Magtek ExpressCard 2000 Hardware Service Manual Download

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MagTek I 1710 Apollo Court I Seal Beach, CA 90740 I Phone: (562) 546-6400 I Technical Support: (888) 624-8350

www.magtek.com

ExpressCard 2000 /

ExpressCard 3000

Instant Issuance Card Personalization System

Hardware Service Manual

February 2020

Document Number:

D99875607-91

REGISTERED TO ISO 9001:2015

Summary of Contents for ExpressCard 2000

Page 1: ...40 I Phone 562 546 6400 I Technical Support 888 624 8350 www magtek com ExpressCard 2000 ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual February 2020 Document Nu...

Page 2: ...3000 are trademarks of MagTek Inc AAMVA is a trademark of AAMVA American Express is a registered trademark of American Express Marketing Development Corp ANSI the ANSI logo and numerous other identif...

Page 3: ...oving side access doors add advisory to not pinch wires when removing left side access door 4 01 Jun 27 2014 Update troubleshooting information about uneven tipping general updates to tipper heater re...

Page 4: ...odule EC2000 with ECP2 EC3000 Add section 5 12 How to Remove Re install the Image Print Head migrated from Installation and Operation Manual Remove Aligning Embossed Characters with Printed Characters...

Page 5: ...y SAFETY REQUIREMENTS Never do any of the following DO NOT use a ground adapter plug to connect equipment to a power socket outlet that lacks a ground connection terminal DO NOT attempt any maintenanc...

Page 6: ...fely Move Transports By Hand 22 2 8 1 XY Transport Carriage 22 2 8 2 Hopper Transport Shuttle 23 2 9 How to Use Maintenance Functions On the Touchscreen 24 2 9 1 How to Use the MCP Commands Page 25 2...

Page 7: ...n Transport Rollers 61 4 4 Update the Software 62 4 5 Update the Firmware 63 4 5 1 Check Firmware Revision Numbers 63 4 5 2 Update the Main Logic Board Controller Firmware 64 4 5 3 Update the Image Pr...

Page 8: ...to Remove Re install the Hopper Module 109 5 8 1 Tools Materials and Documents 111 5 8 2 Remove 112 5 8 3 Re install 124 5 9 How to Remove Re install the Hopper Module Flex Cable 144 5 9 1 Tools Mate...

Page 9: ...3 Re install 205 5 20 How to Remove Re install the XY Transport Ribbon Cable 207 5 20 1 Tools Materials and Documents 208 5 20 2 Remove 209 5 20 3 Re install 211 5 21 How to Remove Re install the Embo...

Page 10: ...Main Logic Board MLB 284 5 30 1 Tools Materials and Documents 284 5 30 2 Remove 285 5 30 3 Re install 287 5 31 How to Remove Re install the Power Controller and Backplane 288 5 31 1 Tools Materials a...

Page 11: ...ate Printer to XY Transport Handoff 332 6 5 3 How to Calibrate XY Transport to Exit Transport Handoff 334 6 6 How to Calibrate the Embosser Module 335 6 6 1 About Embosser Calibration 335 6 6 2 Check...

Page 12: ...3 Card Does Not Exit Image Printer Correctly 351 7 1 4 Uneven Tipping 351 7 1 5 Error message Eject Bin Full 351 7 1 6 Error Message Unable to Start the MTECJobServer Error Message Error Opening Cont...

Page 13: ...cription N A 1 ea Any tools specified in each procedure you will perform N A 1 ea Device top cover key 67800019 or equiv 1 ea Small USB keyboard with touchpad mouse if calibrating N A 1 ea ESD groundi...

Page 14: ...EC2000 EC3000 N A 3 ea Cloth clean and lint free 1 4 Suggested Materials Part Number Quantity Description 33011009 1 ea ASSEMBLY FIELD SERVICE KIT SPARE PARTS STARTER EC2000 EC3000 93400047 1 ea PRIN...

Page 15: ...VICE MANUAL EC2000 EC3000 D99875651 1 ea PROCEDURE PREVENTIVE MAINTENANCE EC2000 D99875646 1 ea CHECKLIST PREVENTIVE MAINTENANCE EC2000 D998200294 1 ea PROCEDURE PREVENTIVE MAINTENANCE EC3000 D9982002...

Page 16: ...es EC2000 and EC3000 It is part of the ExpressCard Service Library which includes D99875600 ExpressCard 2000 Installation and Operation Manual D998200281 ExpressCard 3000 Installation and Operation Ma...

Page 17: ...ding on the service order it may include section 3 Preventive Maintenance section 7 Diagnosis section 6 Adjustments and section 5 Removal and Re installation 2 Gather and test inspect all tools materi...

Page 18: ...for use by trained professional service personnel only It is not intended for general use To maintain the safety and integrity of the device it is important to follow the procedures laid out in this...

Page 19: ...tatic discharge by moving around as little as possible Static charges are produced by rubbing together clothing carpets furniture etc Wear an ESD wrist strap connected to a metal part on the device s...

Page 20: ...s manual uses the words Front Rear Left and Right to describe where to find various parts of the device These terms assume the reader is standing in front of the device facing the touchscreen and are...

Page 21: ...About Installation Operation For detailed instructions about planning installation operation and basic maintenance see D99875600 EC2000 Installation and Operation Manual for EC2000 or D998200281 EC30...

Page 22: ...hand To prevent injury or damage to the device follow the guidelines in the following sections You can rotate the rollers on all transports by hand to push pull cards to where they can be removed 2 8...

Page 23: ...he cable then install new cable ties after re installing Figure 2 3 Figure 2 3 Disconnecting Hopper Shuttle Motor Cable If a card is stuck in the hopper shuttle but has not yet gone into the image pri...

Page 24: ...top access door sensor Be sure to put it back in your toolkit before closing the top access door To access most maintenance functions of the device using the touchscreen do the following 1 Press the M...

Page 25: ...o Hopper Hopper shuttle moves to or stays at hopper 1 slot light stops flashing 6 To Hopper Hopper shuttle moves to or stays at hopper 1 5 To Hopper Hopper shuttle moves to or stays at hopper 1 To Man...

Page 26: ...ort s X carriage moves to the left XY Home Y XY Transport s Y transport moves to the rear of the device XY To Printer XY Transport moves to image printer XY To Printer In XY Transport s X carriage mov...

Page 27: ...navigate to Menu Settings Sensors to open the Sensor Utility page In normal operation with the top access door closed with all card stock hoppers inserted and with the device just powered on and ready...

Page 28: ...ific points in its rotation Card Edge Blocked EITHER when the embosser wheel is turned such that one of the tines blocks the sensor OR when a card enters the area between the embosser wheels Wheel Hom...

Page 29: ...e device MP Card In Reserved for future use Hopper Card In Reserved for future use Hopper1 Present Hopper7 Present Blocked when hopper is in either unlatched or latched Unblocked when hopper is fully...

Page 30: ...re 2 6 All EC2000 Sensors Shown In Red FRONT VIEW In addition to the sensors shown in Figure 2 6 newer models of ExpressCard include additional sensors in the following locations The tipper foil senso...

Page 31: ...ge the value by selecting the 1 per 10 per or 100 per radio buttons the default is for the arrows to add or subtract 100 per press The following sections specify how to use the Embosser Utility page t...

Page 32: ...ting where you want to close the hammers to their calibrated close position but prevent one embosser hammer from moving during testing for example to prevent damage if something is jammed in the devic...

Page 33: ...home position change the Hold setting The setting is in increments of 10 milliseconds so a value of 5 equals a hold time of 50 ms In most cases setting Hold to 0 should produce acceptable results a S...

Page 34: ...een navigate to Menu Settings Service Char Map to open the first Character Mapping password page 5 Enter password 4567890 then press the E key to open the second Character Mapping password page 6 Ente...

Page 35: ...that goes opposite the punch side 4 Install both halves of the character on the new tine 5 On the touchscreen navigate to Menu Settings Service Char Map to open the first Character Mapping password p...

Page 36: ...nce Procedure EC2000 ExpressCard 2000 requires regular preventive maintenance to maintain image quality and reliability Follow the steps in each section below to perform preventive maintenance The fol...

Page 37: ...3 Preventive Maintenance Procedure EC2000 ExpressCard 2000 ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual Page 37 of 356 D99875607 91...

Page 38: ...press the Menu button b Press the Maintenance button to open the Maintenance Menu page c Press the Remove Hopper button and wait for the hopper shuttle to finish moving 5 Open the top access door see...

Page 39: ...aning card partly into the hopper shuttle and press the Roll To Printer button Hold the card there until the rollers stop moving Figure 3 1 Cleaning the Hopper shuttle Rollers TOP VIEW FROM FRONT b Fe...

Page 40: ...OP VIEW FROM FRONT d Feed the cleaning card partly under the exit ramp rollers and press the Exit Eject button Hold the card there until the rollers stop moving Figure 3 4 Cleaning the Exit Ramp Rolle...

