-002
14 Roller, Rubber .750x.2448x.25 1 520529-008
15 Spring, Comp .30od .62l .022w 1 803072-047
16 Block, Upper 1 548376-001
17 Plate, Top Cap 1 548377-001
18 Yoke 2 555145-001
19 Pin, Dowel .0627od .44l 6 800257-029
20 Spring, Comp .088od ..38l .010w 2 803072-098
21 Block, Mount Head IAJ 2 548378-001
26 Assembly, M/S Head (IAJ Only) 1 555715-005
28 Screw, Cap Soc 6-32x1.125 2 800200-318
29 Washer, Lock, Hel Spring 6 2 800175-003
30 Pin, Dowel .0938od .38lg 1 800257-001
31 Pin, Dowel .093od 1.0l 1 800257-035
32 Screw, Cap Soc 2-56x.250 2 800200-104
33 Screw, Fh100 Phil 4-40x.375 2 800072-206
34 Screw, Set, Cup 4-40x.12 4 804020-010
35 Screw, Set, Cup 10-32x.19 2 804020-025
36 Clamp, Cable Routing,Adhes,3/8 2 806792-001
38 Screw, Cap Soc 8-32x.250 1 800200-404
IAJ, Hico/Loco Floating Heads, PR-MBSD (596663-010 in Kit

555103-010)
1 Plate, Mount, Base 1 556283-001
2 Block, Support, Lower 1 548379-001

4 Nut, Thumb 1 596432-001
5 Pin, Dowel .2502od 1.00l 1 800257-010
6 Block, Support Middle 1 548380-001
7 Brg, Ball Mr .25id .50od .19w 2 803128-013
8 Pin, Dowel .1252od 1.00l 1 800257-020
9 Shaft, Encoder 1 555142-001
12 Bearing, Head, Roller 1 590128-004
13 Roller, Rubber 1 590127-002
14 Roller, Rubber .750x.2448x.25 1 520529-008
15 Spring, Comp .30od .62l .022w 1 803072-047
16 Block, Upper 1 548376-001
17 Plate, Top Cap 1 548377-001
18 Yoke 2 555145-001
19 Pin, Dowel .0627od .44l 6 800257-029
20 Spring, Comp .088od ..38l .010w 2 803072-098
21 Block, Mount Head Iaj 2 548378-001
26 Assembly, M/S Head (IAJ Only) 1 555715-005
28 Screw, Cap Soc 6-32x1.125 2 800200-318
30 Pin, Dowel .0938od .38lg 1 800257-001
31 Pin, Dowel .093od 1.0l 1 800257-035
32 Screw, Cap Soc 2-56x.250 2 800200-104
33 Screw, Fh100 Phil 4-40x.375 2 800072-206
34 Screw, Set, Cup 4-40x.12 4 804020-010
35 Screw, Set, Cup 10-32x.19 2 804020-025
36 Clamp, Cable Routing,Adhes,3/8 2 806792-001
38 Screw, Cap Soc 8-32x.250 1 800200-404

Illustrated Magnetic Stripe

Embosser/Indent Assemblies
Embosser Assembly Parts (596664-002)
1 Guide, Card 1 555996-001
2 Screw, Cap Soc 8-32x.500 1 800200-408
4 Washer, Wave, Gap, 2.425 Od 1 806521-001
5 Washer, Driver Spring 1 596415-001
6 Spring, Comp 1 555610-001
7 Driver 1 596421-001
8 Screw, Ca Spc .25-20 X 1.75 3 800200-628
9 Washer, Lock, Hel. Spring, .25 3 800175-014
10 Spacer, Washer, Uns .264x.406x.048 3 803112-057
12 Arm Assembly, Rocker 1 596680-001
13 Shaft, Rocker 1 596416-001
14 Assembly, Lower Emboss Housing 1 596683-998
15 Assembly, Upper Emboss Housing 1 596684-002
16 Washer, Flat, Stl 8x.375 1 800075-004
Daisy Wheel Assembly, 7BSG, 52Char (596678-001)
1 Wheel, Daisy (Numbered) 2 596373-002
2 Gear, Wheel 1 596711-001
3 Home Detect Wheel 1 596712-001
4 Pin, Dowel .0783od .25l 4 800257-048
5 Set, Strip, P/D, Farr-Stdgot,52ch 1 596447-001
6 Standard, Wheel Config. 0 555970-001
Daisy Wheel Assembly, 7BSG, 50Char (596678-002)
1 Wheel, Daisy (Numbered) 2 596373-002
2 Gear, Wheel 1 596711-001
3 Home Detect Wheel 1 596712-001
4 Pin, Dowel .0783od .25l 4 800257-048
5 Set, Strip, P/D, Farr-Stdgot, 52ch 1 596447-001

