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Magtek EXPRESSCARD 1000 Hardware Service Manual

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EXPRESSCARD 1000
HARDWARE SERVICE MANUAL
MARCH 2008
Part Number: 99875357-2
Registered to ISO 9001:2000
20725 South Annalee Avenue
Carson, CA 90746
Phone: (310) 631-8602
Fax: (310) 631-3956
Technical Support: (651) 415-6800
www.magtek.com

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  • Page 1 EXPRESSCARD 1000 HARDWARE SERVICE MANUAL MARCH 2008 Part Number: 99875357-2 Registered to ISO 9001:2000 20725 South Annalee Avenue Carson, CA 90746 Phone: (310) 631-8602 Fax: (310) 631-3956 Technical Support: (651) 415-6800 www.magtek.com...
  • Page 3 Changes or improvements made to this product will be updated in the next publication release. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of MagTek, Inc. ©...

  • Page 4: Table Of Contents

    Table of Contents Section 1: General Information ....................1   1.1: Safety Information ......................1   1.2: Identification Information ....................1   1.3: Product Specifications ..................... 3   Electrical ..........................3   Acoustics ..........................3   Environment ........................3   Communications .........................
  • Page 5 Sensor ..........................50   XY Mover .......................... 50   Embosser ......................... 51   MCP Commands ......................51   3.9: Common Error Messages ..................... 54   Section 4: Removal and Replacement ..................57   4.1: Covers ........................... 57   4.2: Embosser Assembly ..................... 62  ...
  • Page 6 5.6: Printer Assembly ......................122   5.7: Sliding Tray Assembly ....................123   Section 6: Cabling Diagram Index ..................125   Appendix A ..........................185   Acronyms ........................... 185   Accessory Items ......................... 186   Optional Components: ....................... 186   Supplies ..........................
  • Page 7 FCC WARNING STATEMENT This equipment has been tested and found to comply with the limits for Class A digital device, pursuant to Part 15 of FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a residential environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.

  • Page 8: Section 1: General Information

    To maintain the safety and integrity of the machine it is essential that procedures laid out within this manual are followed. CAUTION: Disconnect power from the ExpressCard 1000 (EC1000) before you connect or disconnect any cable, electronic board or assembly for your personal safety and to prevent damage to the machine.
  • Page 9 ExpressCard 1000 Hardware Service Manual...

  • Page 10: Product Specifications

    Section 1: General Information 1.3: Product Specifications Electrical • 100 to 240 VAC at 50 to 60 Hz, 2 Amps Acoustics Idle (standby mode): 66 dB Printing: 76 dB Environment Printer temperature and humidity • Operating – Temperature: 65° F to 80° F –...

  • Page 11: Card And Printing

    ExpressCard 1000 Hardware Service Manual Height of Embossed Characters: NOTE: The height of embossed character is measured from the non-embossed surface of the card to the highest point on the embossed character (optimum character height is 0.46mm /0.018in). Visually and machine readable characters...
  • Page 12 Section 1: General Information Term Description Print Speed – • K: 7 seconds per card/514 cards per hour* • BO: 12 seconds per card/300 cards per hour* • YMCKO: 25 seconds per card/144 cards per hour* Batch Mode • YMCKOK: 33 seconds per card/109 cards per hour* YMCKK (w/Lamination): 35 seconds per card /102 cards per hour* Indicates the Print Ribbon type and the number of Ribbon panels printed where Y=Yellow, M=Magenta, C=Cyan, K=Resin Black, B=Dye-Sublimation...
  • Page 13 ExpressCard 1000 Hardware Service Manual...

  • Page 14: Section 2: Installation & Operation

    Section 2: Installation & Operation Remove the EC1000 from its shipping container and inspect the unit for any possible shipping damage. Place the EC1000 on a flat level surface (capable of supporting at least 85lbs.) then remove all shipping restraints within and outside of the machine. Next, connect the power and data cables.
  • Page 15 ExpressCard 1000 Service Manual 9) Close the EC1000’s top cover. When you start to print, the ribbon drive hubs will automatically engage the notches on both cores of the ribbon roll. Note: If the printer has difficulty recognizing the installed ribbon a calibration of the...

  • Page 16: Loading Cards

    Section 2: Installation & Operation 2.2: Loading Cards Caution: Never run cards with a contaminated, dull or uneven surface through the Printer. Printing onto such cards will ultimately lead to poor print quality and will greatly reduce the life of the Print head. Additionally, always store the card stock in its original packaging or in a clean, dust-free environment.

  • Page 17: User Interface

    ExpressCard 1000 Service Manual 2.3 User Interface Below is the default display for the EC1000. From this screen the system will indicated its current status along with any error that prevents normal operation. When the system displays Offline it will not process a card. In addition to determine the firmware version on the machine select the Help button and it will be displayed.

  • Page 18: Network Configuration

    Section 2: Installation & Operation 2.4: Network Configuration By default the EC1000 will obtain an IP address automatically however, for most networks the IP address must be statically set. To configure the network interface on the EC1000 follow the steps below to configure the network card: 1.
  • Page 19 ExpressCard 1000 Service Manual 3. After selecting the TCP/IP button, two operator passwords must be entered on the screen shown. 4. Once the correct passwords have been entered the screen below will be displayed. At this point, enter the IP address, gateway and subnet of the network you are connecting...
  • Page 20 Section 2: Installation & Operation If a subnet is not entered when configuring the IP address then the error below will be shown. 5. After the network configuration has been entered (shown below) press the set new button on the screen, the network card configuration is now complete. To exit back to the system ready screen press the Status button.