Page 41: ...on the left side of the page to display a File to Upload page 4 Press the Browse button to launch the Choose File to Upload dialog box 5 Navigate to the folder that contains the CAB files you want to...

Page 42: ...Information list note the Controller Firmware and Printer Firmware entries 4 If the Version Information for any component does not match the versions MagTek Support Services has recommended installin...

Page 43: ...e Main Logic Board Controller Firmware To update the controller main logic board MLB firmware follow these steps 1 From the Firmware Download page select the Controller radio button 2 In the list of h...

Page 44: ...tem Hardware Service Manual Page 44 of 356 D99875607 91 4 Wait about 5 minutes for the firmware to finish downloading Do not power off the device 5 After the firmware update is complete the device wil...

Page 45: ...Service Manual Page 45 of 356 D99875607 91 3 5 3 Update the Image Printer Firmware To update the image printer firmware follow the steps from section 3 5 2 but select the Printer radio button and sele...

Page 46: ...ort 1 Use the MCP Commands page see section 2 9 How to Use Maintenance Functions On the Touchscreen to move the hopper shuttle from the front to the rear of the device to verify the movement is smooth...

Page 47: ...s for a replacement 3 Use the MCP Commands page see section 2 9 1 How to Use the MCP Commands Page to move the XY transport from the front to the rear of the device to verify the movement is smooth an...

Page 48: ...LEFT VIEW b Shake the bottle of Tri Flow lubricant and remove the cap c Run a thin 3 4 inch long bead of Tri Flow along the top of that one shaft Figure 3 7 Run a Thin Bead of Tri Flow Along the Top o...

Page 49: ...ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual Page 49 of 356 D99875607 91 e If you have applied too much Tri Flow to the shaft some may drip off the shaft If th...

Page 50: ...at temperatures that are not safe to touch Be sure to cool down the tipper heater to a safe working temperature before working on or near it 1 On the touchscreen navigate to Menu Settings Tipper to op...

Page 51: ...give them to the customer for temporary storage or secure disposal 2 If there is a large visible amount of dirt dust or debris in the device wipe the worst of it out with a clean dry cloth 3 Wipe rem...

Page 52: ...age printed cards causing spots or speckles 4 If the ExpressCard you are servicing has ECP1 installed follow these steps a Clean the card cleaning roller and replace it if necessary See D99875600 Expr...

Page 53: ...or dies can produce characters of poor quality or characters that are raised indented less than the required depth The top and bottom embosser motors each drive a hammer that applies force to the pun...

Page 54: ...How to Remove Re install Embosser Fonts and section 2 9 4 How to Use the Character Mapping Page 4 Inspect the characters on the top embosser wheel to identify any broken or bent cones Top side replac...

Page 55: ...22 How to Remove Re install Embosser Fonts and section 2 9 4 How to Use the Character Mapping Page 7 Check the embosser wheel alignment by standing in front of the device and looking straight down at...

Page 56: ...91 11 Move the hammer follower out of the way and add 2 drops of lubricant to the top and to the front of the top punch hammer 12 Add 2 drops of lubricant to the left and right sides of the shaft that...

Page 57: ...slides smoothly across the punch hammer Press the top rocker arm all the way down and make sure the top of the knuckle remains level and parallel to the floor at all points in the movement cycle The k...

Page 58: ...er completing preventive maintenance follow these steps to test the device and restore it to its original state 1 Re connect the power and network cables 2 Re attach any security hardware 3 Re install...

Page 59: ...ntenance Procedure EC3000 EC3000 requires regular preventive maintenance to maintain image quality and reliability Follow the steps in each section below to perform preventive maintenance The followin...

Page 60: ...4 Preventive Maintenance Procedure EC3000 ExpressCard 2000 ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual Page 60 of 356 D99875607 91...

Page 61: ...ables contain negative imprints of cardholder data and must be handled securely 4 Make sure the device is powered on and connected to the network 5 Park the hopper shuttle at the front of the device b...

Page 62: ...d link on the left side of the page to display a File to Upload page 4 Press the Browse button to launch the Choose File to Upload dialog box 5 Navigate to the folder that contains the CAB files you w...

Page 63: ...on Information list note the Controller Firmware and Printer Firmware entries 4 If the Version Information for any component does not match the versions MagTek Support Services has recommended install...

Page 64: ...ogic Board Controller Firmware To update the controller main logic board MLB firmware follow these steps 1 From the Firmware Download page select the Controller radio button 2 In the list of hex files...

Page 65: ...em Hardware Service Manual Page 65 of 356 D99875607 91 4 Wait about 5 minutes for the firmware to finish downloading Do not power off the device 5 After the firmware update is complete the device will...

Page 66: ...Service Manual Page 66 of 356 D99875607 91 4 5 3 Update the Image Printer Firmware To update the image printer firmware follow the steps from section 4 5 2 but select the Printer radio button and sele...

Page 67: ...How to Use the MCP Commands Page to move the XY transport from the front to the rear of the device to verify the movement is smooth and there is no belt slippage Leave the transport at the rear of th...

Page 68: ...e wipe as necessary 5 Use compressed air to clean each of the sensors see section 2 9 2 How to Use the Sensor Utility Page for an inventory of all sensors in the device 6 Use compressed air to clean o...

Page 69: ...or dies can produce characters of poor quality or characters that are raised indented less than the required depth The top and bottom embosser motors each drive a hammer that applies force to the pun...

Page 70: ...2 How to Remove Re install Embosser Fonts and section 2 9 4 How to Use the Character Mapping Page 4 Inspect the characters on the top embosser wheel to identify any broken or bent cones Top side repla...

Page 71: ...ction 5 22 How to Remove Re install Embosser Fonts and section 2 9 4 How to Use the Character Mapping Page 7 Check the embosser wheel alignment by standing in front of the device and looking straight...

Page 72: ...91 11 Move the hammer follower out of the way and add 2 drops of lubricant to the top and to the front of the top punch hammer 12 Add 2 drops of lubricant to the left and right sides of the shaft that...

Page 73: ...slides smoothly across the punch hammer Press the top rocker arm all the way down and make sure the top of the knuckle remains level and parallel to the floor at all points in the movement cycle The k...

Page 74: ...er completing preventive maintenance follow these steps to test the device and restore it to its original state 1 Re connect the power and network cables 2 Re attach any security hardware 3 Re install...

Page 75: ...ocation to place removed parts and replacement parts 4 Make sure the device is powered on and connected to the network 5 Park the hopper shuttle at the front of the device by following these steps if...

Page 76: ...y of the following within appropriate bounds of safety If you see the hardware use the magnetic retriever tool and or screwdriver or needle nose pliers to carefully pull it out If you do not see the h...

Page 77: ...Covers Figure 5 1 Cover REAR LEFT VIEW REAR RIGHT VIEW Some of the modules inside the ExpressCard you are servicing may look different from the photos in this procedure However the steps of the proced...

Page 78: ...ers N A 1 ea No 2 Phillips screwdriver N A 1 ea Tools materials and documents required for sub procedures Suggested N A 1 ea No 1 Phillips screwdriver N A 1 ea Screwdriver with heavy duty flex extensi...

Page 79: ...by following the steps in section 5 5 How to Remove Re install the Top Access Door including safely powering down and disconnecting external cables 3 Remove the magnetic stripe reader by following the...

Page 80: ...Figure 5 4 Exception Card Entry Sensor Cable REAR VIEW 8 Disconnect the Door 1 sensor cable in the front right corner of the device Figure 5 5 Door 1 Sensor Cable REAR VIEW 9 Disconnect the touchscree...

Page 81: ...there are any cable ties anchoring the touchscreen cables to the cover use the wire cutters or diagonal cutters to cut the cable ties and replace them when re installing the cover If the cables are h...

Page 82: ...access door latch on the left side of the device Disengage the bottom part of the cable from the clip on the wall of the cover Figure 5 9 Door 2 Solenoid Cable RIGHT VIEW 1 Disconnect the correspondin...

Page 83: ...e the screw you have already removed see Figure 5 12 Figure 5 11 Removing the Left Side Cover Screw Near Top Access Door Hinge FRONT RIGHT VIEW 13 Locate the eight screws and washers and the four plas...

Page 84: ...ce Card Personalization System Hardware Service Manual Page 84 of 356 D99875607 91 Figure 5 12 One of Eight Screws On Sides of Cover TOP VIEW FROM FRONT Figure 5 13 Plastic Fastener Plates LEFT VIEW 1...

Page 85: ...illips screwdriver to remove the screws and set them aside 17 Pull the silver portion of the cover forward slightly to release it from the device 18 Carefully remove the cover by pulling it forward a...

Page 86: ...n place before proceeding to the next step To re install the cover follow these steps 1 Move any loose cables toward the center of the device so they will not be in the way of the cover 2 Stand in fro...