Emboss Module Wheel Assemblies
150i C. S. EMB-Standard 556787-001
150i C. S. EMB-Japan Fin 73 Char 556787-002
150i C. S. EMB-Japanese HC 63 Char 556787-003
150i C. S. EMB-Swedish 60 Char 556787-004
150i C. S. EMB-Russian 73 Char 556787-005
150i C. S. EMB-Japanese Credit 556787-006 (inactive)
150i C. S. EMB-Std W/Ind OCR-A1 556787-008
150i C. S. EMB-Std W/Ind OCR-B1 556787-009
150i C. S. EMB STD, MC, A1 0-9 556787-010
150i C. S. EMB-Std W/MC 0-9r 556787-012
150i C. S. EMB-Std W/OCRB1 Fine 556787-013
150i C. S. EMB-Std W/Inv MC 0-9 556787-014
150i C. S. EMB-Visa Elec Fine 52 556787-015
150i C. S. EMB-Korean 75 Char 556787-017
150i C. S. EMB-Czech 75 Char 556787-018
150i C. S. EMB-Japan Credit W/MPC 556787-019
150i C. S. EMB-Japan Credit/Rear J 556787-022
150i C. S. EMB-Japan FIN W/Rear J 556787-024
150i C. S. EMB-Japan FIN MPC W/Rear J 556787-025
150i C. S. EMB-Japan HC W/Rear J 556787-026
150i C. S. EMB-Japan HC MPC W/Rear J 556787-027
150i C. S. EMB-Poland Visa Elec 556787-028
150i C. S. EMB-Poland FIN IND B1 0-9 556787-029
150i C. S. EMB-Japan FIN Spec 58 Ch 556787-030
150i C. S. EMB-STD, Helv, A1 0-9 556787-032
150i C. S. EMB-STD W/Helv 0-9 556787-033
150i Visa Elect +MC, Indent 556787-034

Illustrated Embosser Assembly

Upper Emboss Housing Assembly Parts (596684-002)
1 Housing, Upper 1 555977-001
2 Brg, Ball Mf .38id .88od .28w 2 803128-020
3 Pulley, Cam 1 555051-002
5 Dual Profile Cam 1 547634-001
6 Screw, Set, Cup 10-32x.38 1 804020-027
8 Belt, Htd .118p 5.787l .354w 1 805727-004
9 Cam Motor Assembly (includes motor 1 596682-999
pulley)
10 Nut, Hex Loc, Nyl Ins 8-32unc 1 803053-003
Illustrated Upper Emboss Housing Assembly

Lower Emboss Housing Assembly Parts (596683-002)
1 Housing, Lower 1 555978-001
2 Brg, Ball Mf .38id .88od .28w 2 803128-020
3 Pulley, Cam 1 555051-002
4 Cam 1 555044-002
6 Screw, Set, Cup 10-32x.38 1 804020-027
8 Belt, Htd .118p 5.787l .354w 1 805727-004
9 Motor Assembly, Cam 1 596682-999
10 Nut, Hex Loc, Nyl Ins 8-32unc 1 803053-003
12 Wheel Home Sensor 1 593463-003
14 Washer, Driver Spring 1 596415-001
15 Spring, Comp 1 555610-001
16 Driver 1 596421-001
18 Arm Assembly, Rocker 1 596680-001
19 Shaft, Rocker 1 596416-001
20 Motor Assembly, Wheel 1 596681-999