  • Page 21: Calibration

    ExpressCard 1000 Service Manual 2.5: Calibration Calibration of the printer ribbon is normally not required however; if the ribbon is not recognized automatically follow the calibration instructions below. 1. Select Menu from the system ready screen. 2. Then choose the Printer button from the menu screen.
  • Page 22 Section 2: Installation & Operation 3. Next select the Properties button. 4. Select Printing Preferences.
  • Page 23 ExpressCard 1000 Service Manual 5. Then select the Calibrate tab. 6. Now select Sensors.
  • Page 24 Section 2: Installation & Operation 7. At this point select the Send button and the printer will begin its calibration cycle. During the printer calibration cycle you will hear noise from the printer, when the printer is silent select Ok twice on the next two screens. 8.

  • Page 25: Printing A Test Card

    ExpressCard 1000 Service Manual 9. The display should now say ready and from this point select the Status button; you will be returned to the system ready screen and the calibration procedure is complete. 2.6: Printing a Test Card The main purpose of a test card function is to verify that the EC1000 is working properly. To print a test card press the Samples button at the system ready screen and four sample options will appear as shown below.

  • Page 26: Security

    Section 2: Installation & Operation 2.7: Security The security features of the EC1000 chassis include a cylindrical key lock for the top cover, electronic locks on the top cover and card access door, along with a secure mounting point for the chassis.
  • Page 27 ExpressCard 1000 Service Manual Main Menu screen: Password screen:...
  • Page 28 Section 2: Installation & Operation Unlatch Case/Door: To secure the chassis to a table top surface open the cover and locate the anchor hole (approximately ⅜ inch diameter) in the lower chassis. The anchor hole is on the right side of the machine and visible through the access opening on the upper chassis (next to the exit assembly).

  • Page 29: Changing Default Password

    ExpressCard 1000 Service Manual 2.8: Changing Default Password To change the default password on the EC1000 navigate to the Menu screen and select the Change Pwd button shown below. After selecting the Change Pwd button the screen below will be shown. At this point select the password that you would like to change.

  • Page 30: Section 3: Service Procedures

    Section 3: Service Procedures When you are trying to diagnose a problem with the EC1000 you should follow the steps below to quickly resolve machine errors. 1. Get an accurate description of the symptoms from the end user. This will ensure that you are fixing the actual problem and not making the problem worse.

  • Page 31: Handling Esd-Sensitive Parts

    ExpressCard 1000 Service Manual 3.2: Handling ESD-Sensitive Parts To prevent electrostatic discharge (ESD) damage to sensitive parts, follow the instructions below. • Keep all ESD-sensitive parts in their original shipping containers until you are ready to install the part into the machine.

  • Page 32: Maintenance

    Section 3: Service Procedures 3.3: Maintenance Lubrication The gears used on the EC1000 are made from self lubricating power metal. No external lubrication is required for their optimal operation. If external lubricants are added they may damage the gear and bearing surfaces over time. However, the stainless steel shafts of the XY assembly will need to be oiled every 3 to 6 months to reduce noise and prolong the life of the assembly.
  • Page 33 ExpressCard 1000 Service Manual 7. Locate the Platen Roller and use a cleaning pad from the Printer Cleaning Kit to wipe the roller clean. 8. Then press the FORWARD and BACK on the buttons on the printer utility screen (use step three to navigate to screen) to move the Platen Roller back and forth while cleaning.

  • Page 34: Firmware Update

    Section 3: Service Procedures 3.4: Firmware Update To upgrade firmware on the EC1000, the new files will need to be copied to the hard drive or via a flash drive. To load the new firmware select the Menu button from the Ready screen, then select the Load F/W button that is shown below.

  • Page 35: Software

    (p\n: 99875362 and p\n: 99875347). Updates via the Internet MagTek provides software and firmware updates for the EC1000 through the internet; to update the EC1000’s software follow the instructions below. 1. Access the EC1000 web page by selecting the internet explore icon. Once the page below is displayed select the Software Upload option on the screen below (in the gray field on the left side of the page).
  • Page 36 Section 3: Service Procedures 2. Click the browse button and find the package MTECUPDATE.CAB 3. Click the send button. A message will indicate the status of the upload. 4. Restart the EC1000.
  • Page 37 ExpressCard 1000 Service Manual 5. Access the EC1000 webpage again and select Upload Status (again in the gray field to the left of the page). 6. A successful upload will be indicated with a status of SUCCESS (shown below).

  • Page 38: Activation

    After pressing the Activation button the screen below will be shown and unique challenge code will be displayed in the Challenge window. You must enter the valid response code which you will receive by calling the MagTek help desk at (888) 624-8350. Once you receive and enter the response code press enter (E).
  • Page 39 ExpressCard 1000 Service Manual When activation is completed you will be notified by the onscreen message shown below. Then press the Status button to return to the system ready screen. To check the activation status select the help button from the Ready screen and the screen below will be shown.

  • Page 40: Adjustments

    Section 3: Service Procedures 3.6: Adjustments Y-axis Alignment for Printer Card Handoff 1. Y-axis is aligned such that when the card has come out of the printer, it should depress the aluminum rail .04”-.06” towards the direction shown in picture below. 2.

  • Page 41: Adjusting Printer Xy Handoff

    ExpressCard 1000 Service Manual Adjusting Printer XY Handoff Adjustment of the XY handoff allows you to determine where the XY assembly will start and stop its movement so that it can pick and drop the card in the correct position. To adjust the position, follow the steps below: 1.
  • Page 42 Section 3: Service Procedures 3. When the Font Editing Utility screen appears scroll down the list until you find PrintertHandoffAdjustment for the X and Y position . The number below the heading is the currently set value. (To change the current value press the existing value below the listed description and a keypad will appear on the right side of the screen as shown below.) Note: Adjustment of the printer hand off position is generally a trial and error process.