Page 87: ...e touchscreen power and video cables as shown in Figure 5 17 Figure 5 17 Silicone Adhesive On Touchscreen Connectors REAR VIEW 7 Bring the cover back up to resting squarely on the base as shown in Fig...

Page 88: ...19 Squeeze each side inward carefully and press toward the rear of the device until the base of the device captures them Figure 5 19 Fitting the Silver Portion of the Cover FRONT VIEW 10 Bump the fron...

Page 89: ...b Use your free hand to push the cover into the right position to insert the screws c It may be helpful to use the magnetic retriever tool to insert them into the holes then use the screwdriver or a...

Page 90: ...e top access door by following the steps in section 5 5 How to Remove Re install the Top Access Door 20 Complete any other service that requires the device to be powered off and open 21 Power on the d...

Page 91: ...d manual feed slot This section describes how to replace just the right side of the device s cover The procedure for replacing the entire cover is detailed in section 5 3 How to Remove Re install the...

Page 92: ...or including safely powering down and disconnecting external cables 3 Remove the magnetic stripe reader MSR from the case by following the steps in section 5 35 How to Remove Re install the Magnetic S...

Page 93: ...he device see section 5 35 5 Re install the top access door on the device see section 5 5 6 Complete any other service that requires the device to be powered off and open 7 Power on the device and tes...

Page 94: ...EW Some of the modules inside the ExpressCard you are servicing may look different from the photos in this procedure However the steps of the procedure are the same and are unrelated to unaffected by...

Page 95: ...ion Required N A 1 ea Device top access door key N A 1 ea No 2 Phillips screwdriver N A 1 ea Tools materials and documents required for sub procedures Suggested 33011008 1 ea ASM TOOL KIT FIELD SERVIC...

Page 96: ...powered down with all external cables safely disconnected and the hopper shuttle parked near the front of the device 5 Unlock the top access door see section 2 7 How to Open the Top Access Door 6 Ope...

Page 97: ...cover to the metal plate on the rear of the base The fastener can be found in the rear upper right of the device behind hopper 1 as shown in Figure 5 27 Figure 5 27 Removing the Right Side Cover Screw...

Page 98: ...shings from the top cover s two hinges one on each side and set them aside with the cover and the two screws and washers Figure 5 28 Top Access Door Hinge Bushings FRONT LEFT VIEW 5 5 3 Re install To...

Page 99: ...s plus any sub procedures Approximate time to re install 5 minutes plus any sub procedures The top access door s right latch assembly is attached to the top cover just above the hopper windows It serv...

Page 100: ...ion Required N A 1 ea Device top access door key N A 1 ea No 2 Phillips screwdriver N A 1 ea Tools materials and documents required for sub procedures Suggested 33011008 1 ea ASM TOOL KIT FIELD SERVIC...

Page 101: ...nal cables safely disconnected and the hopper shuttle parked near the front of the device 2 Unlock the top access door see ExpressCard 2000 Installation and Operation Manual 3 Open the top access door...

Page 102: ...stem Hardware Service Manual Page 102 of 356 D99875607 91 7 Unplug the solenoid 8 Use the No 2 Phillips screwdriver to remove the two of the screws and lock washers that attach the right latch assembl...

Page 103: ...5 Removal and Re installation ExpressCard 2000 ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual Page 103 of 356 D99875607 91...

Page 104: ...latch and re fasten it to the case using the three screws and lock washers 2 Connect the solenoid cable 3 Clip the cable into the three cable clips in the front right corner of the case The installat...

Page 105: ...s door and pull up and side to side to make sure the latch holds it firmly locked 8 Use the key to unlock the top access door and make sure it unlocks and opens smoothly then close it again and make s...

Page 106: ...es access to examine or replace the Main Logic Board MLB The left side access door provides access to the power supply and the power controller board sometimes referred to as the Green controller It i...

Page 107: ...rop up the two left rubber feet on a card weight atop a soft cloth or piece of cardboard Be sure card weights do not stick out past the rubber feet toward the left edge of the device Alternatively you...

Page 108: ...ed 2 Slide the side access door s locking tabs into their slots on the bottom of the device s cover You may need to move it forward and back along the cover to find the place where the tabs insert 3 H...

Page 109: ...r Remove side access doors Remove input hopper deck plate gear motor box and hopper module base Remove and re install new flex cable if shipped Re install hopper deck plate gear motor box and hopper m...

Page 110: ...ou are servicing may look different from the photos in this procedure However the steps of the procedure are the same and are unrelated to unaffected by the appearance of the modules The hopper module...

Page 111: ...ea 5 64 hex wrench 96906601 1 ea 5 32 ball end hex wrench 97200033 1 ea Alcohol swab or equivalent N A 1 ea Wire cutters diagonal side cutters or cable tie installation tool Suggested 33011008 1 ea A...

Page 112: ...cables safely disconnected and the hopper shuttle parked near the front of the device 2 Remove the cover by following the steps in section 5 3 How to Remove Re install the Cover 3 Remove all the card...

Page 113: ...re connect them the same way when you install the replacement module later 7 Disconnect the two sensor cables and set the hopper deck plate aside in a safe place with the printed circuit board facing...

Page 114: ...remove the four screws and washers that hold the four corners of the hopper module to the top deck plate and set them aside for later use 10 Find the belt tension screw on the front of the hopper modu...

Page 115: ...are Service Manual Page 115 of 356 D99875607 91 12 Locate the HOPPER SHUTTLE circuit board mounted to the top deck plate below the center of the hopper module 13 Find the HOPPER SHUTTLE EXC HOME SENSO...

Page 116: ...side of the top deck plate 15 If the HOPPER SHUTTLE EXC HOME SENSOR cable is routed underneath the circuit board carefully thread it out and free it If it is routed underneath other cables thread it o...

Page 117: ...zation System Hardware Service Manual Page 117 of 356 D99875607 91 17 Trace the hopper module flex cable to its connector on the hopper shuttle 18 Disconnect the flex cable from the hopper shuttle It...

Page 118: ...9 VERY carefully pull the flex cable free from the double sided foam tape just next to the connector The flex cable will be reused so it is important to not damage it 20 Use your fingers to rub all fo...

Page 119: ...ystem Hardware Service Manual Page 119 of 356 D99875607 91 22 Find the HOPPER SHUTTLE HOME SENSOR cable connected to the J3 HOME SENS connector on the HOPPER SHUTTLE circuit board and disconnect it 23...

Page 120: ...ystem Hardware Service Manual Page 120 of 356 D99875607 91 24 Carefully unthread the HOPPER SHUTTLE HOME SENSOR cable from its routing path to free it completely from the device leaving it connected t...

Page 121: ...e shuttle to retract it above its base 27 Carefully lift the hopper module out of the device Tilt it to avoid hitting the pulley at the rear of the device lift the front end first and make sure it doe...

Page 122: ...Service Manual Page 122 of 356 D99875607 91 29 Use the 5 32 hex wrench to loosen the two screws that hold the hopper module gear box to the top deck plate The screw nearer the front of the device is...

Page 123: ...ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual Page 123 of 356 D99875607 91 31 Remove the hopper gearbox and screws and set them aside 32 Remove the screws and...

Page 124: ...99875607 91 5 8 3 Re install To re install the hopper module follow these steps 1 Pre install the screws and washers you set aside earlier into the hopper gearbox 2 Locate the cutout in the top deck p...

Page 125: ...re Service Manual Page 125 of 356 D99875607 91 4 Slip the hopper gearbox into the hole so it is underneath the lip of the image printer base plate 5 Make sure the thick light colored cable is behind a...

Page 126: ...of 356 D99875607 91 6 Connect the hopper gearbox to the device 7 If the hopper transport module you are installing has the hopper deck installed the steel plate on top of the hopper module uninstall i...

Page 127: ...d circuit board facing the floor 8 If there is not already foam tape installed on the motor below the hopper shuttle use your fingers to rub off any foam tape residue and clean the motor with isopropy...

Page 128: ...ow the pulley on the hopper transport gearbox then lower it to the top deck plate to line it up with the screw holes Use your free hand to make sure the module doesn t pinch any cables or the drive be...

Page 129: ...stem Hardware Service Manual Page 129 of 356 D99875607 91 13 Pull any loose cables toward the outside of the device to make them easy to find and to clear them out of the way 14 Use the 5 32 hex wrenc...

Page 130: ...f the device to give easy access to the HOPPER SHUTTLE circuit board and cables 16 Locate the HOPPER SHUTTLE HOME SENSOR cable that comes from the rear of the hopper module Thread it under the thick l...

Page 131: ...al Page 131 of 356 D99875607 91 18 Plug the HOPPER SHUTTLE HOME SENSOR cable into the J3 HOME SENS connector on the HOPPER SHUTTLE circuit board 19 Use cable ties 89800023 and 89800006 at the location...