Illustrated Lower Emboss Housing Assembly

Front Indent Assembly Parts (555110-001)
1 Assy, Hsg, Front, Front Indent 1 556240-001
2 Assy, Hsg, Rear, Front Indent 1 556241-001
23 Flange, Outer 1 596789-001
27 Screw. Hex Washer, Tf 4-40 X.375 2 805991-206
Front Indent Installation Kit Parts (555111-003)

2 Assembly, Indent Front 1 555110-001
4 Ribbon Assembly, Indent, Black 1 596805-001
5 Bracket, Mounting 1 596701-001
Illustrated Front Indent Assembly

Rear Indent Assembly (555121-999)
1 Left Bracket 1 555176-001
2 Pivot Arm Assembly FRU 1 555928-999
4 Screw, Fh100 Phil 4-40x.250 1 800072-204
5 Wheel, Sensing 1 590331-001
7 Photocell Roller Assembly FRU 1 555924-999
8 Bearing Plate Assembly FRU 1 555927-999
9 Bracket, Right 1 555175-001
10 Screw, Cap Button 6-32x.250 4 803336-304
11 Supply Reel Assembly FRU 1 555930-999
13 Arm, Solenoid 1 555174-001
15 Spring, Ext .12od 1.13l .016w 1 803111-005
16 Roller, Guide, Ribbon 2 557006-001
17 Screw, Cap Soc 4-40x.750 2 800200-212
Rear Indent Installation Kit Parts (555111-002)

6 Pulley Assembly, 90t 1 555929-999
7 Core, Ribbon 1 557205-001
9 Take-Up Hub Assembly 1 555931-999
10 Rear Indent Solenoid Assembly 1 555932-999
11 Flange, Outer 1 596789-001
12 Printer, Rear Indent, Assembly 1 555121-999
13 Label, Ribbon Wind, R Indent 1 555974-001
15 Mount, Solenoid 1 555161-001
16 Ribbon Assembly, Indent, Black 1 596805-001
17 Rear Indent Motor Assembly 1 555122-999
29 Rear Indent Drive Belt 1 803129-123
32 Screw, Set Loc, Cup 5-40 X .2 1 804020-036
38 Screw, Torx, Ph, Tf 8-32 X .38 2 805314-306

Illustrated Rear Indent Assembly

Topper Assembly
C. S. Topper FRU Parts (556787-052)

1 Topper Assembly 1 596665-002
2 Shipping Crate for FRU 1 556793-001
Topper Assembly Parts (596665-002)

2 Topper Heater Assembly 1 555094-001
3 Topper Motor Assembly 1 555096-999
4 Topper Solenoid Assembly 1 555095-001
5 Screw, Buttonhead Cap 1/4-20x.62 4 806213-610
6 Spring, Comp .36od 0.75l .038w 2 803072-106
8 Ring, Lift 1 597970-001
9 Screw, Buttonhead Cap 8-32x.5,Tx 2 806213-408
10 Conn, Hsg, F, Min, 3 Pos 1 803287-003
12 Screw, Set, Knurled 1/4-28x.375 1 804020-037
13 Lower Topper Assembly 1 596675-001
Topper Heater Assembly Parts (555094-001)
1 Plate, Heater Back-Up 1 597994-001
2 Shaft, Bearing 2 596403-001
3 Block, Pivot 1 597997-001
7 Clamp, Platen 3 596383-001
8 Screw, Torx, Ph,Tf 4-40 X .375 5 805314-106
9 Platen Heater Assembly 1 598767-001
10 Flag, Photocell, Home 1 597981-001
Lower Topper Assembly Parts (596675-001)
1 Topper Right Side Plate Assembly 1 555090-001
2 Topper Left Side Plate Assembly 1 555091-001
3 Block, Back-Up 1 596393-001
14 Screw, Buttonhead Cap 1/4-20x.62 4 806213-610
Topper Left Side Plate Assembly Parts (555091-001)
1 Plate, Topper Left Side 1 596382-001
2 Screw, Ph, Tf, Torx 6-19 X.375 2 806575-406
3 Block, Cassette Mounting 1 597980-001