  • Page 43: Tuning Embosser Position

    ExpressCard 1000 Service Manual Tuning Embosser Position The function on the EC1000 allows for adjustment of the embossing position so that embossed characters align properly with the printed characters. To adjust the embossed characters positions follow the steps below. Note: The EC1000 should be re-tuned during periodic maintenance and re-tuning will be required when any firmware on the EC1000 is updated.
  • Page 44 Section 3: Service Procedures Once the Tuning button has been selected you will see the screen below. To adjust the embossing positions select the parameter that you wish to change by selecting the green box next to current position setting. Note: FontID3 values only apply to machine that are equipped with Visa Electron or American Express fonts.
  • Page 45 ExpressCard 1000 Service Manual Note: If there is no value in the “Ribbon installed” field try calibrating the printer (section 2.5) before you adjust the embossing position. If there is an alignment issue it is possible the problem is due to unrecognized ribbon; restarting the system may also resolve this issue.

  • Page 46: How To Align The Embossed Characters And Printed Image

    Section 3: Service Procedures How to Align the Embossed Characters and Printed Image 1. First, print a card from the Tuning Utility screen so that you can determine what type of adjustment is needed. 2. To align the FONT ID2 value, begin with the first character of the name which would be the J in the figure below.
  • Page 47 ExpressCard 1000 Service Manual 4. After the FONTID2 adjustments have been made you can move on to the FONTID4 (rear indent) value. The FONTID4 value controls the placement of the numbers located on the back side of the card next to the magnetic strip. Hint: To adjust the spacing of these numbers change the FONTID4X and the Y FONTID4 Spacing values.

  • Page 48: X_Spi Adjustment

    Section 3: Service Procedures X_SPI Adjustment Adjustment of the SPI (step per inch) value makes it possible to increase or decrease the incremental spacing of the characters (think of this function as a shrinking or stretching adjustment) that is set by default by the manufacture. Note: Adjusting of the SPI value will affect any other card configurations that maybe assigned to a different hopper.

  • Page 49: Hammer Follower Adjustment

    ExpressCard 1000 Service Manual Hammer Follower Adjustment As components of embosser wear naturally, mechanical adjustments to the hammer follower may be required to ensure that embossed characters are at the proper height on the card. To adjust of the follower refer to the instructions on the next page. Note: Adjustment of the hammer follower is generally a trial and error process and should only be used when adjustments made in the Font Editing Utility were not sufficient.
  • Page 50 Section 3: Service Procedures How to Adjust Embosser Hammer Follower 1. Determine and save the original Hammer follower setting before changing the value for future reference. (Refer to figures 2 and 3 for Hammer Follower settings) Top Hammer Follower setting Figure 1 Figure 2 Bottom Hammer Follower...
  • Page 51 ExpressCard 1000 Service Manual 2. Turn the Hammer Follower clockwise or counter clockwise to adjust the embosser character height, refer to figure 3 below. height \ pressure indicator Figure 3 Hammer Follower Height Indicators (Lighter impression) (Deeper impression) The Low to High adjustment is a reference mark on the Hammer Follower edge which indicates the pressure \ height of the current follower surface.

  • Page 52: Embossed Character Height

    Section 3: Service Procedures Embossed Character Height How to check the embosser character height • Print a Card • Measure the Embossed characters on the card using caliper as shown in figure. Manufacture specification: Minimum height: 0.018in. (0.46mm) Maximum height: 0.019in. (0.48mm) (For more specification information refer to section: 1.3) Note: When measuring the embossed character height in the fashion shown above make sure to measure make a separate measurement of the card thickness.
  • Page 53 ExpressCard 1000 Service Manual If the embossed character height is too deep or shallow (refer to section 1.3 for character height specifications) adjustments can be made through the Font Editing Utility. Additional adjustment can be made to other parameters in this utility but will not be discussed in this manual;...
  • Page 54 Section 3: Service Procedures Next, press “C” to clear the current value, enter the new hammer depth and press “E” to enter. Finally, you must select Save (left side of the screen) or the new setting will not be saved. Once this is done press the Menu button and select samples to print a test card.

  • Page 55: Diagnostic Information

    ExpressCard 1000 Service Manual 3.7: Diagnostic Information The information within this section should allow you to accurately diagnose problems with the EC1000 and determine the appropriate solution. When trying to diagnose a problem on the EC1000 check the items listed below first: 1) That there are cards in at least one of the hoppers and they are face up with the stripe toward the back of the EC1000.

  • Page 56: Diagnostic Utilities

    Section 3: Service Procedures 3.8: Diagnostic Utilities This section explains how to individually test the assemblies of the EC1000 to determine the failure point and verify that repairs have corrected the problem. To visually inspect the machine while running open the top cover and block the sensor located on the right rear portion of the top cover track.

  • Page 57: Sensor

    ExpressCard 1000 Service Manual Sensor To check the real time status of the EC1000 sensors select the Sensors button and the Sensor Utility screen will be shown. The display on your EC1000 should match the image below. If you suspect that a sensor is faulty block\ open the sensor and the display will change to red or green.