Page 132: ...of 356 D99875607 91 20 Gently push the hopper shuttle toward the rear of the device past the connectors on the top deck plate 21 Locate the HOPPER SHUTTLE EXC HOME SENSOR cable attached to the front o...

Page 133: ...Manual Page 133 of 356 D99875607 91 23 Route the HOPPER SHUTTLE EXC HOME SENSOR around the front plate of the hopper transport module and down through the cable clip in the front right corner of the d...

Page 134: ...vice Manual Page 134 of 356 D99875607 91 25 Tuck the HOPPER SHUTTLE EXC HOME SENSOR cable underneath the HOPPER SHUTTLE circuit board to prevent it from snagging on moving parts 26 Clip the HOPPER SHU...

Page 135: ...ver the geared pulleys at the front and rear of the device 28 Find the belt tensioner screw on the front of the hopper module Use the 5 32 hex wrench to tighten the screw so the top and bottom of the...

Page 136: ...Page 136 of 356 D99875607 91 29 Pull on the hopper shuttle drive belt to move the hopper shuttle to the front of the device just past hopper 7 and before it rotates to the manual feed slot Do not pull...

Page 137: ...age 137 of 356 D99875607 91 31 Plug the flex cable into the hopper shuttle so it points toward the rear of the device DO NOT STICK IT TO THE DOUBLE STICK TAPE 32 Pull on the hopper shuttle drive belt...

Page 138: ...cable taut and hold it there Make sure the cable is parallel to the top deck plate edge of the device and does not have any bends twists or kinks If the cable is damaged or is mounted to the case inco...

Page 139: ...rvice Manual Page 139 of 356 D99875607 91 35 Make sure the flex cable is making as much contact as possible with the double stick tape 36 Pull on the hopper shuttle drive belt to move the hopper shutt...

Page 140: ...side of the case If it is not laying flat against the case the flex cable may need to be replaced or re installed per the steps in section 5 9 How to Remove Re install the Hopper Module Flex Cable 38...

Page 141: ...the two plugs on the circuit board Make sure they are re connected the same way as when you disconnected them earlier The cable labeled to J2 goes to J2 on the board and the cable labeled to J1 goes t...

Page 142: ...to push the thick light colored sensor cable and the smaller HOPPER SHUTTLE HOME SENSOR cable under the image printer shielding to take up any slack 43 Trace the thick light colored cable to the circu...

Page 143: ...dditional service that requires the device to be powered off and open 46 Re install the cover and top access door by following the steps in sections 5 3 and 5 5 47 Pull on the hopper shuttle drive bel...

Page 144: ...right side of the device and connects the right side of the hopper transport to a circuit board on the top deck Figure 5 34 Hopper Transport Flex Cable Flex Cable 5 9 1 Tools Materials and Documents...

Page 145: ...hould be powered down with all external cables safely disconnected and the hopper shuttle parked near the front of the device 2 Remove the cover For details see section 5 3 How to Remove Re install th...

Page 146: ...h cable is plugged in to the connector closer to the front and which is plugged in to the connector closer to the rear Figure 5 37 Hopper Deck Plate Sensor Cables FRONT LEFT VIEW FROM ABOVE 6 Set the...

Page 147: ...e near the image printer Do not pull directly on the hopper shuttle or you may cause irreparable damage 10 Trace the hopper module s flex cable to a connector on the HOPPER SHUTTLE circuit board on th...

Page 148: ...Cable Disconnected from HOPPER SHUTTLE Circuit Board TOP LEFT VIEW 13 Peel the cable off the foam tape on the right side of the cover see Figure 5 41 and set the cable aside for disposal Figure 5 41 R...

Page 149: ...rd Personalization System Hardware Service Manual Page 149 of 356 D99875607 91 Figure 5 42 Clean Off Foam Tape from Case LEFT VIEW Figure 5 43 Clean Off Foam Tape from Hopper shuttle Motor RIGHT VIEW...

Page 150: ...uit board is unlocked by pulling it outward 2 Route the short leg of the flex cable down from the wall of the case under any wires routed along the wall of the case toward the HOPPER SHUTTLE circuit b...

Page 151: ...5 Use the foam tape to mount the long leg of the flex cable to the right side of the case as shown Figure 5 47 Mount Flex Cable to Case LEFT VIEW 6 Pull on the drive belt to move the hopper shuttle to...

Page 152: ...f 356 D99875607 91 8 Plug the flex cable into the hopper shuttle so it points toward the rear of the device as shown 9 Remove the backing from the foam tape 10 Gently pull the long loop of the flex ca...

Page 153: ...tape 12 Make sure the cable is straight then stick it firmly to the foam tape 13 Re connect the sensor cables to the hopper deck plate 14 Use the 5 64 hex wrench to re install the five screws that att...

Page 154: ...Re install the cover and top access door see section 5 3 How to Remove Re install the Cover and section 5 5 How to Remove Re install the Top Access Door 18 Pull on the hopper shuttle drive belt to mo...

Page 155: ...ate time to remove 15 minutes plus any sub procedures Approximate time to re install 15 minutes plus any sub procedures The image printer located in the rear center of the device takes blank card stoc...

Page 156: ...quired 96906601 1 ea 5 32 ball end hex wrench N A 1 ea Tools materials and documents required for sub procedures Suggested 33011008 1 ea ASM TOOL KIT FIELD SERVICE EC2000 EC3000 33011009 1 ea ASSEMBLY...

Page 157: ...Modules At the end the device should be powered down with all external cables safely disconnected and the hopper shuttle parked near the front of the device 4 Disengage and lean back the top access d...

Page 158: ...screw of the image printer locate the cable labeled Y END SENSOR shown in Figure 5 51 and disconnect it Figure 5 51 Image Printer Exit Sensor Connector TOP LEFT VIEW 9 Use the 5 32 hex wrench to unsc...

Page 159: ...5 Removal and Re installation ExpressCard 2000 ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual Page 159 of 356 D99875607 91...

Page 160: ...er module and line up the screw holes in its base with the screw holes in the top deck plate 3 Make sure the downward facing sheet metal tabs in the base of the image printer insert into the correspon...

Page 161: ...ack 8 Install the original printer ribbon or obtain and install a new image printer ribbon from the customer 9 Re connect the power and network cables to the device and power it on 10 Configure the im...

Page 162: ...steps 1 Obtain a replacement card cleaning roller 2 Open EC2000 s top access door see D99875600 ExpressCard 2000 Installation and Operation Manual 3 Open the image printer and remove the ribbon see D9...

Page 163: ...ensure a lengthy useful life Nonetheless the print head may sometimes need to be replaced ExpressCard is designed to enable operators to do this without needing tools Before replacing the print head...

Page 164: ...the white label stuck on the new print head You will be asked for this code in a later step after the image printer is closed 4 Open EC2000 s top access door see D99875600 EC2000 Installation and Oper...

Page 165: ...en to navigate to Menu Settings Printer Advanced Commands to open the Printer Utility page 17 Select the Command text box and use the on screen keyboard to enter the case sensitive command Pkn xxxx wh...

Page 166: ...ed without replacing the entire image printer module For instructions on removing and re installing the entire image printer module see section 5 10 How to Remove Re install the Image Printer Module E...

Page 167: ...ction 2 7 How to Open the Top Access Door 3 Take a photo of the condition of the image printer to include during Service Request completion 4 If this is a warranty replacement evaluate the customer s...

Page 168: ...8 Use your thumbs to gently spread the hooks on the original lid cover to release them and push the lid cover toward the floor to remove it 9 Remove the cover The image printer lid may lower itself wh...

Page 169: ...11 Go to the other side of the image printer and hold the lid open with one hand 12 Use your thumb to push one of the button s hooks forward and release it from the sheet metal and very gently lift t...

Page 170: ...center post on the replacement release button with the holes in the sheet metal Carefully insert one hook into its hole 2 Gently push the other hook into its hole being careful not to break it Press...

Page 171: ...you may have to change your viewing angle several times to line them up The large square piece on each guide will slide into a slot and the thinner parts of the guides will serve as stoppers 5 Raise...

Page 172: ...ge printer 10 Perform any other service that requires the device to be powered down and open 11 Thoroughly clean EC2000 see D99875600 ExpressCard 2000 Installation and Operation Manual for details 12...

Page 173: ...t If the sample does not look correct e g images do not print correctly contact MagTek Support Services for assistance 17 If the customer is using QwickCards com perform the following additional tests...

Page 174: ...or Remove the image printer 3 screws 3 cables Install the new image printer Configure software Re install top access door Calibrate XY Hopper Ribbon Approximate time to remove 30 minutes plus any sub...

Page 175: ...gTek Support Services N A 1 ea No 2 Phillips screwdriver N A 1 ea Diagonal side cutters or wire cutters 96900657 1 ea 1 8 hex wrench 96906601 1 ea 5 32 hex wrench 89800021 2 ea Cable tie N A 1 ea Tool...