Topper Right Side Plate Assembly Parts (555090-001)
1 Plate, Topper Right Side 1 596382-002
2 Screw, Ph, Tf, Torx 6-19 X.375 2 806575-406
3 Block, Cassette Mounting 1 597980-001
4 Assembly, Foil Motion 1 555092-999
Topper Cassette Assembly Parts (596666-002)
1 Left Cassette Plate Assembly 1 555083-001
2 Worm Gear Assembly 1 555084-001
3 Right Cassette Plate Assembly 1 555086-002
4 Take-up Ribbon Spindle Assembly 1 555087-001
5 Hex Flat Head 6-32 X .75 4 803719-312
8 Screw, Button Head Cap 10-32x.38 1 806213-706
9 Rod, Foil Release 1 596406-001
10 Spindle, Foil Tube (green) 1 597969-001
Foil Motion Assembly Parts (555092-001)
1 Motion Flag 1 596398-001
2 Pivot Arm 1 556609-001
3 Washer, Wave Spring, .194 Id 1 803451-001
4 Spindle, Flag 1 596399-001
5 Screw, Ph Phil 4-40x1.00 1 800073-216
6 O-Ring, .484id .13w Buna-N 1 803478-004
7 Spindle, O-Ring 1 596400-001
11 Topper Platen Sensor 1 593463-003
12 Nut, Hex Mach, Stl 10-24unc 1 800074-005
13 Spring, Torsion 1 555703-001
14 Screw, Shoulder .250x1.00 10-24 1 803140-017

Topper Foil Parts
Silver 597950-015
Gold 597950-003
Black 597950-002
White 597950-004
Dark Blue 597950-001
Process (Light) Blue 597950-008
Red 597950-006
Silver (Taiwan Special) 597950-016
Illustrated Topper Assembly

Main Control Board
The Main Control Board Plate FRU is 555112-998.

Power Supply
Power Supply Assembly Parts (555093-999)

1 36V Power Supply Board Assembly 1 555033-001
2 Screw, Ph Phil 6-32x.250 3 800073-304
3 Plate, Mounting, Power Supply 1 596753-001
See Back Side Panel Assembly (555098-002) for Line Filter and Fuse part numbers.
Power Cords
Item Description Part Number
USA, 120V 556766-001
Australia, 10 amp 556766-002
Europe, 10 amp 556766-003
Denmark, 10 amp 556766-004
India, 10 amp 556766-005
Israel, 10 amp 556766-006
Italy, 10 amp 556766-007
Switzerland, 10 amp 556766-008
Japan, 7 amp 556766-009
United Kingdom, 10 amp 556766-010
Hospital, 10 amp 556766-011
China, 10 amp 556766-012

Illustration of Power Supply

Fan
The part number for the Fan is 594030-001.

Sensor Cable Harness
The part number for the Sensor Cable Harness is 555962-001.

Power Cable Harness
The part number for the Power Cable Harness is 555961-002.

Communications Cable
The part number for the Communications Cable is 555037-002. (The Null modem, 9-
pin to 9-pin communications cable is 806771-001.)
Smart Card Development Cable

The Cable Assembly for 150i Smart Card Applications is part number 556226-001.

Display/Keyboard
The part number for the Display Assembly is 596289-001 and for the Display Cable,
555039-001.
Miscellaneous Spare Parts

Character Type Insertion Tool (MasterCard™ Only) 556335-001
Administrator’s Guide Kit 526701-001
CPX Protocol/Setup Manual Kit 526716-001
Software Developer’s Manual Kit 526709-001

Solenoid Lock Assembly Parts (555113-002)
1 Assembly, Bracket, Lock Mounting 0 555756-001
2 Screw, Ph Phil 4-40x.187 0 800073-203
3 Solenoid, Frame, Pull, 12vdc 0 806747-001
4 Pin, Cotter .0620d 0.50l 0 803196-102
5 Link, Latch 0 596764-001
6 Assembly, Latch Lock 0 555754-001
9 Spring, Ext .188od 1.125l .014w 0 803111-088
11 Bracket, Switch, Interlock* 0 596755-001
* The front panel (556271-001) pushes down on the Interlock Switch.
Key Lock Parts

The part number for the Key Lock Assembly (With Key) is 807100-001.