  • Page 58: Embosser

    MCP Commands The MagTek Command Protocol (MCP) Utility is accessible via the Menu screen and like previous utilities it is used to diagnose problems with the EC1000. However, the MCP Utility is...
  • Page 59 ExpressCard 1000 Service Manual First, from the pull down menu select the type of function you wish to conduct. Next, select the motor that you want to test from the pull down menu.
  • Page 60 Section 3: Service Procedures If a sensor is needed for the testing purposes select it and press the Send Cmd button to run the test. After the test has been completed make sure to press the Stop button or the machine will stay in test mode.

  • Page 61: Common Error Messages

    This indicates there was a problem in starting the Encoder. Please shut down the unit and Encoder restart. Error Parsing This indicates that the XML data sent to the ExpressCard 1000 was not correctly formatted XML Data or was using an incorrect syntax. Please verify the code/command being sent. Error Missing...
  • Page 62 Section 3: Service Procedures Error Code Possible Cause of Error and Resolution Error There is no communication between the motherboard and the embosser. Or the embosser Initializing stalled when the system was initialized. Try restarting the system and checking connections Embosser between the embosser and motherboard.
  • Page 63 ExpressCard 1000 Service Manual...

  • Page 64: Section 4: Removal And Replacement

    Section 4: Removal and Replacement This section describes the removal of the major assemblies within the EC1000 to install replacement components simply reverse the removal instructions. When replacing components be sure to follow the previously stated ESD procedures (section: 3.2) and common safety practices.
  • Page 65 ExpressCard 1000 Service Manual 3. Disconnect the top and side latch solenoids from the XY break out board. 4. Disconnect the top cover and card access door sensors from the exit transport break out board.
  • Page 66 Section 4: Removal and Replacement 5. Remove the two top cover screws located on the upper rear portion of the chassis shown below (Hint: hold the top cover as you remove these screws; the top can fall off easily when the screws are removed). 6.
  • Page 67 ExpressCard 1000 Service Manual 7. Remove the eight side cover screws (four per side) and the two front screws shown below (Hint: applying a little pressure to the outside cover will make it easier to remove and replace the screws). Note: you must open the card access door to gain access to...
  • Page 68 Section 4: Removal and Replacement 8. Open the electronics access door via the thumb screws shown and disconnect the monitor video, USB and power cables. 9. Slowly lift the remaining covers off the chassis while pulling the video cables through the hole in to top deck of the machine.

  • Page 69: Embosser Assembly

    ExpressCard 1000 Service Manual 4.2: Embosser Assembly Replacement time: 30 minutes (after covers have been removed) 1. Disconnect the power and data cables. 2. Remove the outer covers; refer to section 4.1 for instructions. 3. Cut the zip ties on the ribbon and power cables.
  • Page 70 Section 4: Removal and Replacement 5. Remove the three Allen screws (5/32 Allen wrench will be required) located at the base of the embosser assembly. When removing the Allen screws rotate the embosser wheel tines so that the section over the screw does not contain characters (the reason being that is a tine breaks off it will not affect the machines embossing ability) and carefully place the Allen wrench between the tines to gain access to the screws.

  • Page 71: Xy Assembly

    ExpressCard 1000 Service Manual 4.3: XY Assembly Replacement time: 30 minutes (after covers are removed) 1. Disconnect the power and data cables. 2. Remove the outer covers (optional); refer to section 4.1 for instructions. 3. Disconnect the ribbon and power cables from the XY break out board; shown below.
  • Page 72 Section 4: Removal and Replacement Move the sled on the XY assembly to the center of the assembly track. 4. Remove the six Allen screws (1/8 Allen, 6” long will be needed) that secure the XY assembly to the top deck and the Phillips screw that secures the ground wire to the top deck.

  • Page 73: Exit Assembly

    ExpressCard 1000 Service Manual 4.4: Exit Assembly Replacement time: 25 minutes 1. Disconnect the power and data cables. 2. Remove the four screws that hold the break out board in place in the exit assembly. 3. Once the screws have been removed the assembly can be left to dangle.
  • Page 74 Section 4: Removal and Replacement 4. Remove the eight Allen screws (1/8 Allen, 6’’ long will be needed) that secure the exit assembly to the top deck. Note: when reinstalling the exit assembly the Eject Slide portion must be securely attached to the top desk first. After the Eject Slide is mounted the Exit Transport portion needs to be positioned (using slotted screw holes) next to the Eject Slide.

  • Page 75: Printer Assembly

    ExpressCard 1000 Service Manual 4.5: Printer Assembly Replacement time: 35 minutes (after covers are removed) 1. Disconnect the power and data cables. 2. Remove the outer covers; refer to section 4.1 for instructions. 3. Remove the Embosser assembly; refer to section 4.2 for instructions.
  • Page 76 Section 4: Removal and Replacement 9. Place one hand under the card hopper area and the other hand on the opposite side of the printer. DO NOT lift the printer by the card justifier this could bend the justifier and would most likely require it to be replaced.

  • Page 77: Printhead Replacement

    ExpressCard 1000 Service Manual Printhead Replacement Tools Needed: Torx T10 Screwdriver The Printhead kit you will receive should allow for a quick and easy installation of the replacement Printhead Assembly. Overall, the procedure should take no more than ten minutes. Note: The replacement Printhead Assembly will be calibrated by the factory and require no further mechanical adjustments after installation.
  • Page 78 Section 4: Removal and Replacement d. At the Select Function window, press the down arrow once and select [Setup Printer]. e. Next select [Print Settings]. f. At the Print Settings window, press the down arrow seven times and select [Head Resistance]. g.

  • Page 79: Setting The Print Tof

    ExpressCard 1000 Service Manual Setting the Print TOF Step Procedure 1. Choose Menu> Printer> Menu from the LCD display, Print Test Image and the ribbon type to print a test card. 2. Select Setup Printer, Print Settings and Print TOF.