Page 176: ...ling Modules At the end the device should be powered down with all external cables safely disconnected and the hopper shuttle parked near the front of the device 3 Move the XY transport carriage to th...

Page 177: ...Service Manual Page 177 of 356 D99875607 91 8 Use the 1 8 hex wrench to remove the screw and washer holding the rear of the image printer to the top deck plate Look for the screw from the top just to...

Page 178: ...ce around the left side of the image printer and into a circuit board on the left inside This is the image printer s USB cable Disconnect it and move it out of the way You may slide the image printer...

Page 179: ...you just disconnected runs below the front lip of the image printer all the way across to the other side of the device Move it out of the way for safe removal 12 Slide the image printer toward the ba...

Page 180: ...5 Removal and Re installation ExpressCard 2000 ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual Page 180 of 356 D99875607 91...

Page 181: ...r all cables out of the way to make room on the top deck plate for the replacement image printer 3 Make sure the hopper transport shuttle and XY transport carriage are both parked at the front of the...

Page 182: ...mage printer USB cable from the top deck to give more slack 7 Reconnect the USB cable then re clip it to the top deck plate using a long screwdriver or hex wrench You may lift the left side of the ima...

Page 183: ...ced correctly and its base plate drops completely flat against the top deck plate 10 Push the image printer all the way toward the front of the device to lock it in place It is very important to push...

Page 184: ...D99875607 91 12 Use the 5 32 hex wrench to re install the 2 screws and washers that hold the right side of the image printer to the top deck plate 13 Slide the XY carriage all the way to the left 14...

Page 185: ...u disconnected the hopper shuttle motor cable re connect it and tie wrap the two cables back to the motor plate as they were before you disconnected them 17 Remove the right side access door to gain a...

Page 186: ...ies window and edit the text at the top of the window to rename the printer to MagtekEC then press the OK button to save the change 28 Press the power button to power down the device 29 Disconnect the...

Page 187: ...ments notably a Section 6 2 1 How to Calibrate Hopper Transport Home to Printer Handoff b Section 6 2 2 How to Calibrate Hopper Transport Manual Feed Slot to Printer Handoff c Section 6 5 2 How to Cal...

Page 188: ...alization System Hardware Service Manual Page 188 of 356 D99875607 91 5 15 How to Upgrade the Image Printer Module from ECP1 to ECP2 At this time there is no upgrade path to replace the image printer...

Page 189: ...ning roller follow these steps 1 Obtain a replacement card cleaning roller 2 Open the top access door 3 Open the image printer and remove the ribbon see D998200281 ExpressCard 3000 Installation and Op...

Page 190: ...les ensure a lengthy useful life Nonetheless the print head may sometimes need to be replaced ExpressCard is designed to enable operators to do this without needing tools Before replacing the print he...

Page 191: ...6 D99875607 91 5 17 1 Tools Materials and Documents Part Number Quantity Description Required N A 1 ea Image printer cleaning supplies N A 1 ea Pen or pencil N A 1 ea Paper and clipboard N A 1 ea Tool...

Page 192: ...ary but the shape should not If the image printer you are replacing looks different see section 5 12 How to Remove Re install the Image Print Head EC2000 with ECP1 2 Gather the replacement image print...

Page 193: ...from the outlet 6 Open the image printer see D998200281 ExpressCard 3000 Installation and Operation Manual for details 7 Find the print head Figure 5 61 Locating the Image Print Head 8 Look at the pri...

Page 194: ...ding Print Head Hooks 9 Press in on the plastic parts of the head either the forks or the plastic rib centered below the head to unhook the head then tilt it down to clear it past the hooks Figure 5 6...

Page 195: ...e of the new print head with the groove in its installation location 2 Reverse the process you used to remove the original head to install the new one by re engaging the print head with the two hooks...

Page 196: ...earlier then press the Send button For example if the print head label number is 179 004 00048 the command to enter would be Pkn 179 004 00048 If the print head label number is not entered correctly...

Page 197: ...n ExpressCard 2000 ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual Page 197 of 356 D99875607 91 5 18 How to Remove Re install the Image Printer Top Door Cover EC3...

Page 198: ...device for removing reinstalling modules Prepare top access door Disconnect cables Remove XY transport module 4 screws Install new XY transport module 4 screws Reconnect cables Calibrate XY transport...

Page 199: ...ide the ExpressCard you are servicing may look different from the photos in this procedure However the steps of the procedure are the same and are unrelated to unaffected by the appearance of the modu...

Page 200: ...ription Required N A 1 ea No 2 Phillips screwdriver 96900657 1 ea 1 8 hex wrench N A 1 ea Tools materials and documents required for sub procedures Suggested 33011008 1 ea ASM TOOL KIT FIELD SERVICE E...

Page 201: ...ked near the front of the device 2 Disengage and lean back the top access door by following the steps in section 5 5 How to Remove Re install the Top Access Door up to the point where the top access d...

Page 202: ...XY transport see Figure 5 67 9 Hold the two connectors not the wires and disconnect them Figure 5 67 XY Transport Y Stepper Connection Cable TOP VIEW FROM LEFT 10 Use the 1 8 hex wrench to remove the...

Page 203: ...nual Page 203 of 356 D99875607 91 a If the device you are servicing does not have a SPARE 2 cable or this sensor cable skip these steps Figure 5 68 Indent Ribbon Sensor Cable from XY Transport b Uncli...

Page 204: ...of 356 D99875607 91 13 Use the 1 8 hex wrench to remove the three screws securing the XY transport to the top deck plate near the front of the device see Figure 5 64 and set them aside 14 Use both han...

Page 205: ...y Hand 5 Use the 1 8 hex wrench to fasten and tighten the front three screws securing the XY transport to the top deck plate see Figure 5 64 6 Move the XY transport carriage toward the front of the de...

Page 206: ...rate the XY transport using the information in section 6 5 How to Calibrate the XY Transport 15 On the touchscreen navigate to Menu Samples create a sample card and make sure the device functions prop...

Page 207: ...Transport Showing Ribbon Cable FRONT VIEW Some of the modules inside the ExpressCard you are servicing may look different from the photos in this procedure However the steps of the procedure are the...

Page 208: ...uments Part Number Quantity Description Required N A 1 ea Tools materials and documents required for sub procedures Suggested 33011008 1 ea ASM TOOL KIT FIELD SERVICE EC2000 EC3000 33011009 1 ea ASSEM...

Page 209: ...parked near the front of the device 2 Open the top access door by following the steps in section 2 7 How to Open the Top Access Door 3 Move the XY transport to the front of the device to expose its ca...

Page 210: ...9875607 91 Figure 5 72 Unlocking XY Transport Ribbon Cable TOP VIEW FROM LEFT REAR LEFT VIEW 5 Open the clip that secures the ribbon cable to the top deck plate 6 Disconnect the ribbon cable from the...

Page 211: ...PORT BOARD and connect it to the circuit board on the top deck plate with the cable coming off the board toward the front of the device Press down to make sure the connection is solid Figure 5 73 Circ...

Page 212: ...iented as shown in Figure 5 75 Figure 5 75 XY Transport End of Ribbon Cable TOP VIEW FROM LEFT 4 Connect the cable to the XY transport as shown in Figure 5 76 It should come off the XY transport towar...

Page 213: ...ibbon cable should wind and unwind in a straight line it should not twist bend diagonally or move to the side b The ribbon cable should not contact any objects in its path c If the ribbon cable touche...

Page 214: ...Remove top access door Remove cover Remove embosser seven screws one cable Install new embosser Install cover top access door Set CamAngleAdjustments from embosser s base label using the Edit Config...

Page 215: ...8 hex wrench N A 1 ea Diagonal side cutters or wire cutters N A 1 ea Mallet or hammer for embosser packaging N A 1 ea Pliers or pliers wrench such as Knipex 86 03 180 N A 1 ea Micrometer or digital ca...

Page 216: ...box upside down so the side with the exposed bolt heads faces the ceiling as shown in Figure 5 78 Figure 5 78 Position of Replacement Embosser Box to Open Safely 3 Use the medium or large slotted scr...

Page 217: ...s holding the replacement embosser to the bottom of the box as shown in Figure 5 81 Set the hardware aside in the bottom of the box for later re packaging Figure 5 81 Unfastening the Replacement Embos...

Page 218: ...ear indent cartridge by pressing the orange release button Set it aside in a secure location or give it to the customer for temporary storage or secure disposal 5 Prepare the device for replacing part...

Page 219: ...if the broken tine were not empty you would have to re install the font to another tine and re map it in the software 11 Use the 1 8 hex wrench to remove the three screws that attach the indent modul...