DC1 Key Only 807100-201
DC2 Key 807100-202
DC3 Key 807100-203
DC4 Key 807100-204
DC5 Key 807100-205
DC6 Key 807100-206
DC7 Key 807100-207

Illustrated Solenoid Lock Assembly

Reject Full Sensor
The part number for the Reject Full Sensor is 593463-003.

Smart Card Assembly
The part number for the Smart Card Front IC Assembly is 596668-003.

Datacard I50i Card Personalization System Maintenance Manual

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Datacard I50i Card Personalization System Maintenance Manual

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Datacard I50i

Card Personalization System

Part No. 539110-001 Rev. B

Torx is a registered trademark of Textron, Inc. Windows is a registered trademark of

© 2001 Datacard Corporation.

Chapter 1: System Description ___________________________________________________ 1-1

Chapter 2: Installation ___________________________________________________________ 2-1

Chapter 3: Preventive Maintenance ______________________________________________ 3-1

Chapter 4: Theory of Operation___________________________________________________ 4-1

Chapter 5: Troubleshooting ______________________________________________________ 5-1

Chapter 6: Adjustments __________________________________________________________ 6-1

Chapter 8: Illustrated Parts Breakdown____________________________________________ 8-1

Appendix A: Glossary ___________________________________________________________ A-1

Appendix B: Wheel Table Configurations__________________________________________ B-1

Revision Date Affected Description of Changes

B June 2001 Chapter 8 Added Chapter 8, Illustrated Parts Breakdown to his

Notice for Canada (CUL)

Le présent appareil numérique n'émet pas de bruits radioélectriques dépassant les

Notice for Europe

Safe Human Interface

Repair Ability 1-2

Serial Numbers 1-2

Use of this Document 1-3

Product Specifications 1-4

Magnetic Stripe Encoding Specifications 1-6

Standard Financial Emboss Line Locations 1-6

Standard Emboss Character Height 1-7

Standard Emboss Character Spacing 1-7

150i Card Personalization System Maintenance Manual 1-1

• Ability to set up the 150i communication parameters.

1-2 System Description

Chapter 1: System Description

Chapter 3: Preventive Maintenance

Chapter 4: Theory of Operation

Chapter 7: Removal and Replacement

Appendix B – Wheel Table Configurations

150i Card Personalization System Maintenance Manual 1-3

Topper Cassette Capacity

1-4 System Description

150i Card Personalization System Maintenance Manual 1-5

Table 1-1: Magnetic Stripe Encoding Specifications

Standard Financial Emboss Line Locations

1-6 System Description

Standard Emboss Character Spacing

150i Card Personalization System Maintenance Manual 1-7

Preparing the Site 2-2

Functional Tests 2-6

Administrator Setups 2-6

Financial Card Password 2-10

150i Card Personalization System Maintenance Manual 2-1

Table 2-1: Installation Materials and Special Tools

Equipment/Material/Tool Note Required for

Vernier Calipers Standard tool Measuring distances on

Magnetic Stripe Sight Glass Datacard Part No. Checking encoding

Magnetic Tape Developer Datacard Part No. Checking encoding

Topper Foil Shipped with the 150i Checking Topper operation.

Laptop PC equipped with 150i 150i Setup Utility Running diagnostics,

Figure 2-1: Unpacking/Packing

150i Card Personalization System Maintenance Manual 2-3

Input Hopper Power Cord Null Modem

Figure 2-2: Included Packed Materials

Remove Cable Tie

Remove Cable Tie

Figure 2-3: Packing Material Removal