  • Page 80: Setting The Print Eof

    Section 4: Removal and Replacement Setting the Print EOF This procedure positions the printed image correctly on the trailing edge of the card. Step Procedure 1. Choose Menu> Printer> Menu from the LCD display, Print Test Image and the correct ribbon type to print a test card (remember to press select).

  • Page 81: Adjusting The Image Darkness

    ExpressCard 1000 Service Manual Adjusting the Image Darkness Step Procedure 1. Choose Menu> Printer> Menu from the LCD display, Print Test Image and the correct ribbon type to print a test card. 2. Select Setup Printer, Print Settings and Image Darkness.

  • Page 82: Sliding Tray Assembly

    Section 4: Removal and Replacement 4.6: Sliding Tray Assembly Replacement time: 1 hour 1. Disconnect the power and data cables. 2. To open the Sliding Tray access door, open the EC1000 the top cover and unscrewing the two thumb screws located on the top deck next to the embosser and XY assemblies.
  • Page 83 ExpressCard 1000 Service Manual 4. Unscrew the thumb screw at the rear of the tray which can be seen in the cut out on the top deck next to the Exit Transport and Eject Slide, shown below. 5. Unscrew the thumb screw located just inside Sliding Tray access door way on the front side portion of the tray.
  • Page 84 Section 4: Removal and Replacement 7. Once the tray is about three inches out disconnect the ribbon and power cables and power cables for the XY assemble and the embosser. These connectors are located on the front right side of the MLB board (shown below). 8.
  • Page 85 ExpressCard 1000 Service Manual 9. Next, disconnect the assorted cables at rear of the MLB board along with the exit assembly ribbon cable. Note: all cables within the EC1000 are labeled by name and the corresponding board connector number. 10. Now that the MLB cables have been disconnected slowly pull the tray out of the chassis and you are able to angle the tray to the right and move it away from the chassis to expose the computer power plug and the rear cooling fan connector (shown below).
  • Page 86 Section 4: Removal and Replacement 11. Disconnect the computer power cable and rear cooling fan connector, then move the tray to a suitable where components can be replaced if needed. The picture below identifies the components that make up the electronics tray. When reinstalling the tray reverse the removal instructions and make sure that cables do not get snagged or pinched when reinstalling the tray into the chassis.
  • Page 87 ExpressCard 1000 Service Manual...

  • Page 88: 24-Volt Power Supply

    Section 4: Removal and Replacement 4.7: 24-Volt Power Supply Replacement time: 10 minutes To remove the 24V power supply from the chassis, follow the steps below: 1. Disconnect the power cord from the wall socket if not already done. 2. Disconnect the green output power connectors from the top on the power supply. 3.

  • Page 89: Magneprint Swipe Reader (Msr) Rail

    ExpressCard 1000 Service Manual 4.8: MagnePrint Swipe Reader (MSR) Rail Replacement time: 10 minutes To replace the MSR rail, remove the three screws shown below and slowly pull the rail away from the front cover. When the MSR board becomes accessible, disconnect the MSR cable...

  • Page 90: Monitor Replacement

    Section 4: Removal and Replacement 4.9: Monitor Replacement Old Version: Replacement time: 20 minutes after covers are removed 1. Disconnect the power and data cables. 2. Remove the outer cover assemble; refer to section 4.1 for instructions. 3. After removing the cover assemble place the assembly on a table top monitor side down as shown in the figure below.
  • Page 91 ExpressCard 1000 Service Manual 5. Once the monitor and bracket have been removed from the cover assemble remove the Allen screws that secure the monitor to the bracket. 6. With the Allen screws and monitor bracket removed you will need to remove the nut plate which is in the channel on the rear of the monitor.
  • Page 92 Section 4: Removal and Replacement New Version: Replacement time: 20 minutes removal of covers not required. 1. Disconnect the power and data cables. 2. Open the top cover of (using key or open before disconnecting power), disconnect the monitor video cable and remove the four screws that secure the monitor bracket to the cover assembly.
  • Page 93 ExpressCard 1000 Service Manual...

  • Page 94: Section 5: Parts Catalog

    Section 5: Parts Catalog Assembly 5.1: Covers Assembly 5.2: Chassis Assembly 5.3: Embosser Assembly 5.4: X-Y Transport Assembly 5.5: Exit Transport Assembly 5.6: Printer Assembly 5.7: Sliding Tray...

  • Page 95: Covers Assembly

    ExpressCard 1000 Service Manual 5.1: Covers Assembly...

  • Page 96: Top Cover

    SCREW SEMS CONE WASH 6-32 X 3/8 33070297 TOP COVER-FRONT 33070377 PIN HINGE COVER 85600135 BEARING FLANGED .188 ID X .25 OD X .25 LG 33070390 LABEL EC1000 MAGTEK LOGO 33070298 TOP COVER-REAR 88400007 LOCK KEY TUBULAR 33070376 CAM KEYLOCK 1-10...

  • Page 97: Front Cover With Display

    ExpressCard 1000 Service Manual Front Cover with Display Assembly Index Part Number Description Quantity 33070369 ASSY COVER FRONT W/ LCD DISPLAY 1-13 33070294 FRONT COVER EC1000 1-14 93600157 EC-1000 8" LCD TOUCH SCREEN,SIL 1-15 33070392 ASSY HEAD AND RAIL 1-16...