Page 220: ...tem Hardware Service Manual Page 220 of 356 D99875607 91 Figure 5 86 Unfastening Embosser TOP VIEW FROM FRONT and TOP VIEW FROM REAR 13 Use both hands to lift the embosser and indenter modules out of...

Page 221: ...he device in the same position and orientation as the one you just removed Line up the four corner screw holes in the embosser with the four corresponding screw holes in the top deck plate Figure 5 87...

Page 222: ...removal and replacement This includes tying the embosser cable to the solenoid cable next to it as shown in Figure 5 89 and in some cases may include re tying additional cables Use the wire cutters o...

Page 223: ...tant to make sure the embosser will not stall or break and that embossed cards will meet customer requirements and will be properly tipped 17 Calibrate the indenter using the information in section 6...

Page 224: ...and the 1 8 hex wrench to fasten the indenter if any to the embosser using the three nuts and bolts you set aside earlier Figure 5 91 Nuts and Bolts Holding Replacement Indenter to Replacement Emboss...

Page 225: ...Personalization System Hardware Service Manual Page 225 of 356 D99875607 91 Figure 5 93 Packing Embosser for Shipping 3 Bend the tabs flat to hold the bottom of the box in place 4 Pack the tools into...

Page 226: ...become less effective at holding characters If a tine breaks however it may be necessary to move its character to a new tine Figure 5 94 Removing a Character from the Embosser Wheel 5 22 1 Tools Mater...

Page 227: ...ice should be powered down with all external cables safely disconnected and the hopper shuttle parked near the front of the device 2 Insert an X Acto knife between the tine and the character as shown...

Page 228: ...l Steps Prepare device for removing reinstalling modules Remove the top access door and cover Remove the exit transport module and tipper module Reverse to re install the exit transport module and tip...

Page 229: ...ervicing may look different from the photos in this procedure However the steps of the procedure are the same and are unrelated to unaffected by the appearance of the modules The exit transport module...

Page 230: ...8 hex wrench N A 1 ea Tools materials and documents required for sub procedures Suggested 33011008 1 ea ASM TOOL KIT FIELD SERVICE EC2000 EC3000 33011009 1 ea ASSEMBLY FIELD SERVICE KIT SPARE PARTS ST...

Page 231: ...afely disconnected and the hopper shuttle parked near the front of the device 3 Remove the tipper module For detailed steps see section 5 25 How to Remove Re install the Tipper Module 4 Locate the mul...

Page 232: ...sconnect the exit transport magnetic stripe reader MSR cable as follows a On the left side of the exit transport find the connector between the cable and the MSR head and disconnect it Carefully note...

Page 233: ...5607 91 Figure 5 97 Disconnecting Exit Transport MSR Cable 7 Use the 1 8 hex wrench to remove the four screws and washers that secure the corners of the exit transport module to the top deck plate sho...

Page 234: ...dule you are replacing and if necessary modify the replacement so the two tippers have identical features a Examine the front of the exit transport you just removed If it does not have the sensor show...

Page 235: ...er height sticker c Route the foil sensor cable under the embosser cable d Connect the foil sensor cable to SPARE 3 on the sensor connector cable e Re connect the embosser cable and press down on both...

Page 236: ...dule High level Steps Prepare device for removing reinstalling modules Remove the top access door and cover Remove the exit and tipper together Reverse to re install the exit and tipper together Re in...

Page 237: ...ves them either to the card rejection bin or to the tipper module It includes an integrated MagnePrint reader which can optionally be used to read each issued card s magnetic stripe and produce a digi...

Page 238: ...32 ball end hex wrench N A 1 ea Wire cutters or small diagonal side cutters N A 1 ea Tools materials and documents required for sub procedures Suggested 33011008 1 ea ASM TOOL KIT FIELD SERVICE EC200...

Page 239: ...ipper foil cartridge see D99875600 ExpressCard 2000 Installation and Operation Manual or D998200281 ExpressCard 3000 Installation and Operation Manual for detailed instructions and set it aside in a s...

Page 240: ...ti connector panel in the top deck plate to the left of the exit transport 16 Find the exit transport module s cable connected to the rear right corner plug and the embosser module s connector connect...

Page 241: ...a cable clip on the top deck d Unclip the cable and follow it further to the connector e Disconnect the cable Figure 5 102 Foil Sensor Cable TOP VIEW FROM FRONT 19 Disconnect the exit transport magne...

Page 242: ...Exit Transport MSR Cable 20 Use the 5 32 and 1 8 hex wrenches to remove the eight sets of screws and washers that secure the modules to the top deck plate shown in Figure 5 99 and set the screws asid...

Page 243: ...5 Removal and Re installation ExpressCard 2000 ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual Page 243 of 356 D99875607 91...

Page 244: ...ity and access disconnect the top motor cable covering the cable you are examining then re connect see Figure 5 104 b Examine the cables near the base on the left side of tipper you just removed below...

Page 245: ...st removed If it does not have the sensor shown in Figure 5 106 use diagonal side cutters or wire cutters to cut the sensor s cable off the replacement tipper Figure 5 106 Tipper Foil Sensor On Exit T...

Page 246: ...wo modules together for shipping The ties are in the left and right inner corners of the combined module through the screw holes in the bases 5 Reverse the steps for removing the modules making sure n...

Page 247: ...or connector cable e Re connect the embosser cable and press down on both sides of the connector to make sure it is all the way in f Re tie any cables you had to cut free 8 Re connect the exit transpo...

Page 248: ...607 91 b On the touchscreen navigate to Menu Settings Tipper c In the Tipper page use the on screen buttons to fill in the Heater Temp field with the number written on the side of the heater d Press t...

Page 249: ...he Tipper Module High level Steps Prepare device for removing reinstalling modules Remove the top access door and cover Remove the tipper module Reverse to re install the tipper module Re install cove...

Page 250: ...ate cooling time before touching the tipper heater Some of the modules inside the ExpressCard you are servicing may look different from the photos in this procedure However the steps of the procedure...

Page 251: ...utters or small diagonal side cutters N A 1 ea Tools materials and documents required for sub procedures Suggested 33011008 1 ea ASM TOOL KIT FIELD SERVICE EC2000 EC3000 33011009 1 ea ASSEMBLY FIELD S...

Page 252: ...cartridge see D99875600 ExpressCard 2000 Installation and Operation Manual or D998200281 ExpressCard 3000 Installation and Operation Manual for detailed instructions and set it aside in a secure locat...

Page 253: ...h come out the front of the tipper above the exit ramp Depending on the age of the heater the cables may be colored differently from the pictures The procedure is the same Figure 5 109 Tipper Heater C...

Page 254: ...d Personalization System Hardware Service Manual Page 254 of 356 D99875607 91 Figure 5 110 Tipper Heater Cable Tie TOP VIEW FROM LEFT TOP VIEW 10 If the heater cable and sensor cable are held together...

Page 255: ...Tipper Top Motor Connector FRONT VIEW 13 Use the 5 32 and 1 8 hex wrenches to remove the four sets of screws and washers that secure the module to the top deck plate shown in Figure 5 107 14 Use both...

Page 256: ...a From connector J4 on the board disconnect the Tipper Foil Advance Motor cable b From connector J3 on the board disconnect the Tipper Cog Grip Motor cable c From connector J15 on the board disconnect...

Page 257: ...nstant Issuance Card Personalization System Hardware Service Manual Page 257 of 356 D99875607 91 Figure 5 114 Tipper Circuit Board FRONT VIEW 16 Use both hands to remove the tipper module from the dev...

Page 258: ...he cable you are examining then re connect see Figure 5 127 b Examine the cables near the base on the left side of tipper you just removed below the rear motor If the original tipper does not have the...

Page 259: ...ome cases you may want to trace the cable back to the motor or sensor it is connected to 6 Perform any additional service that requires the device to be powered off and open 7 Re install the tipper fo...

Page 260: ...607 91 b On the touchscreen navigate to Menu Settings Tipper c In the Tipper page use the on screen buttons to fill in the Heater Temp field with the number written on the side of the heater d Press t...

Page 261: ...ion ExpressCard 2000 ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual Page 261 of 356 D99875607 91 5 26 How to Upgrade the Tipper Module from 4 1 Model to 1 1 Mode...

Page 262: ...res Figure 5 117 Tipper Heater The tipper heater is hot and can burn your skin Make sure the device has been turned off or the heater has been turned off and no cards have been produced for at least 1...

Page 263: ...a Diagonal side cutters or wire cutters 96901477 1 ea 3 32 hex wrench 96901478 1 ea 1 8 L handle hex key N A 1 ea Tools materials and documents required for sub procedures Suggested 33011008 1 ea ASM...

Page 264: ...ough time to cool below 50 C so it is not too hot to touch Cooling can take up to 15 minutes so begin the service appointment with work away from the tipper heater 3 Remove the tipper foil cartridge s...

Page 265: ...ontact MagTek Support Services for alternate instructions 6 If the tipper heater connector is cable tied to the tipper cut the cable tie and discard it Figure 5 119 LEFT If the cable is clipped to the...

Page 266: ...9 Use the 3 32 hex wrench to remove the two screws that hold the tipper sensor in the tipper housing and set them aside On some devices the sensor may be a different color The procedure is the same Fi...

Page 267: ...875607 91 Figure 5 122 Removing and Re installing the Tipper Sensor TOP VIEW 11 Use the 1 8 L handle hex key to remove the two spring loaded posts that hold the tipper heater in the tipper module and...

Page 268: ...d Re installation ExpressCard 2000 ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual Page 268 of 356 D99875607 91 Figure 5 124 Removing Re inserting the Tipper Heat...

Page 269: ...nd insert it into the tipper resting on the ramp 2 Route the cable out the front of the tipper 3 Use the 1 8 L handle hex wrench to push down on the right spring loaded post line it up with the screw...

Page 270: ...ardware Service Manual Page 270 of 356 D99875607 91 7 Use the 3 32 hex wrench to insert and tighten the two screws that hold the tipper sensor 8 Re connect the tipper heater cable to the plug on the l...

Page 271: ...the middle of the tipper heater plug Figure 5 119 LEFT 11 Make sure the cables and plugs are clear of the embosser wheel and any other moving parts 12 Perform any additional service that requires the...

Page 272: ...te to Menu Settings Tipper c In the Tipper page use the on screen buttons to fill in the Heater Temp field with the number written on the side of the heater d Press the Save button 18 On the touchscre...

Page 273: ...es Approximate time to re install 15 minutes plus any sub procedures The embedded PC provides the user interface on the ExpressCard s touchscreen and connects to the Main Logic Board MLB to communicat...

Page 274: ...ight or equivalent 97200121 0 1 tube Silicone RTV adhesive N A 1 ea Tools materials and documents required for sub procedures Suggested 33011008 1 ea ASM TOOL KIT FIELD SERVICE EC2000 EC3000 33011009...

Page 275: ...f the device 2 Open the right side access door by following the steps in section 5 7 How to Remove Re install the Side Access Doors 3 Locate the embedded PC behind the right side access door toward th...

Page 276: ...ight Edge of the Embedded PC TOP VIEW FROM RIGHT 6 If possible take a photo of the connections to the embedded PC for reference during re installation 7 Disconnect all the cables connected along the r...

Page 277: ...e sure its cables do not snag inside the device 9 Support the embedded PC with your hand or an appropriate work surface while completing the final steps 10 If possible take a photo of the connections...

Page 278: ...Personalization System Hardware Service Manual Page 278 of 356 D99875607 91 Figure 5 131 Connectors On Left Half of Embedded PC TOP VIEW FROM RIGHT 12 Make sure there are no cables connected to the e...

Page 279: ...t panel connector On some units the connector directions may be different Make sure the wire COLORS are oriented as shown in your reference photos or in the figure 2 If you have connected one or more...

Page 280: ...two thumb screws that secure it to the lower deck line up with their holes see Figure 5 127 Do not push it too far in 7 Tighten the thumb screws 8 Tuck the cables back into the space behind the right...

Page 281: ...re It is mounted to the embedded PC in the rear right corner of the lower deck tub of the device 5 29 1 Tools Materials and Documents Part Number Quantity Description Required N A 1 ea No 1 Phillips s...

Page 282: ...down with all external cables safely disconnected and the hopper shuttle parked near the front of the device 2 Perform the first few steps in section 5 28 How to Remove Re install the Embedded PC jus...

Page 283: ...se section 5 28 How to Remove Re install the Embedded PC as a reference 4 Perform any additional service that requires the device to be powered off and open 5 Depending on the situation it may be nece...

Page 284: ...movements and sensor states as the device performs operations It is located in the front right of the device s lower deck behind the right side access door and in front of the embedded PC Figure 5 136...

Page 285: ...When handling or working around the MLB be careful not to remove jumper JP1 shown in the photos below Removing this jumper triggers a security response that completely erases the MLB s bootloader fir...

Page 286: ...evice 2 Open the right side access door by following the steps in section 5 7 How to Remove Re install the Side Access Doors 3 Locate the MLB behind the right side access door toward the front of the...

Page 287: ...it is lined up properly Figure 5 140 Tracks for Embedded PC and Main Logic Board RIGHT VIEW After re installing the MLB follow these steps 1 Depending on the situation it may be necessary to complete...

Page 288: ...s any sub procedures The power controller monitors the power button on the front of the device and coordinates activity between the device s embedded PC main logic board and power supply to properly p...

Page 289: ...ed 96901399 1 ea 5 64 ball end hex wrench N A 1 ea Tools materials and documents required for sub procedures Suggested 33011008 1 ea ASM TOOL KIT FIELD SERVICE EC2000 EC3000 33011009 1 ea ASSEMBLY FIE...

Page 290: ...ing the steps in section 5 3 How to Remove Re install the Cover 3 Remove both side access doors by following the steps in section 5 7 How to Remove Re install the Side Access Doors 4 On the right side...

Page 291: ...Unplug all four connectors from the right connector panel noting which cable connects where 9 Locate the left connector panel near the exit transport and behind the embosser see Figure 5 145 Figure 5...

Page 292: ...s are part of the power controller tray and should spring up when they are disengaged Do not attempt to remove them from the tray 13 Lift the cables that run across the edge of the power controller tr...

Page 293: ...Service Manual Page 293 of 356 D99875607 91 Figure 5 147 Disconnect Three Cables from Power Controller LEFT VIEW 15 Use the finger holes to continue carefully pulling the tray out of the device Make s...

Page 294: ...efore inserting the tray re route the two cables that come off the right end of the tray as shown in Figure 5 148 then pull them through the right access door as shown in Figure 5 149 Before pushing i...

Page 295: ...nstallation ExpressCard 2000 ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual Page 295 of 356 D99875607 91 Figure 5 150 Routing Power Supply Cables Before Final In...

Page 296: ...oving reinstalling modules Remove left side access door Remove power supply Remove AC filter Reverse to re install Approximate time to remove 10 minutes plus any sub procedures Approximate time to re...

Page 297: ...582 1 ea 7 64 L handle hex key N A 1 ea Flashlight N A 1 ea Wire cutters or small diagonal side cutters N A 1 ea Tools materials and documents required for sub procedures Suggested 33011008 1 ea ASM T...

Page 298: ...external cables safely disconnected and the hopper shuttle parked near the front of the device 2 Remove the power supply by following the steps in section 5 33 How to Remove Re install the Power Suppl...

Page 299: ...case until it hangs freely outside the case see Figure 5 155 If the cable is not long enough to expose the connectors outside the case as shown use the wire cutters or diagonal side cutters to careful...

Page 300: ...nd Re installation ExpressCard 2000 ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual Page 300 of 356 D99875607 91 Figure 5 156 AC Filter Connectors 8 Set the AC fi...

Page 301: ...e sure it is oriented correctly 4 The final 1 8 of insertion requires more force than the initial insertion Use both thumbs to press hard To make sure the AC filter is fully inserted use the flashligh...

Page 302: ...Approximate time to re install 15 minutes plus any sub procedures The power supply receives AC power from the AC power cord plugged in to the rear of the device and converts it to the power levels req...

Page 303: ...tion Required N A 1 ea No 2 Phillips screwdriver N A 1 ea Assistant for safe lifting N A 1 ea Tools materials and documents required for sub procedures Suggested 33011008 1 ea ASM TOOL KIT FIELD SERVI...

Page 304: ...tle parked near the front of the device 2 Open the left side access door by following the steps in section 5 7 How to Remove Re install the Side Access Doors 3 Take appropriate steps to protect the wo...

Page 305: ...e Service Manual Page 305 of 356 D99875607 91 Figure 5 160 Four Power Supply Screws Exposed BOTTOM LEFT VIEW 5 Locate the power supply on the rear left side of the device behind the left side access d...

Page 306: ...re the three power input wires to the power supply then disconnect the wires Figure 5 162 Power Supply Input Wires LEFT VIEW 8 Unplug the white plastic power supply control and monitoring connector sh...

Page 307: ...4 Power Supply Output Cables LEFT VIEW 10 Use the No 2 screwdriver to remove the four screws on the bottom of the device that hold the power supply in place see Figure 5 160 on page 305 11 Remove the...

Page 308: ...Re connect the output wires according to Figure 5 164 5 Plug in the control and monitoring cable 6 Re connect the input wires Insert the spade connectors behind the plate behind the screws not directl...

Page 309: ...rity anchor ring on the rear of the device Figure 5 165 Ethernet Jack and Cable 5 34 1 Tools Materials and Documents Part Number Quantity Description Required N A 1 ea Diagonal side cutters or wire cu...