  • Page 98: Left Cover

    Section 5: Parts Catalog Left Cover Assembly Index Part Number Description Quantity 33070367 ASSY COVER LFT SIDE W/ LATCH 1-23 33070296 LEFT SIDE COVER EC1000 1-24 33070381 ASSY SOLENOID TOP RIGHT LATCH 1-25 33070421 PLATE NUT HALF LENGTH 1-26 46500040 SCREW SEMS CONE WASH 6-32 X 3/8...

  • Page 99: Left Top Cover Latch Assembly

    ExpressCard 1000 Service Manual Left Top Cover Latch Assembly Assembly Index Part Number Description Quantity 1-24 33070380 ASSY SOLENOID TOP RIGHT LATCH 1-27 85300032 SOLENOID-LINEAR 24V 1-28 33070380 ASSY SOLENOID TOP LEFT LATCH 1-29 45106003 SCREW PAN HD PHIL 6-32x3/16...

  • Page 100: Right Cover

    Section 5: Parts Catalog Right Cover Assembly Index Part Number Description Quantity ASSY COVER RT SIDE ACCESS DOOR 33070366 W/LATCH 1-40 46500040 SCREW SEMS CONE WASH 6-32 X 3/8 1-41 33070340 CBL,PANEL DOOR OPEN SENSOR 30 1-42 33070471 TOP COVER SENSOR BRACKET 1-43 33070295 RIGHT SIDE COVER EC1000...

  • Page 101: Right Top Cover Latch Assembly

    ExpressCard 1000 Service Manual Right Top Cover Latch Assembly Assembly Index Part Number Description Quantity 1-47 33070381 ASSY SOLENOID TOP RIGHT LATCH 1-51 87900006 SCREW SHDR 8-32 X 3/16LG; 3/16D X 1/4LG 1-52 48110000 WASHER FLAT #10 1-53 33070437 LATCH, DOG-LEG...

  • Page 102: Card Access Door Latch Assembly

    Section 5: Parts Catalog Card Access Door Latch Assembly Assembly Index Part Number Description Quantity 1-46 33070387 ASSY SOLENOID ACCESS DOOR LATCH 1-64 33070385 LATCH SLIDER DOOR 1-65 33070470 SHAFT, 3/32 DIA X .75L 1-66 85800004 RETAINING RING, E TYPE 3/32 SHAFT 1-67 33070386 BRACKET SOLENOID DOOR...

  • Page 103: Chassis Assembly

    ExpressCard 1000 Service Manual 5.2: Chassis Assembly...

  • Page 104: Outer Components Of Chassis

    Section 5: Parts Catalog Outer Components of Chassis Assembly Index Part Number Description Quantity 33070300 BASE EC1000 33070359 DOOR,PCB ACCESS 46500039 SCREW,SEMS CONE WASH,6-32 X 5/16 33070301 TOP DECK EC1000 64300106 PWR EC1000 PS 115-230VAC, 24VDC 15A 33070357 BIN CARD 33070457 BAD CARD TRAY...

  • Page 105: Inner Components Of Chassis

    ExpressCard 1000 Service Manual Inner Components of Chassis Assembly Index Part Number Description Quantity 33070359 DOOR,PCB ACCESS 46500040 SCREW SEMS CONE WASH 6-32 X 3/8 2-10 33070468 GUIDE CENTER 2-11 46500028 SCREW SEMS CONE WASH 6-32 X 1/4 2-12 33070424...
  • Page 106 Section 5: Parts Catalog Inner Components of Chassis Assembly Index Part Number Description Quantity 2-20 46500155 SCREW BUTTON HD CAP 6-32 X 1 BLK FAN GUARD FOR 50MM FAN (CHROME WIRE 2-21 66300011 SCREEN) 2-22 88500029 HEX WITH TOOTH WASHER 8-32 2-23 33070405 PSY CBL PC ETHERNET CABLE 28.5"...

  • Page 107: Embosser Assembly

    ExpressCard 1000 Service Manual 5.3: Embosser Assembly Note: There are three possible font configurations of the embosser assembly. If the configuration is not known when ordering a replacement embosser, verify the configuration by contacting technical support.

  • Page 108: Top Half Of Embosser

    Section 5: Parts Catalog Top Half of Embosser Assembly Index Part Number Description Quantity 33070266 EMBOSSER ASSY 33070533 EMBOSSER ASSY,VISA ELECTRON 33070534 EMBOSSER ASSY,AMEX 64900044 STEPPER MOTOR 24V,2.8A/PHASE,EC1000 33070255 CHASSIS,EMBOSSER 85600138 BEARING .251 IDX .316 ODX .25 LG .437 FL 33070085 PUNCH,HAMMER,EMBOSSER PIN DOWEL ROCKER ARM 3/8 DIA X 1.75 LG...
  • Page 109 ExpressCard 1000 Service Manual Top Half of Embosser Assembly Index Part Number Description Quantity 3-12 48300002 WASHER-EXT TOOTH LOCK #6 SCREW, 9/16 3-13 86100057 STANDOFF 1/4 OD ROUND X 1.0 LG 6-32 X .25 3-14 48306000 WASHER LOCK #6 (SPLIT)

  • Page 110: Embosser Wheel

    Section 5: Parts Catalog Embosser Wheel Assembly Index Part Number Description Quantity 3-26 33070052 GEAR,EMBOSSER,C-AXIS RING CONTACT HELP DESK FOR SPECIFIC 3-27 CHARACTER PART NUMBER 3-28 33070427 SPRING WAVE,2.93 IDX 3.38ODX.275 FREE HT 3-29 86600079 DOWEL PIN METRIC 2.0 DIA X 6.0 LG 18-8 SS 3-30 33070051 WHEEL,EMBOSSER TYPE...

  • Page 111: Bottom Half Of Embosser

    ExpressCard 1000 Service Manual Bottom Half of Embosser Assembly Index Part Number Description Quantity 3-31 33070262 ROCKER ARM ASSY 3-32 33070085 PUNCH,HAMMER,EMBOSSER 3-33 88300186 SPRING-COMP,.188 OD X .690LG X 018WRE 3-34 33070481 PUNCH HAMMER BEARING 3-35 86100057 STANDOFF 1/4 OD ROUND X 1.0 LG 6-32 X .25...
  • Page 112 Section 5: Parts Catalog Bottom Half of Embosser Assembly Index Part Number Description Quantity 3-44 46500128 SCREW SOCKET HD CAP 10-24 X 1 1/2 3-45 48310000 WASHER LOCK #10 3-46 46500095 SCREW-BUTTON HD SKT CAP,4-40 X 3/16 3-47 64900044 STEPPER MOTOR 24V,2.8A/PHASE,EC1000 3-48 33070255 CHASSIS,EMBOSSER...

  • Page 113: Embosser Base

    ExpressCard 1000 Service Manual Embosser Base Assembly Index Part Number Description Quantity 3-54 33070288 MOUNTING BRACKET,EMBOSSER ASSY 3-55 33070287 STAND-OFF, EMBOSSER MOUNT 3-56 45106010 SCREW PAN HD PHIL 6-32x5/8 3-57 46500018 SCREW SOCKET HD CAP 6-32 X 1/2 3-58 48106000...

  • Page 114: X-Y Transport Assembly

    Section 5: Parts Catalog 5.4: X-Y Transport Assembly...

  • Page 115: Y Portion Of Assembly

    ExpressCard 1000 Service Manual Y Portion of Assembly Assembly Index Part Number Description Quantity 33070260 XY TRANSPORT ASSEMBLY 46500055 SCREW SEMS CONE WASHER 4-40 X 3/8 46500156 SOCKET HD CAP 10-24 X 3/4 (BLACK IRON OXIDE) 33070251 PLATE,XY-AXIS END 33070169...
  • Page 116 Section 5: Parts Catalog Y Portion of Assembly Assembly Index Part Number Description Quantity 4-14 48104000 WASHER FLAT #4 4-15 33070258 BRACKET,Y-AXIS,MOTOR MOUNT 4-16 33070178 SHAFT,Y-AXIS MOTOR 4-17 33070413 PM X-TRANSFER GEAR 4-18 64900037 MOTOR-STEP,1.8DEG 3.7V W/WRE,MICR2000 4-19 33070163 SHAFT,Y AXIS GUIDE...

  • Page 117: Xy Carriage

    ExpressCard 1000 Service Manual XY Carriage Assembly Index Part Number Description Quantity 33070277 CARRIAGE,X-Y AXIS 4-20 33070107 LOCK, Y-AXIS BELT CLAMP 4-21 46500027 SCREW SEMS CONE WASH 4-40 X 1/4 4-22 33070175 BEARING, X AXIS LINEAR 4-23 46404001 SOCKET SET SCREW 4-40 X 5/8...
  • Page 118 Section 5: Parts Catalog XY Carriage Assembly Index Part Number Description Quantity 4-32 33070020 BREAK OUT BOARD 4-33 33070506 XY STATIC BRUSH BEARING,SNAP-IN THRUST NYLON 3/8 ID X 4-34 85600126 7/16 OD 4-35 33070259 CARRIAGE,Y-AXIS 4-36 33070285 MOUNT,X-AXIS MOTOR 4-37 46500040 SCREW SEMS CONE WASH 6-32 X 3/8 4-38...

  • Page 119: Card Clamp Assembly

    ExpressCard 1000 Service Manual Card Clamp Assembly Assembly Index Part Number Description Quantity 33070271 ASSY,CARRIAGE X-AXIS 4-40 22312412 ASSY,MOTOR PICKER 4-41 46500055 SCREW SEMS CONE WASHER 4-40 X 3/8 4-42 45104012 SCREW PAN HD PHIL 4-40x3/4 4-43 33070274 HUB FLAG, CLAMP MOTOR...
  • Page 120 Section 5: Parts Catalog Card Clamp Assembly Assembly Index Part Number Description Quantity 4-53 46500028 SCREW SEMS CONE WASH 6-32 X 1/4 5-54 33070272 LINK CARD CLAMP, TOP 4-55 33070099 LINK,CARD CLAMP, REAR 4-56 33070474 CBL X CARD CLAMP HARNESS 4-57 47104000 NUT, HEX #4-40...

  • Page 121: Exit Transport Assembly

    ExpressCard 1000 Service Manual 5.5: Exit Transport Assembly...

  • Page 122: Eject Card Slide

    Section 5: Parts Catalog Eject Card Slide Assembly Index Part Number Description Quantity 33070462 EJECT SLIDE ASSEMBLY 33070451 SLIDER LEFT WALL 8.955L 33070452 SLIDER RIGHT SIDE 33070502 FAN MOUNT, EJECT SLIDE 33070443 CARD EXIT SLIDE 33070466 EJECT BIN SEN/EXIT FANS PATCH 2 CABLE 46500027 SCREW SEMS CONE WASH 4-40 X 1/4 33070467...