Page 310: ...er supply by following the steps in section 5 33 How to Remove Re install the Power Supply 3 Remove the right side access door by following the steps in section 5 7 How to Remove Re install the Side A...

Page 311: ...clip follow these steps to loosen it a Use a slotted screwdriver to indent the metal on the right side as shown in Figure 5 170 This unlocks the right edge of the Ethernet jack from the ExpressCard ca...

Page 312: ...the Ethernet Jack REAR VIEW Figure 5 171 Use the Slotted Screwdriver to Release the Black Clip REAR VIEW 11 Ease Ethernet jack into the ExpressCard case through the mounting hole see Figure 5 172 Fig...

Page 313: ...fer to section 5 28 How to Remove Re install the Embedded PC for details 7 Perform any other service that requires the device to be open and powered off 8 Re install the right side access door 9 Re in...

Page 314: ...etic stripes and transmit the card s data to the embedded PC It is located in the slot at the top front center of the device just above the MagTek logo 5 35 1 Tools Materials and Documents Part Number...

Page 315: ...s in section 2 7 How to Open the Top Access Door 3 Locate the magnetic stripe reader module behind the curve at the top front of the cover 4 Open the image printer to make room for the screwdriver you...

Page 316: ...hten the right and middle screws 5 Close the image printer and re insert and tighten the left and final screw 6 Re clip or re tie the MSR cable to the cover 7 Perform any other service that requires t...

Page 317: ...h transmits video for display and receives mouse commands when a user presses on the screen It is mounted to the front center of the cover Figure 5 176 Cover and Touchscreen REAR RIGHT VIEW ROTATED 5...

Page 318: ...o Prepare the Device for Removing Re installing Modules At the end the device should be powered down with all external cables safely disconnected and the hopper shuttle parked near the front of the de...

Page 319: ...the screws 5 Perform any other service that requires the cover to be removed 6 Re install the cover by following the steps in section 5 3 How to Remove Re install the Cover 7 Secure the touchscreen c...

Page 320: ...he touchscreen are registering in the wrong place for example after replacing the touchscreen follow these steps 1 Contact MagTek Support Services for assistance signing in to the device as an adminis...

Page 321: ...e Manual Page 321 of 356 D99875607 91 7 Press and hold the center of the X on the screen until it stops flashing and turns solid blue 8 Repeat for all Xes that appear on the screen until the system re...

Page 322: ...ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual Page 322 of 356 D99875607 91 10 Press the OK button at the bottom of the eGalaxTouch USB Controller or Touchkit US...

Page 323: ...nter top access door 10 If the card is not centered at the printer opening or if it hit either side of the printer opening or if the card skewed to one side when entering the printer a Pull on the tri...

Page 324: ...f the card skewed to one side when entering the printer a Pull on the triangular belt on the front side of the hopper shuttle to back the card out of the hopper shuttle and remove the card b Inspect t...

Page 325: ...the card the stretching and position of images the fonts it uses to print each embossed Font ID and so on 6 3 2 How to Set Ribbon and Driver Settings To set the image printer to factory settings follo...

Page 326: ...2000 ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual Page 326 of 356 D99875607 91 6 Press the Auto Self Adj button 7 Wait about 10 seconds and listen for the ima...

Page 327: ...a window advising you that sending commands will require a password Press the OK button to launch the first Printer Commands password page c Use the on screen keypad to enter password 1234567 and pre...

Page 328: ...justments ExpressCard 2000 ExpressCard 3000 Instant Issuance Card Personalization System Hardware Service Manual Page 328 of 356 D99875607 91 g Press the Close button to return to the Printer Utility...

Page 329: ...e printer stops making sounds 6 3 3 How to Calibrate Image Alignment The ExpressCard image printer s factory settings are calibrated to within 0 01 1 100 of a reference image which is finer than can b...

Page 330: ...image relative to the left edge of the card The Y up down position of the image relative to the top of the card The X size length of the image with additional rows added at the right edge of the card...

Page 331: ...1 4 steps smaller than the Y value reported by Ry to bring the top edge of the image closer to the top edge of the card c Create a set of test cards that represent the full range of the application s...

Page 332: ...to straighten the card against the XY transport s card clamp If the XY transport needs to be calibrated follow the steps in this section 6 5 2 How to Calibrate Printer to XY Transport Handoff To cali...

Page 333: ...e C button then entering the new number on the on screen keypad and pressing the E button f If the card did not make contact with the plastic portion of the clamp or did not press on the justifier and...

Page 334: ...se the ExitHandoffAdjustmentX setting by selecting the number in the list pressing the C button then entering the new number on the on screen keypad and pressing the E button Adjust about 10 steps at...

Page 335: ...ssed deeply enough into the card and to make sure the card is being squeezed evenly on both sides see Figure 6 3 Figure 6 3 Embosser Knuckles REAR LEFT VIEW and PROFILE VIEW Each knuckle can be rotate...

Page 336: ...l Page 336 of 356 D99875607 91 6 6 2 Check Knuckle Position The replacement embosser should have ink marks indicating factory calibrated positions for the top and bottom knuckle Make sure the inked po...

Page 337: ...e touchscreen navigate to Menu Settings Service MCP Commands to open the Controller Commands page 3 Press Calibrate Wheel Home button and wait for 10 seconds until the embosser stops moving The system...

Page 338: ...he 0 character is centered 7 After successfully calibrating press the Save button to save the new embosser wheel center value 8 Press the OK button to dismiss the popup window confirming it has been s...

Page 339: ...2 On the touchscreen navigate to Menu Settings Edit Config to open the Configuration Editing password page 3 Use the onscreen keypad to enter password 1234567 and press the E key 4 Use the onscreen k...

Page 340: ...from MagTek Support Services to the device to create a test card 3 Place the test card on a flat surface with the embossed characters facing the ceiling and look it from the side Note whether the lon...

Page 341: ...leTop FontID1 CamAngleBottom FontID2 CamAngleTop and FontID2 CamAngleBottom settings described earlier in this section to adjust the relief height and card flatness and create another FullSet_v4_NoTip...

Page 342: ...UNLOAD position When removing the indent cartridge it moves all the way out for easy removal If the indent ribbons are aligned such that indented characters are too far toward one edge of the indent...

Page 343: ...he ribbon 6 If they are not centered a Navigate to Menu Settings Edit Config to open the Configuration Editing password page b Enter password 1234567 and press the E button c Enter password 7654321 an...

Page 344: ...i Press the Save button to save your changes The system will report The modified configuration has been saved Press the OK button to close the popup window 7 Navigate to Menu Settings Service MCP Cmd...

Page 345: ...t Indent Cartridge Positions If the device you are calibrating has a front indent ribbon cartridge which has white ribbon and mounts above the embosser follow the steps from section 6 7 2 How to Calib...

Page 346: ...normal tipper platen wear 6 8 1 Set Correct Calibrated Temperature New tipper heaters and tippers come with a pre calibrated temperature marked on the side of the heater To set the ExpressCard to use...

Page 347: ...ation and Operation Manual or D998200281 ExpressCard 3000 Installation and Operation Manual for detailed instructions Be sure you have offered to give the customer any used tipper foil rolls for secur...

Page 348: ...the tipper is not calibrated correctly follow these steps a Navigate to Menu Settings Tipper b If the tipper is overflashing use the arrow buttons to decrease the Tipper Motor Angle setting subtract...

Page 349: ...covers properly 6 8 6 Calibrate Foil Cool Time During the tipping cycle the hot tipper fuser presses the foil against the card holds for a certain amount of time then stops heating and cools down bef...

Page 350: ...e device yourself and attempt to reproduce the symptoms If the symptoms are intermittent and you are unable to reproduce them ask the end user to take detailed notes to provide a video recording of th...

Page 351: ...rds do not exit the image printer to the XY transport correctly card is crooked diagonal in the XY transport carriage s clamp too far to either side of the clamp or not deep enough into the clamp adju...

Page 352: ...rror Opening Controller 4 If the device is exhibiting these behaviors contact MagTek Support Services to make arrangements for RMA rework or replacement There is a related case where the device s firm...

Page 353: ...ge 353 of 356 D99875607 91 Appendix A Technical Support For technical support for the ExpressCard 2000 within the United States contact MagTek Support Services by phone or email If you are outside the...

Page 354: ...the identification card cores Returned Cards A card that has been issued to a card holder and returned for the purpose of testing SSL Secure Sockets Layer SSL protocol Originally developed by Netscap...

Page 355: ...tem Hardware Service Manual Page 355 of 356 D99875607 91 Term Definition YMCKOK The designation of colored Ribbon by the panels of color in the order in which they are applied Yellow Y Magenta M Cyan...

Page 356: ...ssCard 3000 Instant Issuance Card Personalization System Hardware Service Manual Page 356 of 356 D99875607 91 Appendix C Key Loading For information about loading keys for chip cards see D99875603 EC2...

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