  • Page 123: Card Transport (Left Side)

    ExpressCard 1000 Service Manual Card Transport (Left Side) Assembly Index Part Number Description Quantity 33070461 EXIT TRANSPORT ASSEMBLY 5-11 33070446 LEFT SIDE WALL 5-12 33070341 CBL,REJECT BIN SENSOR 5" 5-13 33090045 ASM EC1K EXIT EJECT XPORT BOARD 5-14 46500027 SCREW SEMS CONE WASH 4-40 X 1/4...
  • Page 124 Section 5: Parts Catalog Card Transport (Left Side) Assembly Index Part Number Description Quantity 5-18 88300195 TORSION SPRING .255 ID X .355 OD 5-19 85600139 FLANGE BEARING .188 ID X .25 5-20 46500039 SCREW,SEMS CONE WASH,6-32 X 5/16 5-21 46500055 SCREW SEMS CONE WASHER 4-40 X 3/8 5-22 85800002...

  • Page 125: Card Transport (Right Side)

    ExpressCard 1000 Service Manual Card Transport (Right Side) Assembly Index Part Number Description Quantity 5-23 33070447 RIGHT SIDE WALL 5-24 85600139 FLANGE BEARING .188 ID X .25 5-25 46500055 SCREW SEMS CONE WASHER 4-40 X 3/8 5-26 86400038 SPC SPACER - NYLON .25 OD X 15/32...
  • Page 126 Section 5: Parts Catalog Card Transport (Right Side) Assembly Index Part Number Description Quantity 5-33 86300021 SPACER-ALUM,.145 ID X 1/4 OD X 7/16L 5-34 48190002 WASHER-FLAT .114 X .375 X .030 BELT-TIMING,.08 PITCH X .125 WIDE,80 5-35 85200114 TEETH 5-36 46500056 SCREW SEMS CONE WASH #4-40 X 1/2 5-37...

  • Page 127: Card Transport (Center)

    ExpressCard 1000 Service Manual Card Transport (Center) Assembly Index Part Number Description Quantity 5-45 33070442 BAD CARD EXIT SLIDE 5-46 33070127 SPACER,EJECT-AXIS 5-47 33070509 ASSY BACK UP WHEEL EXIT TRANSPORT 5-48 33070473 LEFT ENTRY RAIL, EXIT TRANSPORT 5-49 33070508 ASSY DRIVE WHEEL EXIT TRANSPORT...
  • Page 128 Section 5: Parts Catalog Card Transport (Center) Assembly Index Part Number Description Quantity 5-55 85300031 SOLENOID-LINEAR, 24V 5-56 46500028 SCREW SEMS CONE WASH 6-32 X 1/4 5-57 66300012 FAN-DC24V 6W 50MM X 50MM X 15MM 5-58 46500055 SCREW SEMS CONE WASHER 4-40 X 3/8 5-59 46500027 SCREW SEMS CONE WASH 4-40 X 1/4...

  • Page 129: Printer Assembly

    ExpressCard 1000 Service Manual 5.6: Printer Assembly Assembly Index Part Number Description Quantity 33070270 FARGO PRINTER WITH I-380 33070280 PRINTER,FARGO 33070269 I-380 WITH MAGNEPRINT,EC1000 33070177 BRACKET,FARGO CARD JUSTIFIER 46500152 BRACKET,FARGO CARD JUSTIFIER 46500055 SCREW SEMS CONE WASHER 4-40 X 3/8...

  • Page 130: Sliding Tray Assembly

    Section 5: Parts Catalog 5.7: Sliding Tray Assembly Assembly Index Part Number Description Quantity 33070431 ASSY COMPONENT TRAY 33070410 PLATE MOUNTING TRAY 46500039 SCREW,SEMS CONE WASH,6-32 X 5/16 64300109 POWER SUPPLY 400W 93600151 GENERIC HARDDRIVE 40GB, SATA 33070504 HARD DRIVE W/ PRE LOADED SFTWR 33090032 PCB ASSY,EC1000 MLB 93600160...
  • Page 131 ExpressCard 1000 Service Manual...

  • Page 132: Section 6: Cabling Diagram Index

    Section 6: Cabling Diagram Index Assembly 1 & 2: Covers and Chassis Description Part Number Page MLB Input Power, 24V 33070304 Fargo Printer Power 33070342 EC1000 Power Switch 33070397 SPI P/S Cabling 33070398 I380/ Fargo /PC Interface 33070399 Main Power Harness 33070402 12V Power Patch Cord 33070403...
  • Page 133 ExpressCard 1000 Service Manual Assembly 4: XY Transport (Transport Module) Description Part Number Page XY Transport / MLB Power 33070317 XY Transport / MLB Ribbon 33070318 XY Transport / X Clamp Ribbon 33070319 Y Stepper 33070323 Y End Sensor 33070328...
  • Page 134 Section 6: Cabling Diagram Index Assembly 6: Printer (I-380) Description Page I-380 Serial Comm Port Extension cable 33070522 Assembly 6: Printer (EC1000 Cabling) Description Part Number Page Cover Solenoids Cable 33070320 Access Door Solenoid Cable 33070321 Access Door / Cover Solenoid Patch Cable 33070396 Fan Power Cable 33070494...
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  • Page 192: Acronyms

    Appendix A Acronyms Main Logic Board MagnePrint Swipe Reader MagTek Control Protocol EC1000 ExpressCard 1000 DHCP Dynamic Host Configuration Protocol Assembly that travels in the X-axis and Y-axis Extensible markup language Abbreviation for polyvinyl chloride, often called vinyl. PVC is the component of the 0.002"...

  • Page 193: Accessory Items

    Printer’s interior and exterior. • Ten (10) Cleaning Roller replacement loops for replacement of the Cleaning Cartridge tape. Technical Support For technical support on the ExpressCard 1000 contact the MagTek Help Desk by phone or email: Phone: (651) 415-6800 Email:...
  • Page 194 Appendix A Notes:...

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